Additive Manufacturing @UGent-FEA Open Product and Materials Test Center Centre for Polymer & Material Technologies Prof. Ludwig Cardon CPMT staff 1 ZAP 1 Postdoc 4 PhD’s 5 Research assistants 3 joined PhD researchers 2 • • • Education Chemistry & ElectroMechanics BSc & MSc courses Specialization polymers (1955) • • • • • • • Research (1970) Physical and physical-chemical analyses of polymers-textiles-materials/metals Polymer processing - composites Mould making – hybrid moulds Flow simulation (Moldex3D) Biobased polymers & biomedical applications Re-processing of polymers & composites Additive manufacturing Education (1955) Engineering in Chemistry & Electromechanics Related BSc/MSc courses Mouldmaking Polymer Processing Additive Manufacturing & Prototyping & Product Development Polymers - Composite Materials & Characterization Engineering projects (@ BSc and MSc level) MSc final project work (& involved in research projects) Post graduate IVPV Additive Manufacturing Polymers & Polymer Processing 4 Research (1970) EU Leonardo da Vinci projects Rapid Design (1999-2001) E-Learning Hybrid Moulds (2003-2006) Pro-Mould (2008-2010) Re-Mould (2012-2014) EU & other EFRO 916 (2013-2014) “Open Product and Materials Test Center” @ Technologiepark 915 Zwijnaarde together with TPVision & partners >1.4 million euro 5 Research EU & other Common PhD & MSc projects together with KULeuven UMinho TUDelft Aalen Birmingham … ERA-SME BioMoulding Sichuan University Chengdu – China Summer Courses joined PhD research State Key Lab Polymer Engineering & AM 6 Research Flemish projects IWT-HOBU SLS materials (2003-2005) IWT-TIS Additive Manufacturing (2004-2006) IWT-TETRA HybridMoulds (2005-2007) IWT-TIS HybridMoulds (2006-2010) IWT-TETRA AM Valorization (2008) IWT-TETRA MicroMoulding (2008-2010) IWT-TETRA BioMoulding (2010-2012) IWT-TETRA Recycling (2013-2015) IWT-SBO DiRaMAP (2008-2012) SIM-SBO STREAM-PolyForce (2013-2017) IWT-VIS “Pack4Food – intelligent packaging” (2011-2015) IWT-VIS “DURBIO – sustainable products for T&P” (2012-2015) IWT-TETRA “Re-processing of postconsumer PE/PP” (2013-2015) …. 7 Research Recent approved projects at startup phase AO-KMO “TataSteel” AO-KMO “AM for vacuum applications” EFRO 916 ”Open Product and Materials Test Center” Hercules “FLAMINCO” Hercules “E-Beam Lithography” IWT – CICI “PUPA 1.0” New printing heads for FDM based technologies Re-processing of postconsumer polymers Current applications IWT-VIS “FDM4TP” (Sirris & Centexbel) IWT-SBO “Compohex” 8 Service Collaborative research with industry Collaborative research with collective institutes such as Flanders’ PlasticVision, Centexbel, Sirris, … Agentschap Ondernemen DV.T210166 Technologieverkenning 9 Publications Over 80 publications in the field of AM >10 A1 >10 P1 >60 C1 Bi-annual International PMI Conference Joined organization with UMinho Portugal www.pmiconference.eu 10 Polymer processing facilities 4 injection machines (Engel 80T, Engel 28T, Boy 22T, Klockner 70T) 3 single screw extruders 2 Brabender lab extruders, 1 axson compounder 2 twin screw extruders Coperion 18D & 1 reactive extruder (Prof. Du Prez) 1 extrusion blow moulderBekum 1 Stretch blow moulderBekum 1 Co-injection/intrusionMain 3 thermoset presses Comming soon: plate & foil co-extrusion unit equiped with 2 single screw extruders and 1 conical twin screw extruder 11 Polymer processing moulds Injection moulds for research Co-extrusion 2 layer plate die 120 mm Extrusion plate die 150mm Extrusion blow film die diameter 150mm Extrusion blow moulding bottle 1L Extrusion stretch blow moulding bottle 1L Thermoforming mould for packaging applications Comming soon: co-extrusion plate die 500 mm (1/3/5 layers) and co-extrusion blow film die (1/2/3 layers) Collaborative equipment of other FEA research groups 12 Polymer characterization Dynamometers up to 5kN (including heating chamber) Impact tester Peel tester HDT-VICAT MFI Dart drop Weatherometer Viscosimeter DSC-TGA-STA-FTIR Collaborative equipment of other FEA research groups 13 AM facilities 3D BioScaffolder 4 FDM based & modified machines for research 2 new printing head methods LowCost printers in collaboration with the FEA department of Material Sciences and Engineering and other FEA departments Tool & equipment for AM extrusion based wire production Joined equipment with project partners (SLA, SLS, SLM, FDM, EBM, ...) 14 Research lines “Processing of polymer materials” is a result of the large experience related to conventional polymer processing technologies (injection, (blow/film)(co)extrusion and thermoforming). This research studies the processability of polymers (conventional, nano-filled, bio-based, recycling, biomedical, thermal sensitive and high-tech polymers), related to aspects such as: The influence of specific material characteristics and/or –composition on the processability into functional products Special processing techniques for conventional and high-tech materials such as micro-injection, gas assisted injection, intrusion, micro-extrusion, 3D-plotting en multi-material production (co-extrusion) Sustainable use of materials: processing and evaluation of post-industrial and postconsumer recyclates for re-processing 15 Research lines “Additive Manufacturing” (AM) focusses on: The selection and development of new polymer based materials for Laser Sintering (LS) en Fused Deposition Modelling (FDM) or extrusion based AM technologies. The development of printing heads and equipment for polymer extrusion based techniques. The use of AM metal inserts for applications in mould making (hybrid moulds). The use of AM for biomedical applications (scaffolds for tissue engineering). 16 Research lines “Material Characterization and Product Optimalization” are applied to validate the processing results of the other research lines. It defines the relation between material properties and - selection, product development and related processing technologies. Using physical (mechanical, microscopy, density, ...) and physicochemical (DSC, TGA, FTIR, ...) tests, the processing and/or processed materials are evaluated, which provides insight into the relationship between structure/composition and properties, which ensures scientific feedback loop to the other research areas. Where necessary, tests are requested to partner laboratories for techniques that are not available (SEM, TEM, XPS, NMR, GPC, ...). 17 Open Product and Materials Test Center Joined contact point for expertise and networking for education - industry - spin-offs - … Follow up for UGent via CPMT Open innovation center for existing companies, starters, students (entrepreneurs),… Collection of current equipment of both CPMT and TPVision and planned expansion related to current needs Focuss on: Additive Manufacturing Materials Test Center 18 Open Product and Materials Test Center Within the scope of: Nieuw Industrieel Beleid van de Vlaamse regering om de maakindustrie in Vlaanderen te versterken The center also offers the opportunity to translate business expertise and technology that fits in the Key Enabling Technologies of Advanced Materials, Advanced Manufacturing (Additive Manufacturing), Nanotechnology and Nano-electronics and implement them into concrete products. 19