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1PADT CONFIDENTIAL

Answers to your Questions

on Metal 3D Printing

February 2016

Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.

Rey ChuPrincipal, PADT Inc.

Email: metal-am@padtinc.com

Concept Laser Metal 3D Printing at NASA Marshall

2PADT CONFIDENTIAL

• 50 min talk, 10 minutes open Q&A

• Submit questions or issues through chat window (bottom left) at any time– Select “Send to Presenters”

• Submit question via email after the webinar to metal-am@padtinc.com

Webinar Logistics

3PADT CONFIDENTIAL

Dhruv Bhate

• Senior Technologist at PADT, Inc.

• Ph.D. in Mechanical Engineering (Purdue, 2008), M.S. in Mechanical Engineering (CU Boulder, 2003)

• 7 years experience in laser-based manufacturing in the semiconductor industry

• Currently focused on 3D printing of high performance polymers and metals at PADT

Speaker Bios

Rey Chu

• Co-Founder of PADT, Inc. and Principal, Manufacturing Technologies

• Over 25 years experience in additive manufacturing / 3D printing processes, involved with process and application development since the early 1990s

• Frequent speaker at additive manufacturing seminars and conferences

4PADT CONFIDENTIAL

Objectives of this Webinar

1. Introduce PADT and Concept Laser

2. Describe metal 3D printing technology by answering the questions we most often get about it

3. Provide a gateway to assessing if and how metal 3D printing can benefit you and your company

5PADT CONFIDENTIAL

• Introductory:– Who are PADT and Concept Laser?

– How does laser-based metal 3D printing work?

– Are there other ways to 3D print in metal and how do they compare?

• Technical:– What are the different process steps involved?

– How “good” are 3D printed metal parts?

• Strategic:– What materials and machines do you offer?

– Who uses this technology today?

– What is the value proposition of metal 3D printing for me?

– What can I do after this webinar?

Outline of Questions

6PADT CONFIDENTIAL

Who are PADT and

Concept Laser?

7PADT CONFIDENTIAL

PADT: What We Do

ManufacturingProduct

Development

Simulation

Sales Services Training ConsultingR&D

8PADT CONFIDENTIAL

PADT by the Numbers

• Founded in 1994, 21 years in business

• 82 employees

– 19 years average experience, 4 PhDs & 13 Masters degrees

• R&D labs with $2M in equipment

• Over 1700 Customers served

– Over 100000 Prototypes & Functional Parts Delivered

• 3D Printing since 1994

– Over 350 product development projects completed

– Over 7200 numerical simulation models run

• Over 7600 Support Cleaning Apparatus (SCA) Systems Sold

• Stratasys Platinum Partner 2015 – Highest commercial reseller award

• ANSYS Channel Partner

• 13 Small Business Innovation & Research (SBIR) awards since 1999

9PADT CONFIDENTIAL

PADT Additive Manufacturing (AM) Technology Timeline

20152010200520001995

Stereo

lithography

1994*

SLA 250

Selective Laser

Melting (Metal)

MLab Cusing R

Selective Laser

Sintering

Material Jetting

(Polyjet)

1999

Sinterstation 2000 plusHiQ Thermal

Sensing Upgrade

2005

Multi-zone

Heating Upgrade

2012

Viper Si2

2006

ProJet 6000

2011

Connex 500

2009

Objet 500

2014

2015

Fused Deposition

Modeling

FDM 2000

1995*

Prodigy

2000*

Dimension

2002

Fortus 400 Fortus 450

2009

*retired

10PADT CONFIDENTIAL

PADT Recognition & Outreach

Voting member, ASTM Standards

F42 on Additive Manufacturing

Additive Manufacturing Users Group 2012 DINO Award (Brad Palumbo)

Supporting startups at the Center for Entrepreneurial Innovation (CEI)

America Makes Silver Member

Highest partner status for commercial resellers

2011 Governor's Celebration of Innovation Pioneering Award

2011 Spirit of Enterprise Award (Entrepreneurial Leadership)

Supporting AM Capstone Project for 6 Engineering Seniors

AZ Bio Fast Lane Award 2011 (PADT Medical)

13 awards, Commercialization Index of 90, Small Business Innovation Research (SBIR)

www.concept-laser.de11 | Concept Laser GmbH

About - Concept Laser

Concept Laser is the global leader in the design and manufacture of powderbed-based laser metal additive manufacturing systems.

www.concept-laser.de12 | Concept Laser GmbH

About - Concept Laser - Background

· 1997 – Development of Laser Melting Technology

· 1999 – First patent for stochastic exposure

· 2000 - Concept Laser GmbH established

· 2002 – First machine delivery for metal 3D Printing

· 2003 – Sales, Marketing and Service structureimplemented

· 2012 - Concept Laser, Ningbo (China) established

· 2014 - Concept Laser Inc., Dallas (USA) established

13PADT CONFIDENTIAL

Concept Laser and PADT

• PADT exclusive reseller for Concept Laser Inc. in AZ, NM, CO, UT and CA

• PADT offices in all 5 states,

HQ in AZ with metal machine

and benchmark capability

• Strong partnership between the two companies built on relationships extending back over two decades

• Partnership based on each company’s technical strengths

14PADT CONFIDENTIAL

How does Metal 3D

Printing Work?

15PADT CONFIDENTIAL

Laser

Inert gas

Coating

Powder

Metal 3D Printing Working PrinciplePowder Bed Laser Fusion (LaserCusing®)

Video (dual laser)

16PADT CONFIDENTIAL

Process Physics

Wayne King et al. (LLNL), 2015

Wayne King et al. (LLNL), 2015

https://str.llnl.gov/january-2015/king

Gockel et al., 2014

17PADT CONFIDENTIAL

Are there other ways to

3D print metal and how

do they compare?

18PADT CONFIDENTIAL

Electron Beam Melting

Metal 3D Printing Technologies

Powder Bed Fusion Directed Energy Deposition

Powder Bed Binder Jetting

http://www.sciaky.com/

http://www.optomec.com/

Laser based fusion (LaserCusing®, SLM, DMLM)

http://www.me.vt.edu/dreams/binder-jetting/

19PADT CONFIDENTIAL

Comparison of Metal AM Technologies

Laser Powder Bed Fusion Electron Beam Powder

Bed FusionDeposition Binder Jetting

� High build temperature provides good shape stability and low residual stress in the part requiring fewer or no supports

� Surface morphology well suited for bone integration

� Good mechanical properties

� Reduced material choices (Ti, CoCr)

� Higher capital cost� Poor surface roughness

� Very high deposition rates and very large structures

� Lower material costs especially with wire

� No need for recycling powders, higher material usage efficiency

� Functionally graded materials

� Large material options

� Poor detail and resolution compared to laser melting

� Poor surface roughness compared with laser melting

� Good mechanical properties and high densities

� Large build volumes� Large material options

� Need for support structures requires expert design and setup for print

� Stress relief and support removal post processing steps

� No support structures needed

� Faster and more affordable to print than powder bed fusion

� Large material options

� Limited mechanical properties compared to powder bed fusion techniques

Versatile, Strong

Properties Very Large Parts

Complex Designs in

Titanium, Strong

PropertiesFast, Affordable

20PADT CONFIDENTIAL

What are the

different process

steps involved?

21PADT CONFIDENTIAL

Concept Laser LaserCusing Process

https://www.youtube.com/watch?v=Ar2LmOpm8W0

22PADT CONFIDENTIAL

Post-Processing for a Finished Part

www.protolabs.com

Excavation

Parts fused to build

platform by supports

Heat Treatment

• Stress relief• Void minimization• Microstructure optimization

Ti6Al4V

Unoptimized

Vacuum furnace

Support Removal

Bandsaw

Wire EDM

Shot peening

Finishing

Tumbling &

Polishing

Other Processes:

• Electrochemical polishing• Abrasive Flow Machining

(Extrude Hone) for internal surfaces

http://www.sjf.tuke.sk/transferinovacii/pages/archiv/transfer/21-2011/pdf/143-148.pdf

23PADT CONFIDENTIAL

Ancillary Requirements for Operating Machines

Vacuuming & Disposal

Milling Bead Blasting Demagnitization

PPE & Class D Fire Extinguisher

Data Preparation Software Build Plate Preparation

Inert Gas (N2/Ar)

Sieving

Magics

24PADT CONFIDENTIAL

How “good” are 3D

printed metal parts?

25PADT CONFIDENTIAL

Solidification Structure: Macrostructure

• Dimensional resolution and tolerances

• Surface Roughness (Rz)

EPMA

Layer Thickness Min. Feature Size

20 µm (0.0008”) 150 µm (0.006”)

30 µm (0.0012”) 380 µm (0.015”)

Beam spot size = 50um

Layer Thickness (varies)

Tolerances: “Typically, tolerances of ±0.003 in. (76µm), plus an additional 0.001

in./in. (0.001mm/mm), are expected and achieved on well-designed parts”

- Real-world experience from ProtoLabs Yasa et al. (2014)

26PADT CONFIDENTIAL

Solidification Structure: Microstructure

• Density

EPMA

- Densities of 99.7-99.9% demonstrated for Ti6Al4V, further improvements possible with HIP

Ti6Al4V

Ti6Al4V

Kruth et al, ISEM XVI

• Grains and Phases

- Fine grains due to rapid solidification

Top

Side

27PADT CONFIDENTIAL

Mechanical Properties

EPMA (from Fraunhofer IFAM)

3D

Pri

ntin

g +

HT

3D

Pri

ntin

g +

HT

3D

Pri

ntin

g +

HT

3D

Pri

ntin

g +

HT

Fo

rge

d

Fo

rge

d

Fo

rge

d

PM

+H

IP

PM

+H

IP

PM

+H

IP

28PADT CONFIDENTIAL

Industry-specific Applicability

Mantel, 2011, Stellenbosch University, South Africa, http://hdl.handle.net/10019.1/18142

29PADT CONFIDENTIAL

Real Time Quality Management (QM)

30PADT CONFIDENTIAL

Aerospace and Medical Certification

Aerospace

• FAA and FDA approving each product on a case-by-case basis.

• FDA additional concerns of device cleanliness, biocompatibility and removal of processing materials.

• Ongoing efforts along with ASTM and ISO to establish 3D printing certifications

Medical

Sensor Housing: First metal 3D printed engine part, FAA approved April 2015

Spinal Implant: Titanium alloy, approved by FDA July 2015

Hip Implant: Titanium alloy, approved by FDA in 2011

31PADT CONFIDENTIAL

What Materials and

Machines do you offer?

32PADT CONFIDENTIAL

Non-Reactive Metals Reactive Metals

http://www.conceptlaserinc.com/materials/

Materials

316L Stainless Steel 30Al/31Al Aluminum Alloy Ti6Al4V Titanium Alloy

Commercially Pure Titanium

Maraging Hot-Work Steel

Bronze Alloy

Stainless Hot-Work Steel

17-4 PH Stainless Steel Inconel 718 Inconel 625

Biocompatible CoCrW Alloy

Biocompatible Ti6Al4V Alloy

33PADT CONFIDENTIAL

Machines OfferedB

uil

d

Vo

lum

eC

ost

*M

ate

rials

Xline 2000R

31.5” x 16” x 20”

Reactive & Non-Reactive

$2.1-2.3 M

M2 Cusing

10” x 10” x 11”

Reactive & Non-Reactive

Single Laser: $ 650-750 KDual Laser: $750-950 K

M1 Cusing

10” x 10” x 10”

Non-Reactive only

$ 450-600 K

Mlab Cusing R

3.5” x 3.5” x 3”

Reactive & Non-Reactive

$ 235 K

Mlab Cusing

3.5” x 3.5” x 3”

Non-Reactive only

$ 200 K

*Prices are approximate, shipping costs not included

34PADT CONFIDENTIAL

Who uses these

machines today?

35PADT CONFIDENTIAL

Application Sectors

Aerospace Automotive Tooling

Medical Dental Jewelry

36PADT CONFIDENTIAL

Case Studies

Drills with improved cooling flow

Mapal Inc.http://www.etmm-online.com/additive_technology/articles/511008/

Fuel system assembly (10 parts reduced to 1 with 70% cost, and

42% weight reduction)

Airbushttps://youtu.be/Cy3V3KR1LWc

Dental crowns and implants

Laser Add Center, GmBHhttp://www.laser-add-center.de/application/dental.html

37PADT CONFIDENTIAL

What is the Value

Proposition of Metal

3D Printing for me?

38PADT CONFIDENTIAL

The Metal 3D Printing Value PropositionDriver 1: Functional Prototypes in Product Development

Flypcap

39PADT CONFIDENTIAL

The Metal 3D Printing Value PropositionDriver 2: Design Opportunity

Internal Features

Assembly Consolidation

Strength-Weight Optimization

Bio-Inspired

Concept Laser

Airbus

Boeing

GE

40PADT CONFIDENTIAL

The Metal 3D Printing Value PropositionDriver 3: Supply Simplification

2011 Committee on Examination of the U.S. Air Force's Aircraft Sustainment Needs…

Airbus

41PADT CONFIDENTIAL

The Metal 3D Printing Value PropositionDriver 4: Low Volume, High Mix Manufacturing

Mass Customization

High Volume Manufacturing

Low Volume, High Mix

42PADT CONFIDENTIAL

The Metal 3D Printing Value PropositionDriver 5: New Applications & Research

http://www.fastcoexist.comWyss Institute, Harvard U

Applications! Fundamental Research

http://3dprinting.com/bio-printing/

http://www.3dprinterworld.comDeLoitte Genesis

& Simulation

Concept Laser is open source

powder and SW architecture

43PADT CONFIDENTIAL

Metal 3D Printing Trends

Worldwide Metal Systems Sales (2015)

Percentage of AM Revenue from Functional Parts

Forecast metal AM costs [EUR/cm3]

2013 costs = approx. $55 per cu. inch.

44PADT CONFIDENTIAL

What now?

45PADT CONFIDENTIAL

Contact Us to Assess if Metal 3D Printing is Right For You!

Send an email to: metal-am@padtinc.comOr fill out survey at end of webinar to have us contact you

PADT – your partner in Metal 3D printing

Initiate a conversation about:

• Industry- and Application specific Landscape• Challenges & Opportunities• Total Cost of Ownership, Unit Cost• Concerns about changing to Metal 3D Printing

46PADT CONFIDENTIAL

• Company Pages:

– PADT: www.padtinc.com

• Follow our AM Blog: http://www.padtinc.com/blog/additive-manufacturing

– Concept Laser (US): http://www.conceptlaserinc.com/

• Papers & Reports:– European Powder Metallurgy Association (EPMA) Brochure: “Introduction to Additive

Manufacturing”: http://www.epma.com/am

– Wohlers Report (annual, fee): http://wohlersassociates.com/

– Review Paper (free access): “Metal Additive Manufacturing: A Review”: http://link.springer.com/article/10.1007/s11665-014-0958-z#/page-1

• Conferences:– AMUG: http://www.additivemanufacturingusersgroup.com/events.htm

– RAPID: www.rapid3devent.com

– SFF Symposium: http://sffsymposium.engr.utexas.edu

– formnext: https://www.mesago.de/en/formnext/The_conference/Welcome/index.htm

• Metal Additive Manufacturing Magazine (free digital editions): http://www.metal-am.com/

Learn More

47PADT CONFIDENTIAL

Thank You!

Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.

dhruv.bhate@padtinc.com

Rey ChuPrincipal, PADT Inc.

rey.chu@padtinc.com

PADT HEADQUARTERS

at the ASU Research Park7755 S. Research Dr.Suite 110Tempe, AZ 85284480-813-4884 Office480-813-4807 Fax

Contact Us to Assess if Metal 3D Printing is Right For You!

Send an email to: metal-am@padtinc.comOr fill out survey at end of webinar to have us contact you