Why the use of 3D Printing Improves the Engineering

Field

How the 3D Printing Process Works• Create the 3D part model• Load the model into the printer and let the additive

manufacturing process take over– 3D printers build parts layer by layer until the part is

complete (as opposed to being pressed, casted, etc)

• Apply finish to the part if needed– Printed parts may need to undergo finishing steps in order

to create a smooth part

Types of 3D printing and usable materials3-D Printing TechnologiesTechnology Description Applicable Materials Key Players

Stereolithography Selectively cures a uniform layer of material with a UV laser Photopolymers 3D Systems

Digital light processingCures an inkjet-deposited material layer in a support material with a UV light

Photopolymers Texas Instruments, Envisiontec

PolyjetCures an inkjet deposited layer with multiple materials using a UV light

Photopolymers Objet(Stratasys)

Selective layer sintering Selectively fuses material powder using a laser Thermoplastics, metals EOS, Morris Technologies (GE

Aviation), Optomec

Electron beam melting Selectively fuses material powder using an electron beam Metals Arcam

Selective heat sintering Selectively fuses material powder using a thermal head Thermoplastics Blueprinter

Fused filament fabrication Extrudes a material filament through a heated nozzle

Thermoplastics, food, wood and ceramic composites with a thermoplastic binder

Stratasys, Makerbot, Printrbot

Powder bed inkjet printingSelectively inkjet prints a liquid binder to fix material powder into a solid

Thermoplastics, food, wood and ceramic composites with a thermoplastic binder

Zcorp (3D Systems),ExOne

Laminated object manufacturing

Trims sheets of material and joins with adhesive

Paper, polymer films, metal sheets Mcor, TNO, Solido, Kira

Source: Lux Research ©2013

Fields of UseKey 3-D sectorsAerospaceMaterials: Titanium, high-performance thermoplastics, stainless steel, CFRP, GFRP, nickel alloys, cobalt-chromeUse: Engine components, brackets, connectorsMedicalMaterials: High-performance thermoplastics, titanium, stainless steelUse: Implants, prostheticsAutomotiveMaterials: Steel, stainless steel, magnesium, thermoplasticsUse: Interior components, aesthetic components, body panelsElectronicsMaterials: Thermoplastics, functional materialsUse: Embedded electronics, smart objects, sensors, conductive tracesConsumer useMaterials: Thermoplastics, paperUse: Art, architectural models, replacement partsSource: Lux Research ©2013

Advantages of 3D Printing

• Fast creation– 3D printed parts have short lead times and can be made on short

notice

• No need for drawings– No need for drawings during prototyping or manufacturing

process – Saves time for those making, checking, and approving drawings

• Not limited by shape and intricacy of part– Manufacturing methods such as casting will be limited in part

intricacy due to pouring mechanics– Allows for custom parts to be made with ease

• Less waste– The additive manufacturing approach keeps waste to a minimum

3 Major Engineering Processes

• Prototyping

• Manufacturing

• Post-Manufacture

Prototyping

• The prototyping process is used to create one or more parts to test in order to produce an improved final product

• 3D printing aids in this process by…– Creating multiple parts in a short amount of time– Cutting the costs of manufacturing processes,

tooling, and machining– Allowing quick changes to be made along the way

Prototyping Continued

• Shapeways = 3D printed• Protomold = Molded part• Small Bracket = 1 cm3

• Large Jig = 50 cm3

• As you can see, 3D printing has a cost advantage when making a smaller number of parts

3sourceful

Ford Example of Prototyping Advantages

• “Using 3-D printing, Ford saves an average of one month of production time to create a casting for a prototype cylinder head for its EcoBoost family of engines, designed for better fuel efficiency. This complex part includes numerous ports, ducts, passages and valves to manage fuel and air flow.”

Manufacturing

3D printers have seen little use in large scale manufacturing due to material costs, but 3D printers are still a viable option because…• Cuts cost of tooling and machining (which can

be very expensive depending on the process)• Tweaking the product is as easy as tweaking

the 3D model• Can decrease the lead time for customers

GE Aviation and Manufacturing

GE is building a light aircraft engine– Shaving off 15% of fuel usage ($1 million/year)

3D printers will be used to manufacture parts– “Instead of depositing materials, it uses a laser to turn

metal powder into solid shapes, layer by layer. The method simplifies the manufacturing of precisely shaped fuel nozzles that help the engine run at high temperatures without producing nitrogen oxides.”

Post-Manufacturing(part of the 3D printing future)

No matter the material, a finished product will not last forever. Replacement parts can be hard to come by and expensive.

• 3D printers allow the manufacturer or customer to replace a broken part with ease and in without having to wait weeks for procurement and shipment

– Military example: Build a new part oversees instead of waiting for a new one to arrive. The part file is all that’s needed.

Conclusion

• 3D printers can create parts from thermoplastics, metals, and polymers

• 3D printers are currently used in many fields and are growing in popularity– Due to its advantages over other manufacturing

processes in prototyping, manufacturing, and post-manufacturing

Sources• Hayes, T. (2013, July). The future of 3-d printing. Retrieved from

http://www.osaopn.org/home/articles/volume_24/july_august_2013/features/the_future_of_3-d_printing/

• Bullis, K. (2013, May 14). A More Efficient Jet Engine Is Made from Lighter Parts, Some 3-D Printed. Retrieved from http://www.technologyreview.com/news/514656/a-more-efficient-jet-engine-is-made-from-lighter-parts-some-3-d-printed/

• Sujay (2013, February 20). Cost = f(size, quantity, technology) + a whole lot more. Retrieved from http://blog.3sourceful.com/post/43619184865/ cost-f-size-quantity-technology-a-whole-lot-more

• Ford Motor Company’s EcoBoost V-6 cylinder head with DI. (2009). Retrieved August 2, 2013, from: http://www.thecarconnection.com /news/1020747_fords-ecoboost-almost-ready-for-liftoff

• [Untitled Photograph of Composite fan blade test]. Retrieved August 2, 2013, from: http://www.technologyreview.com/news/514656/a-more-efficient-jet-engine-is-made-from-lighter-parts-some-3-d-printed/

• [Untitled Photograph of 3D printing process]. Retrieved August 2, 2013, from: http://shop.felixprinters.com/learn

• The New Z Printer 850 by 3D Systems. Retrieved August 1, 2013, from: http://i.materialise.com/blog/entry/the-month-of-april-in-3d-printing

• [Untitled photograph of 3D printed gears]. Retrieved August 1, 2013, from: http://www.3dprintingera.com/how-to-3d-print-gears/

Reflective Note

My audience here would be those who work with me and are in my field. I felt that they should understand why it is that 3D printing is a manufacturing process that should be used in engineering. This type of document would be presented to my group or sent around to those it pertains to.