State of the art
of 3D printing/additive manufacturing technologies
and their possible application in
buildings/curtain wall/construction industry
Natasa Mrazovic, M.Arch.Eng., lic.arch., M.CE.
Permasteelisa, Middelburg, 14/08/26
I STATE OF THE ART OF THE INDUSTRY
1) 3D PRINTING – GENERAL INFO, DEFINITIONS, THE BIG PICTURE
2) COMPARISON OF EXISTING AM TECHNOLOGIES
3) STATE OF THE ART OF THE INDUSTRY
4) STATE OF THE ART IN SCIENTIFIC RESEARCH (MATERIALS,
SIMULATIONS, ETC.)
5) RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION
IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
II AM FOR CURTAIN WALLS
1) AM SYSTEMS AND MATERIAL POSSIBLY APPLIED FOR CURTAIN WALLS
2) WHAT IS POSSIBLE TODAY
3) WHAT IS POSSIBLE WITH EXTENDED KNOWLEDGE
4) POSSIBLE NEW FUNCTIONS AND APPLICATIONS
5) BRAINSTORMING ….
CONTENT
3D PRINTING - THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
ASTM (2009): 3D Printing can be defined as “joining materials to make objects from 3D model
data, usually layer upon layer […]”
CONTROLLED DEPOSITION OF MATERIAL, usually layer by layer
Courtesy of Buswell, Soar, Gibb and Thorpe
3D PRINTING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of dr Martin Baumers
MAJOR ADVANTAGES
1.
2.
3.
4.
GENERIC DISADVANTAGES-DUE TO TECHNOLOGY – IT WILL
CHANGE
COMPLEX GEOMETRY
OPTIMIZATION
CUSTOMIZATION
TRIGGERED REVOLUTION IN
MANUFACTURING AND DESIGN
1.
2.
3.
4.
5.
6.
LIMITED MATERIALS
LOW PROCESS PRODUCTIVITY
PROBLEMS WITH DIMENSIONAL ACCURACY
POOR SURFACE FINISH
REPEATABILITY ISSUE
UNCOMPETITIVE PRODUCTION COST AT MEDIUM AND
LARGE VOLUMES
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of John Hornick / Finnegan/ Inside 3D Printing Conference in
San Jose, 2013
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of John Hornick / Finnegan/ Inside 3D Printing Conference in
San Jose, 2013
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Engineering Implications
 More complex geometries
- internal features
- parts consolidation
- designed internal structures
- material design - NO WASTE
- special geometries and functions not considered before
 No tools, molds or dies
- direct production from CAD
 Unique materials
- controllable microstructures
- multi-materials and gradients ; new products emerging
- embedded electronics / Integrated functional new structures
- commercialization expected to be 10-15 years away
- substantial technological hurdles need to be overcome
Business implications
-
Enables business models used for 2D printing, e.g. photographs, to be applied
in 3D - Print at home, at local FedEx Kinkos, through Shapeways or at local store
Removes the low-cost labor advantage
Entrepreneurship
Patents expiring (new machines); Software tools; Service provides
User-changeable web content plus a network of AM producers already
enables new entrepreneurial opportunities (Shapeways.com, Freedom of
Creation, FigurePrints, Spore, etc.)
Courtesy of Prof Brent Stucker and dr. Martin Baumers
3D PRINTING – BIG PICTURE
Impact on logistics
-
-
-
Eliminate drivers to concentrate production
“design and manufacture anywhere” is now possible
Manufacture at the point of need rather than at lowest labor location
Changing “Just-in-time Delivery” to “Manufactured-on-Location Just-In-Time”
Make local manufacturing of products normative
Small business can compete with multi-national corporation to produce goods for
local consumption
Parts produced closer to home cost the same as those made elsewhere;
minimizing shipping drives regional production
Reverse increasing urbanization of society, e.g. No need to move to the “big city” if I
can design my products and produce anywhere
Make jobs resistant to outsourcing , e.g. Creativity in design becomes more important
than labor costs for companies to be successful
The future
- The industry will grow significantly (according to predictions)
- Estimated market penetration now 1-8%
- Current global growth rate : 30 % p/a
- New products, new designs, new design systems
- New business models will emerge
- Industrial 3D printing will become cheaper
- - faster build speed
- Process innovations needed
- Current hype around amateur (low cost) 3D printing will be reduced
Courtesy of Prof Brent Stucker
3D PRINTING – BIG PICTURE
Courtesy of dr
Martin Baumers
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of dr
Martin Baumers
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of John Hornick/ Finnegan/ Inside 3D Printing Conference in
San Jose, 2013
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of dr
Martin Baumers
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Courtesy of dr
Martin Baumers
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
COMPARISON OF EXISTING AM TECHNOLOGIES
Technology
(Categories
ASTM F2792)
Vat
Material Binder Material
Photopoly Jetting
Jetting Extrusion
merization
Powder Bed
Fusion
Sheet
Lamination
Directed
Energy
Deposition
Definition/
Major
Characteristics
Market
known/Patent
names
Developments
/State of the
art
Characteristics/
Disadvantages/
Secrets
Materials in ...
What is the
technology best
for?
Courtesy of dr Martin Baumers
COMPARISON OF EXISTING AM TECHNOLOGIES
Technology
Definition/
Major
Characteristics
Material Jetting
Vat
Photopolymerization
-
an additive
manufacturing
process in which
liquid photopolymer
in a vat is selectively
cured by lightactivated
polymerization
- Projection systems :
a) use a projector (LED
or DLP) to illuminate the
cross-section
b) resolution limited by
pixels of projector
c) typically faster per
layer d) common for
micro-Stereolithography
-an additive
manufacturing
process in which
droplets of built
material are
selectively deposited
Binder Jetting
-an additive
manufacturing
process in which a
liquid bonding agent
is selectively
deposited to join
powder materials
-Wax or
Photopolymers; Multiple nozzles;
-Single nozzles
Material Extrusion
an additive
manufacturing process
in which material is
selectively dispensed
through a nozzle or
orifice
it is based on Stratasys
FDM machines; it is
office friendly; DIY
community; bestselling
platforms, etc.
Powder Bed Fusion
- an additive
manufacturing process
in which thermal energy
selectively fuses regions
of a powder bed
- SLS, SLM, DMLS,
EBM, BluePrinter, DMD
etc.
- Polymers, metals and
ceramics
Sheet Lamination
an additive
manufacturing process
in which sheets of
material are bonded to
form an object
Paper (LOM) – using
glue,
Plastic – using glue or
heat
Metal – using welding or
bolts; ultrasonic AM, ...
Directed Energy
Deposition
- an additive
manufacturing process
in which focused
thermal energy is used
to fuse materials by
melting as they are
being deposited
- Wire & Powder
Materials
- Laser & Electro Beams
- Great for feature
addition & repair
Single-Droplet : Solidscape
Modelmakers; 0.0005” layers –
small, accurate parts made
slowly
Market known/
Patent names
Multi-droplet: Thermojet and
Actua from #D Systems; prints
waxy-like materials – no longer
in production, but still serviced
Stereolithography ,
Objet; 3D systems
Envisiontec DLP , Micro-SLA Projet; Stratasys
, 2-photon lithography etc.
Solidscape
machines; Several
Direct Write
machines , etc.
Zcorp; Voxeljet;
ProMetal/ExOne ,
etc.
SLS, SLM, DMLS, EBM,
BluePrinter, Lase
Cusing, etc.
COMPARISON OF EXISTING AM TECHNOLOGIES
Technolo Vat
Material Jetting
gy
Photopolymerization
Binder Jetting
Material Extrusion
Powder Bed Fusion
Sheet Lamination
Directed Energy
Deposition
Develop
ments /
State of
the art
- increased
proliferation of
DLP/LCD/LED
technology to cure
entire layer at once
- new
photopolymer
materials which
mimic engineering
photopolymers
- expiration of initial
Stereolithography
patents are
opening up the
marketplace
- renewed interest
in 2-photon
polymerization for
nano-scale
components
- New Stratasys/Objet
Connex 500 ;
multimaterial & Multicolor
- Many traditional “2D
printing” companies are
investigating 3D printing:
a) thermoplastics are
difficult (viscosity issues)
b) metals are starting to
be publically discussed
- significant interest in
printed electronics;
major industry interest at
the intersection between
2 1/2D & 3D geometries
- 3D Systems
purchased Zcorp and
has changed
marketing to “Colorjet”:
a) printing sugary food
and ceramics (pottery
& art)
b) Announced a color
personal 3D printer
- ExOne is pushing
“sand printing” and
builds metal parts for
Shapeways
-Voxeljet, fcubic, etc.
make marketplace
dynamic:
a) continuous build
platform design has
major ramifications
- expiration of initial FDM
patents has led to a vast
proliferation or personal 3D
printers
- more “personal” machines
sold at $1k-2k than “industrial”
machines for $10k-$200k
- lots of new materials,
competitors
- many ways for consumers to
access & buy these machines
- 3D Systems and Stratasys
offer personal 3D printers in
addition to their industrial
offerings
- renewed interest in
“manufacturing” parts via
extrusion
- high-temperature materials,
concrete, fiber-reinforced
composites, etc.
- people seem to be taking it
more seriously than a few
years ago
- the most used platform
for “functional parts”
- significant R&D
investment
- many metal laser
sintering machine
manufacturers; SLM
Solutions, ConceptLaser,
EOS, Phenix, Renishaw,
Realizer
- Starting to see new
polymer machine
manufacturers; several
companies entering the
marketplace to compete
with 3D Systems & EOS
- open vs. Closed machine
architecture battles
- GE’s purchase of Morris
Technologies (2012) is still
having major ramifications
on the metal laser sintering
marketplace
- Renewed interest in
paper-based machines
at the low-end by Mcor
and others
- Fabrisonics sells 3
platforms based upon
metal ultrasonic AM
Other solid state AM
methods are being
investigated (friction stir
AM, etc.)
- Electron Beam with
wire seems to be
leading for part
production currently
- DoD is interested in
laser powder deposition
for repair (America
Makes project)
- manufacturers are
marketing laser
deposition heads as
add-ons to existing
machine tools
Character
istics/
Disadvan
tages/
Secrets
- always need
support ; thus, we
must remove them
and downward
facing surfaces are
inferior
- photopolymers do
not have long-term
stability in the
presence of light –
they continue to
react and degrade
overtime
always need supports;
1) thus we must remove
them;
2) downward facing
surfaces are inferior
(particularly true if
secondary support
materials are not used)
- secondary support
materials make support
removal easier:
a) different strength,
b) water soluble
c) different melting
temperature
1) parts from
starch/plaster look
pretty but are quite
brittle
- post-process
infiltration of these
materials by
cyanoacrylate or
another material
needed for strength
(infiltration makes
these parts very
heavy)
2) metal parts are not
engineering-grade:
-mostly applicable to
art
-need infiltrated
(highest accuracy) or
sintered (shrinks)
- always needs supports
a) thus we must remove them
b) downward facing surfaces
are inferior
- secondary support material
make support removal easier
(water soluble, easier to
remove etc)
- fundamental tradeoffs in
build style mean you can
NEVER be fully dense and
simultaneously achieve
maximum accuracy without
post-processing
- an expert user is the
most critical aspect of
getting a good part
- user-selected trade-offs
between speed, accuracy
and strength in polymer
laser sintering
- takes about a year to
learn enough to
consistently make good
parts in metal processes
- polymers are not 100%
recyclable
- metal supports are a
huge problems
- $50k-$100k/year per
machine waste is common
(blade crashes and/or
over-supporting)
- Getting rid of excess
material is difficult
cut then stack – vs.
Stack and cut
- Mechanical properties
are typically quite poor
- Material needs
something to land on
(supports)
- we don’t typically make
3D complex parts, just
complex parts with
mostly upward- facing
features
- there is a direct
correlation between
feature size and build
speed
- accurate processes
are painfully slow
- fast process is very
inaccurate
- surface finish &
accuracy requirements;
almost always require
finish machining
http://www.isis3d.net/pages/isisonefeatures
COMPARISON OF EXISTING AM TECHNOLOGIES
Technology Vat
Material Jetting
Photopolymerization
Materials in
...
What is the
technology
best for?
Binder Jetting
Material Extrusion
Materials in VP:
- over 20 years of
photopolymer
research, including
by major chemical
companies, has
led to many resins
which you can buy
- no materials are
“standard
engineering-grade”
polymers – they
are just speciallyformulated to
mimic engineering
polymers
-only commercial
materials are waxlike materials or
photopolymers
a) need low
viscosity
b) waxes melt at
low temperature,
but solidify quickly
c) photopolymers
are cured using
light just after
deposition
- no materials are
“standard
engineering-grade”
polymers – they
are just speciallyformulated to
mimic engineering
polymers
- majority of the
build material is
powder (- makes
the process very,
very fast)
- materials are by
nature “composite”
- gradients in
color/properties
possible by printing
different binders
- any powder
which can be
spread and then
glued, reacted,
catalyzed, or
otherwise fused
using a binder is a
candidate
- living tissues and
dental ceramics
are promising
- Commercial
materials include
easy to extrude
engineering
polymers:
a) ABS, PC,
PC/ABS, PPSF, etc.
b) Chocolate and
meltable food
products
c) many DIY
materials being
explored
- Syringe & pumped
nozzles also
available
a) pastes, glue,
cement
b) frosting and other
food products
- Need materials
which soften under
shear load and
maintain their shape
after deposition
- high accuracy
parts that don’t
have stringent
structural
requirements
- patterns: investment casting,
RTV molding, etc.
-smooth, accurate
parts that don’t
have stringent
structural
requirements
-mixing of stiff and
flexible
materials/colors
gives tremendous
variability in
design:
a) artwork
b) full-color mockups
c) gradient material
assemblies, etc.
- color parts used
for marketing or
proof-of-concept
- metal parts for
artistic purposes or
with limited
engineering
functionality
- powder metal
green parts
- sand casting
molds
- inexpensive
prototypes
- functional parts
without stringent
engineering
constraints (limited
fatigue strength)
- great platform on
which to try lots of
things:
a) living tissue
b) food
c) toys
Powder Bed Fusion
- Polymer Materials in PBF
you can use any material you want as long
as it’s nylon (or if it meets the cooling
curve)
opposite of injection molding (fast heating,
slow cooling)
- Metal material in PBF
most casting and welding alloys can be
processed using metal laser sintering
very fast melting & solidification times
gives unique properties & challenges
high reflectivity, high thermal conductivity
materials are difficult to process (copper,
gold, aluminum, etc.
- Titanium is the “sweet spot” for EBM
- Other materials in PBF
Ceramics are difficult, but possible to
directly process
Green parts are easy to process
powder metallurgy, sand casting, etc.
Manufacturing end-use products:
- polymer parts from Nylon 11 or 12
(including glass filled nylons)
- metal parts from Titanium, Stainless
Steel, Inconel super alloys, tool steels and
more
- Prototyping components where functional
testing is required on prototype
Sheet Lamination
Directed Energy
Deposition
- Paper is used for
proof of concept parts
color printing on the
paper gives color parts
- Metal sheets can be
cut and stacked for
tooling and other
applications
- Ceramic tapes can
be cut and stacked
and then fired for
ceramic parts
- Polymer sheets (such
as Solido) can be
bonded and cut to form
prototypes
- most metal alloys can
be deposited with some
success
- rapid cooling affects
properties
- polymers and ceramics
rarely used, but possible
- Paper machines
make cheap physical
representations of your
design
- Original LOM-like
machines can be used
like wood as patterns
for sand casting, or as
topographical maps,
etc.
- Metal laminated
tooling reduces the
time to build large
molds such as for
stamping
- micro-fluidic ceramic
parts can be made
using ceramic tapes
- Adding features to
existing structures;
replace complex ; forgings with sheet
structures that we build
up near-net shape parts
on
- Repair & refurbishment
of existing components;
- qualified for many
high-performance
applications
COMPARISON OF EXISTING AM TECHNOLOGIES
Material Jetting
Technology Vat
Photopolymerizat
ion
Special info
Binder
Jetting
Material
Extrusion
Powder Bed Fusion
Sheet Lamination
Directed Energy
Deposition
Electron Beam Melting (EBM) Arcam
- electrons are emitted from a heated filament >2500
deg C
- electrons accelerated through the anode to half the
speed of light
- a magnetic lens focuses the beam
- another magnetic field controls deflection when the
electrons hit the powder, kinetic energy is transformed
to heat
- the heat melts the metal powder
EBM vs. Laser Processes:
- EBM Benefits :
energy efficiency
high power (4kW) in a narrow beam
incredibly fast beam speed (no galvanometers)
fewer support
- EBM drawbacks:
only works in a vacuum (gases, even inert, deflect the
beam)
does not work well with polymers and ceramics
(needs electrical conductivity)
needs larger powder particles
POWDERS:
- small powder particles
give better feature resolution, surface
finish, accuracy and layer thicknesses
are difficult to spread and/or feed
become airborne easily (repel in EBM)
react with oxygen easily
- spherical powders with a tight PSD are
best
- powder morphology, packing density,
fines, etc. make a HUGE difference in
some processes
Courtesy of Prof Brent
Stucker, Founder and
CEO of 3DSIM LLC,
Professor of Industrial
Engineering Edward Reep
Clark Chair of Computer
Aided Engineering,
Department of Industrial
Engineering, University of
Louisville
“Reshaping Manufacturing;
Understanding 3D Printing
Processes”, Inside 3D
Printing, New York, 2014
COMPARISON OF EXISTING AM TECHNOLOGIES
Technolog Vat
Material
y
Photopolymerizati Jetting
on
video
Binder
Jetting
Material
Extrusion
Powder Bed
Fusion
Sheet
Lamination
https://www.yout
ube.com/watch?v
=vHg0-nZK2P4
https://www
.youtube.co
m/watch?v
=lgcKYjqnMs
https://www
.youtube.co
m/watch?v
=NVJifm2b
6-c
Aluminum
extrusion:
https://www.yo
utube.com/wa
tch?v=QMMSr
hhaj1s
Arcam EBM :
https://www.you
tube.com/watch
?v=lUIipa3AgN
g
https://www.y
outube.com/w
atch?v=YmX3
qKJdqvA
Stereolithograph
y:
Objet’s
PolyJet:
https://www
.youtube.co
m/watch?v
=TQgbMM
w1GHo
Stratasys’
FDM
technology:
https://www.you
tube.com/watch
?v=jqjDFWMexo
https://www.y
outube.com/w
atch?v=Z1WN
A6tdfWM
ZPrinter
line:
FDM:
https://www.yo
utube.com/wa
tch?v=dpL0Y2
l_BSI
https://www.you
tube.com/watch
?v=dpL0Y2l_B
SI
Mcor
Technologie
s printers
FDM:
https://www.yo
utube.com/wa
tch?v=SPtkO
mP_HoA
https://www.you
tube.com/watch
?v=E7-ZWPVVdQ
EOS’ direct
metal laser
sintering
https://www.you
tube.com/watch
?v=iLndYWw5_
y8
Directed Energy
Deposition
Optomec
LENS
systems:
https://www.yo
utube.com/wat
ch?v=mkUVU
RLkxS4
Source:
various online
websites
COMPARISON OF EXISTING AM TECHNOLOGIES
STATE OF THE ART OF THE INDUSTRY
STATE OF THE ART OF THE INDUSTRY
http://www.solidconcepts.com/
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
•
•
•
•
•
•
PolyJet Technology https://www.youtube.com/watch?v=Som3CddHfZE
Stereolithography (SL) Technology
https://www.youtube.com/watch?v=NM55ct5KwiI
Laser Sintering (LS) Technology
https://www.youtube.com/watch?v=9E5MfBAV_tA
Fused Deposition Modeling (FDM) Technology
https://www.youtube.com/watch?v=WHO6G67GJbM
Metal Laser Sintering (MLS) Technology
https://www.youtube.com/watch?v=bgQvqVq-SQU
Cast Urethane Technology https://www.youtube.com/watch?v=rjFdbhCjKPY
http://www.solidconcepts.com/
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS
Solid Concepts : Hybrid projects
Courtesy of Chuck
Alexander , Solid Concepts Ins; conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
http://www.materialise.com/, Belgium
Courtesy of Materialise;
conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
http://www.materialise.com/, Belgium
Courtesy of Materialise;
conference: Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
http://www.within-lab.com/UK
https://www.youtube.com/watch?v=22Gb0PbmZYU
Video : EOS M270 + Within technologies + design
https://www.youtube.com/watch?v=k-wMKnjGa4Q
2.46 - 5.00; lattice structure 5.37 – 6.50, 9.40 FEA software;
e.g. Orthopedic implants 12.50-15:35 if time
Or 24:07; 26:17 shoe; 39 future 39- 42:06
Special designs of heat exchangers
Courtesy of Within-lab; conference:
Inside 3D printing
STATE OF THE ART OF THE INDUSTRY
Courtesy of Rupert Soar and Farid Fouchal
Construction Processes for the Digital ‘Trinity’ (2008)
DIGITAL TRINITY
http://vimeo.com/80893331 0:20-2:20
STATE OF THE ART OF THE INDUSTRY
A) 3D scanning
123Dcatch/ Mudbox/AutoCAD
B) 3D modelling
C) 3D printing
Rhino/Grasshopper
Kangaroo – FEA of structural
performance of the object (pressure)
Symvol : Adding new function –
e.g. hygroscopic performance of the bulk material
DEVELOP PLATFORM FOR ANY PURPOSE
MATERIAL – BASED DESIGN COMPUTATION
SUBTERRAINS
RAYCOUNTING
MIT MediaLab: 3-D printing with variable densities
https://www.youtube.com/watch?v=0nFyuxGEhzY
BEAST
CARPAL SKIN
Courtesy of Neri
Oxman; various sources and presentations;
Thesis: Material-based design computation
http://hdl.handle.net/1721.1/59192
RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
STATE OF THE ART IN SCIENTIFIC RESEARCH (MATERIALS,
SIMULATIONS, ETC.)
“Materials are key to the future success of 3D printing”
Wohlers Report
Examples of special cases materials:
Washington State University : bone-like material (support for new bone growth)
University of Glasgow: organic compounds and inorganic clusters (customized medicines)
University of Warwick : Carbomorph – conductive plastic (“functioning electronic device”)
Cambridge University & PARC: thin film transistors
Xerox PARC: Chiplets
- grain of sand
- containing intelligent data
-microscopic electronic building blocks
Tsinghua University & Chinese Academy of Sciences : Self – forming Metal
North Caroline State University: Liquid metal
- flexible, stretchable, alloy of gallium and indium
- liquid at room temperature
- “self-healing” – mechanically and electrically
Carbomorph
Thin film transistors
NASA/ Ames Research Center: Bio- Composites
- “in-situ, on demand printing of advanced bio-composites”
- 3D printing cells – from molecules in surrounding environment into usable material
- €1 billion European Commission Initiative /75 institutions and partners/17 EU countries: Graphene flagship
- Graphene: flexible, transparent, conductive, harder than diamond, 200x stronger than steel
- Graphene 3D Labs/Lomiko Metals
- University of Pittsburgh, Harvard School of Engineering, University of Illinois / US Army Grant: 4D materials
- materials that modify their own structure at the macro level; adaptive, biomimetic composites that
reprogram their shape, properties or functionalities on demand, based upon external stimuli”
3D PRINTING/ ADDITIVE MANUFACTURING – THE BIG PICTURE
Materials in general, 3000 common types
Polymers in general
Thermoplastics
Material demands for 3DP
Form proper feedstock
Fabricator processability
Post - procesabillity as needed
Acceptable Service Properties
Materials’ grand challenge in AM
Quality
Process consistency
Reliability
Wide diversity of compositions
Superior structure and properties
Low (feedstock and processing) cost
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: “Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS
Materials for AM
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: “Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS
Mechanical properties
-
Stress or Strength (take a load without failing)
Ductility (permanent elongation at failure)
Stiffness (Measure of Springiness)
Fracture Toughness (Ultra-strong or ultra-brittle)
Fatigue (Elastic cyclic loading)
POROSITY : Processing Effects on Porosity in SLM Processed 17-4 Stainless Steel
Strength
<0.5 ksi A part “falls apart”
20ksi Most Wood/Plastic
80 ksi Structural Steel/Aluminum
400 ksi High-Strength Steel
A.B. Spierings, K. Wegener, G. Levy, “Designing Material Properties Locally with Additive
Manufacturing technology SLM “, Proc. SFF Symposium (2012), pp. 447-455.
POROSITY : Examples of Porosity in EBM Ti-6AI-4V
Summary of AM Mechanical Behavior
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: “Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
Khalid Rafi. H, Karthik N.V, Thomas L. Starr*, Brent E. Stucker, “Defect formation in EBM parts
built in horizontal orientation“, Proc. SFF Symposium (2012), pp. 456-467.
STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS PROPERTIES
STRENGTH
STRENGTH : Modulus of Elasticity
316L Stainless Steel SLM, As
Processed
J. P. Kruth et al, “Binding mechanisms in selective laser sintering and selective
laser melting, Proc. SFF Symposium (2004), Univ. Texas at Austin, pp. 44-58.
STRENGTH: SLM 316 Metals
Majewski C & Hopkinson N (2011) Effect of section thickness and build orientation on tensile properties and
material characteristics of laser sintered nylon-12 parts. RAPID PROTOTYPING JOURNAL, 17(3), 176-180“
or on, Proc. SFF Symposium (2010), Univ. Texas at Austin, pp. 422-34.
STRENGTH : Modulus of Elasticity
Unpublished results,
Tom Starr, U. Louisville
STRENGTH: SLM of Ti-6Al-4V
Table for AM Ti-6Al-4V;;
Unpublished results,
Tom Starr, U. Louisville
S. Rusenberg, L. Schmidt, and H.-J. Schmid, “ Mechanical and Physical Properties
– A Way to Asses Quality of Laser Sintered Perts, Proc. SFF Symposium (2011),
Univ. Texas at Austin, pp. 239-51.
SCIENTIFIC RESEARCH / MATERIALS PROPERTIES
STRENGTH AND DUCTILITY
STRENGTH
66Co-28Cr-6Mo
EBM, HIP,
Homogenized
Yasa E., Kempen K., Kruth J.-P.
Catholic University of Leuven, Dept. of Mechanical Engineering
MICROSTRUCTURE AND MECHANICAL PROPERTIES OF MARAGING STEEL 300 AFTER
SELECTIVE LASER MELTING
“, Proc. SFF Symposium (2010), Univ. Texas at Austin, pp. 383-96.
R.S. Kircher, A.M. Christensen, K.W. Wurth “Electron Beam Melted (EBM) Co-Cr-Mo Alloy for Orthopaedic
Implant Applications
“, Proc. SFF Symposium (2009), Univ. Texas at Austin, pp. 428-36.
Mechanical behavior of LS Nylon
Mukesh Agarwala, D. L. Bourell, B. Wu and J. J. Beaman,
An Evaluation of the Mechanical Behavior of Bronze-NI Composites Produced by Selective Laser Sintering
193 ; Proc. SFF Symposium (1993), Univ. Texas at Austin, pp. 193-203
D.K. Leigh, Harvest
Technologies, priv. comm., 2011.
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: “Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
http://utwired.engr.utexas.edu/lff/symposiu
m/proceedingsArchive/toc.cfm.
SCIENTIFIC RESEARCH / MATERIALS PROPERTIES
MECHANICAL PROPERTIES OF AM PARTS:
DUCTILITY
SLM Ti-6Al-4V (BASED ON POST-PROCESS ANNEALS
(FURNACE COOLED)
M. Thöne, S. Leuders, A. Riemer, T. Tröster, H.A. Richard;
Influence of heat-treatment on Selective Laser Melting products –e.g. Ti6Al4V
Proc. SFF Symposium (2012), Univ. Texas at Austin, pp. 492-498.
Ti DUCTILITY
D.K.Leigh, D.L.Bourell, J.J.
Beaman, “ Basis for Decreased
Mechanical Properties of
Polyamide in Selective Laser
Sintering”, Proc. SFF
Symposium (2011), Univ. Texas
at Austin,
Ben Vandenbroucke and Jean-Pierre Kruth,
Selective Laser Melting of Biocompatible Metals for Rapid Manufacturing of
Medical Parts 148”,
Proc. SFF Symposium (2006), Univ. Texas at Austin, pp. 148-159
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: “Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
SCIENTIFIC RESEARCH / MATERIALS PROPERTIES
MECHANICAL PROPERTIES OF RM PARTS:
FATIGUE / FRACTURE
MECHANICAL PROPERTIES OF RM PARTS:
FATIGUE
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing
Center, LFF; Laboratory for Freeform Fabrication:
“Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
MECHANICAL PROPERTIES OF RM PARTS:
FRACTURE TOUGHNESS
P. A. Kobryn and S. L. Semiatin:
Mechanical Properties of Laser-Deposited Ti-6Al-4V 179
Proc. SFF Symposium (2001), Univ. Texas at Austin, pp. 179-186
MECHANICAL PROPERTIES OF RM PARTS:
FATIGUE
Reid, Fatigue of Fused
Deposition Modeled
(FDM) Acrylonitrile
Butadiene Styrene
(ABS) Stage Three
Individual Project MEC
3098, Newcastle
University School of
Mechanical and
Systems Engineering
2011.
P. A. Kobryn and S. L. Semiatin:
Mechanical Properties of Laser-Deposited Ti-6Al-4V 179
Proc. SFF Symposium (2001), Univ. Texas at Austin, pp. 179-186
SCIENTIFIC RESEARCH / MATERIALS PROPERTIES
AGING EFFECTS ON MECHANICAL PROPERTIES OF SL POLYMER
SUMMARY OF AM MECHANICAL BEHAVIOR




Karina Puebla, Dissertation:
Effects of build orientation, aging, and pre-conditioning on mechanical properties for
Stereolithography-manufactured ASTM type I specimens using a design of experiments
approach;
Karina Puebla, Karina Arcaute, Rolando Quintana, Ryan B. Wicker: Effects of environmental
conditions, aging, and build orientations on the mechanical properties of ASTM type I
specimens manufactured via Stereolithography,
Rapid Prototyping Journal 07/2012; 18(5):374-388.
ASTM STANDARDS wrt MATERIALS/PROPERTIES
Mechanical behavior is predictable based on the traditional understanding
of microstructure and processing
Porosity has a strong influence on the mechanical behavior
Anisotropy is not an issue if parts are built with low porosity and good
layer interface
Polymer produced using best practice have isotropic strength and anisotropic
ductility
OVERALL SUMMARY

3DP is here to stay and the market is developing explosively

Materials for 3DP offer an opportunity for business venture

Market timing is a factor entry into 3DP materials

3DP fabricators will continue to proliferate driven by expiration of founding
patents over the next 1-5 years

There is not much brans loyalty of materials among users of 3DP materials
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication:
“Materials for 3D Printing”,, Inside 3D Printing, San Jose, 2013
ALL RELEVANT SCIENTISTS IN THE FIELD:
SFF SYMPOSIUM AT THE UNIVERSITY OF TEXAS AT AUSTIN
ALL UP TO DATE PROCEEDINGS AND THE INFORMATION ABOUT THE SCIENTISTS:
http://utwired.engr.utexas.edu/lff/symposium/proceedingsArchive/toc.cfm
SCIENTIFIC RESEARCH / MATERIALS PROPERTIES
State of the art in SIMULATIONS related to AM technologies
It is still NOT POSSIBLE to:
-
Efficiently represent multi-scale geometry in a CAD environment
Efficiently optimize multi-scale features
Efficiently simulate the link between AM process parameters and microstructure
Efficiently compute the effects of changes in microstructure on part performance
It IS NEEDED:
- Improved computational design tools for additive manufacturing
- like those used for injection molding and casting/forging
- Physics- based tools are inefficient when applied to AM
- Requires dramatic simplification of the process and/or geometry
- AM industry software focuses primarily on geometry and not process control or performance/quality
- forces the AM industry to continue to Build/Test/Redesign cycle of traditional manufacturing
- Process simulations that are faster than an AM machine builds a part
- predict residual stress and distortion so we know how to place support and how to pre-distort
our CAD model
- Material simulations which can predict crystal level details and the resulting mechanical properties
- Lighting fast solutions on GPU-based platforms
- We simulate only what we need to get a practical answer as FAST as possible
Courtesy of Prof Brent Stucker, Founder and CEO of 3DSIM LLC, Professor of Industrial Engineering Edward Reep Clark
Chair of Computer Aided Engineering, Department of Industrial Engineering, University of Louisville
“Reshaping Manufacturing; Understanding 3D Printing Processes”, Inside 3D Printing, New York, 2014
STATE OF THE ART OF THE INDUSTRY & RESEARCH IN SIMULATIONS
PRICING?
IMPOSIBLE TO GET CREDIBLE QUOTES FROM SPECIFIC SERVICE PROVIDERS
http://gpiprototype.com/blog/dmls-in-aluminum-inconel-or-titanium-is-it-worth-it.html
http://pencerw.com/feed/2014/1/6/dmls-pricing
PROTOTYPE A SEGMENT OR A POLIFUNCTIONAL CUSTOMIZED UNIT OF A CURTAIN WALL
Courtesy Adam Cohen, Principal Consultant and CEO of Additive Insight LLC
STATE OF THE ART OF THE INDUSTRY
Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK
RESEARCH/ MATERIALS: ENERGY CONSUMPTION
Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK
RESEARCH/ MATERIALS: ENERGY CONSUMPTION
Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK
RESEARCH/ MATERIALS: ENERGY CONSUMPTION
Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft, E. Rosamond, and R. Hague
COMBINED BUILD – TIME, ENERGY CONSUMPTION AND COST ESTIMATION FOR DIRECT METAL LASER SINTERING
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham,
NG7 2RD, UK
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Courtesy of M. Baumers
Production cost, machine productivity and the emergence of an Additive Manufacturing
industry
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Courtesy of M. Baumers
Production cost, machine productivity and the emergence of an Additive Manufacturing
industry
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK
RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST
Specifications
Cm3 / cm2x1cm
AM tech
DMLS
Material
Jetting
EBM
AM machine
EOSINT M270
Object
Connex 260
S12 EBM
Profile
96.645
20.618
16.05
(3mm thick)
16.8
(2mm thick)
Energy
MJ/cm3 : 2.13
205.98
MJ/part
43.94
MJ/part
34.1865
(x100/m’)
35.784
(x100/m’)
Cost
$/cm3 : 10.25
990.61
$/part
211.33
$/part
164.51
(x100/m’)
172.2
(x100/m’)
Energy
MJ/cm3 : 0.11
10.63
MJ/part
2.27
MJ/part
1.7655
(x100/m’)
1.848
(x100/m’)
Cost
$/cm3 : 2.56
247.41
$/part
52.78
$/part
41.088
(x100/m’)
43.008
(x100/m’)
Energy
MJ/cm3 : 0.47
45.42
MJ/part
9.69
MJ/part
7.54
(x100/m’)
7.90
(x100/m’)
Cost
$/cm3 : 3.97
384.87
$/part
81.85
$/part
63.72
(x100/m’)
66.70
(x100/m’)
Build rate
g/h : 37.58
Build rate
cm3/h : 17.75
Build rate
g/h : 69.24
PROTOTYPE A SEGMENT OR A POLIFUNCTIONAL CUSTOMIZED UNIT OF A CURTAIN WALL
SYSTEMS ASSEMBLY
http://www.projectara.com/
http://gigaom.com/2014/04/16/googles-project-ara-still-has-along-way-to-go-before-modular-smartphones-become-a-thing/
STATE OF THE ART OF THE INDUSTRY
SYSTEMS ASSEMBLY
https://www.tno.nl/am
https://www.tno.nl/downloads/LR%20Leaflet%20
Fast%20and%20Flexible%20production21.pdf
STATE OF THE ART OF THE INDUSTRY
RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY
APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
3D printing IS COMPETITIVE
with traditional processes and products
Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED
Courtesy of Buswell, Soar, Gibb and Thorpe
3D PRINTING - BENEFITS FOR THE INDUSTRY
3D printing IS COMPETITIVE
with traditional processes and products
Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED
Courtesy of Buswell, Soar, Gibb and Thorpe
3D PRINTING - BENEFITS FOR THE INDUSTRY
Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED
Courtesy of Buswell, Soar, Gibb and Thorpe
3D PRINTING - BENEFITS FOR THE INDUSTRY
General Problems  Possible Approaches to Solutions
1) Delivery components large enough for building structures = not scaled up RM
segments  new systems and processes
2) Material cost and its heterogeneity  integral part of new delivery systems
3) Construction speed is not greater than in traditional approaches  the
automation process should be re-designed
4) A greater performance of building elements, build-in materials and
specialists’ applications  clever innovative design
3D PRINTING - BENEFITS FOR THE INDUSTRY
DUS Dutch architects/ KamerMaker XL
http://vimeo.com/80355705 0:13 – 1:07
RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
Möbius, Landscape House Janjaap Ruijssenaars
Universal Architecture
D-shape Dini + Rinus Roelofs
Enrico Dini “The Man Who Prints Houses
http://vimeo.com/29984723# 00:39-1:34
RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
Courtesy of Joris Laarman Lab
Courtesy of Berok Khoshnevis, USC
http://www.youtube.com/watch?v=NFF0QQIQDXE 0:07-1:00
Contour Crafting: Automated Construction: Behrokh Khoshnevis at TEDxOjai
https://www.youtube.com/watch?v=JdbJP8Gxqog 6:45 – 8:09
Sciaky http://www.sciaky.com/additive_manufacturing.html 0-1:27
AUTOMATION IN CONSTRUCTION / RESEARCH PROJECTS