Additive Manufacturing For 3-Dimensional (3D) Structures: (Emphasis On 3D Printing)

TECHNOLOGY OVERVIEW Update - Summer 2019
ADDITIVE MANUFACTURING
FOR 3-DIMENSIONAL (3D)
STRUCTURES
(EMPHASIS ON 3D PRINTING)
Jurgen Daniel
Teclination Consulting Services
San Diego, USA
www.teclination.com
daniel@teclination.com
Source: APWorks
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Consulting Services
This slide deck is an overview of technologies related to Additive Manufacturing
with focus on 3D printing. While it covers many recent technology
developments, it is impossible to capture all of them due to the vast variety of
technologies and continuous innovation. Much of the information and the
figures originated from websites as annotated on the slides.
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Consulting Services 2
a brand new high-performance turboprop aircraft
Source: www.geaviation.com, cessna.txtav.com

GE's Catalyst™
Advanced turboprop engine
world’s first turboprop engine with 3D-printed parts
Development started in 2015

Certification expected 2020
1/3 of engine parts are 3D printed

855 distinct components down to 12
GE's Catalyst™
Advanced turboprop engine
1/3 of engine parts are 3D printed
• Simplified
Ø supply chain logistics
Ø assembly
Ø maintenance
• >100 pounds in weight savings
• Improved fuel burn (20 %)
Development started in 2015
Certification expected 2020 • 10 percent more power
Conventional vs Additive Manufacturing (AM)
Conventional Additive Manufacturing
Example 1
Example 2
Structures carry the same

structural loads and forces
Conventional bicycle frame AM bicycle frame

Source: www.arup.com; mx3d.com; www.halfords.com
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Problems with Conventional Manufacturing
Milling, molding, casting, cutting, sawing, stamping, drilling, …
High cost for prototyping and small runs
Long design / setup time (Tooling, etc.)
Materials waste in subtractive methods (milling)
Complex assembly required for complex designs
Limited materials combinations
… others
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Benefits of Additive Manufacturing
Directed deposition, e.g. printing, selective lamination, …
Freedom of complexity (designs difficult to do conventionally)
On-demand production (reduced inventory)
Cost and time savings (for prototyping and small runs) -

no part-specific tooling
Example: aerospace bracket

(70% lighter while stiffer) Lighter, stronger, better performing, safer parts -
Source: 3D Systems enabled by design optimization software
Reduced waste material
… others
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Cost Comparison: Additive vs Conventional
Additive
manufacturing
Source: Deloitte
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Market and Opportunities for AM
AM is key to the 4th Industrial Revolution
3D printing market is expected to grow from

USD 9.9 billion in 2018 to USD 34.8 billion by
2024, at a CAGR of 23.25% (Feb 2019)
Forging Magazine, March 2018
IDTechEx, March 2018
Global 3D printing revenues: $3.1B in 2020

Deloitte Insights, 2019
Predictions heavily depend on assumptions and included technologies

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AM Stock – “Between Hype and Reality”
Examples of Public 3D Printing Companies
3D Systems: DDD Example:
8/2018
ExOne: XONE Stratasys: SSYS
Source: etrade.com
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AM Sectors and Technologies
Electronic Mechanical Biological Food, etc.
Structures Structures Structures
LOM • Laminated Object Manufacturing

• e.g. Composites PE • Printed Electronics
• e.g. screen printing, inkjet
FDM • Fused Deposition Modeling EPD • Electrophoretic Deposition
SLS / SLM • Selective Laser Sintering / Melting

• also Direct Metal Laser Sintering (DLMS) ME • Material Extrusion
EBM • Electron Beam Melting PNP • Pick and Place
SLA / DLP • Stereolithography / Digital Light

Processing BJT • Binder Jet Technology
• Including Multi Jet Fusion™
PVD • Physical Vapor Deposition

• e.g. Plasma DED • Directed Energy Deposition
• e.g. Plasma Arc Welding concepts
MJ • Material Jetting
• e.g. PolyJet ™ …
see also: ASTM/ISO standard for AM terminology (ISO/ASTM 52900-15)
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AM Value Chain
Tool
Plus: *Information Services (Conferences / Journals)

*Test & Evaluation
*Design & Fabrication Software Tools
Source: am.vdma.org and Teclination (*)

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Major Risks in AM
Digitalization of physical products

Cyber threats
• reliance on digital files and connectivity
Issues in supply chain

• firmware, network, IT, design, printer/production and
third-party supply chain areas
Counterfeit objects
• easy to produce with a stolen design file
• hackers could build failure points into part design
Reliability of mechanical structures

Material integrity
• machine-to-machine & print-to-print variations
• quality variation of starting material
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Selected Technologies
- Electronics -
Source: DuPont, TaktoTek

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2.5D Technologies
LDS (Laser Direct Structuring)
laser activation and plating
Hot Stamping
Source: www.mid-tronic.de
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Injection Molded Electronics (2.5D)
In-Mold Structural Electronics Manufacturing Process
Using stretchable conductive ink from DuPont

Source: DuPont, TaktoTek (www.tactotek.com)
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Aerosol Printing – 2.5D Electronics
Printing onto 3D surfaces
printing process
Sensor Structures via

Aerosol Jet printing
and
5 axis printing system
printed smartphone antennas
Source: www.optomec.com & www.neotech-amt.com

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3D Electronics Integration
3D Structural Electronics
3D printed signal conditioning circuit Source: Science, 30 Sep 2016
Hybrid of AM, robotic component placement and

Related process:
embedding of conductors
commercial printers from
Voxel8 & Nano Dimension
Source: Eric MacDonald, Ryan Wickers, et al. (2014) - W.M. Keck Center for 3D Innovation & U Texas, El Paso
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3D Printed Electronics
First on-demand 3D-printed electronics service
DragonFly Pro
Printed electromagnet printed circuit board
Printed 4-layer PCB
Printed digital thermometer inkjet printer
Conductive silver nanoparticle ink (metal) and insulating ink (dielectric polymer)
Source: www.nano-di.com
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PolyStrata Process (3D)
mmWave RF circuits
compact, high isolation, low loss
PolyStrata transmission lines
10x - 100x
improvement
in size, weight, and
power (SWaP)
Photo of RF module
Source: www.nuvotronics.com
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- Mechanical Structures
• plastics
• metals
• ceramics
• composites
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Plastic Structures
Source: Formlabs
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Fused Deposition Modeling (FDM)
filament Examples of FDM printers
Cartesian Delta
(heated
build chamber)
Filament
heated
nozzle
heated Monoprice MP Select Mini
build plate (~$200)
FDM nozzle (source:3dnatives)

Rostock
Examples:
e.g. Marlin firmware control:

Ultimaker
Filament Materials:
• thermoplastic polymers
(e.g. PLA, ABS, PI, PEI, PC)
3DBenchy PLA model Airwolf3D EVO 22
• also metal / ceramic / fiber filler (source: hackaday) (~$12k)
ULTEM air duct
(source: Stratasys) RepRapPro
Source: Manufacturingguide
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Droplet Printing of Polymers
ARBURG Plastic Freeforming (AFP)
Hannover Messe 2019
Piezo Hot
actuator Polymer
Toothbrush
• Typically 25-30 micron layer thickness
• >40micron resolution
• Isotropic material / smooth surface
Ø Inexpensive qualified standard injection molding granulates Material: ABS, TPU and armat 21
Ø 2 materials/colors (e.g. hard & soft materials)
Ø Quality lies in-between SLS and FDM Related concept: polymer-jetting
Source: www.arburg.com
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VAT Polymerization: SLA (Stereolithography) / DLP (Digital Light Projection)
Laser galvo-scanning, DMD or LCD projection, holography e.g.:
FDM vs SLA
Laser beam
Resin vat
Formlabs Form 2
(Laser scanning)
Source: Formlabs ~$3,400 (2018)
Example: Laser galvo-scanning &

top-down process
Photopolymer (resin)
• solidified resin:
Ø rigid
27x magnification
Ø flexible
Ø colored • Typically 25-30 micron layer thickness
Ø high temperature
Ø dental grade • >40 µm resolution Sparkmaker FHD
(LED / LCD projection)
Ø ceramic, metal (sintered) • Isotropic material / smooth surface ~$279 (2018)
Source: formlabs; sparkmaker3d, www.tth.com DMD: Digital Mirror Device; LCD: Liquid Crystal Display
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Fast SLA / DLP Processes
Continuous printing enabled by a ‘dead zone’ in bottom-up process
Problem in conventional bottom-up SLA: Peeling and repositioning the build platform slows down process
CLIP (Continuous Liquid Interface Production) CLIP process
Adidas Futurecraft 4D midsole
Oxygen Dead zone

Other approaches
permeable
glass
Projector
Continuous Digital Light Manufacturing
Oxygen inhibits polymerization and creates a dead zone
(channel partners:
CLIP process XYZprinting & Bego Dental)
Lubricant Sublayer Photo-curing (LSPc)

(e.g. silicone oil /PTFE lubricant layer)
Intelligent Liquid Interface (ILI)

Riddell custom helmet liner (transparent wettable membrane)
+ others
Source: www.carbon3d.com, newpro3d.com
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Laser Powder Bed Fusion
Selective Laser Sintering / Melting (SLS / SLM) - suitable for polymers, metals and ceramics
Laser
Powder coater
Breathable ankle orthosis Nylon duct
Source: IOPScience: Shirazi, et al., 2015 System Example: EOS P 770 2021 target: LaserProFusion
Typical powder particle size:

~60 - 90 micron
Polymers 1 million diode laser array

• Polyamides (Nylon)
• Polystyrenes
• Thermoplastic elastomers
Related system examples:
• Polyaryletherketones, … Fuse 1 Lisa
Build volume: 700 x 380 x 580 mm ProX SLS 6100, …

Source: www.eos.info; www.plusmedicaot.com (2 x 70W CO2 lasers)
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Binder jetting / High Speed Sintering (HSS)
Combining binder jetting and selective laser sintering
Infrarded Inkjet IR light

absorbing
ink
Sintered
polymer
Inkjet printing of IR-light-absorbing ink onto polymer particles and irradiation with IR light
System: VX200
“10 to 100x faster than current

industrial 3D printing processes”
Related processes:
Build volume: 290 x 140 x 180 mm Multijet Fusion (MJF)

Source: www.voxeljet.com; www.xaar3d.com
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STEP (Selective Thermoplastic Electrophotographic Process)
Xerography based high-speed plastic AM
spun out of Stratasys
Partnership with Kodak

on imaging technology
US Patent 8488994 B2 (2013)
3D printing alternative to injection molding

- with added benefit of possible materials variation
- 50x faster than High Speed Sintering
Source: www.evolveadditive.com
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Wave Applied Voxel (WAV) Printing
WAVTM-printer
Addresses issues of vat-based systems (e.g. SLA process):

• No large vats to maintain, less waste, rapidly swappable materials
• Small footprint
• Solves the issue of trapped volumes One-piece Wav-printed
surfboard
• Projected speeds of 4x, 8x, 24x+ of the fastest large vat system
Qualified material: Ultracur3D

Source: www.paxis.com
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Metal Structures
Source: Velo3D
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Laser Powder Bed Fusion of Metals
Selective Laser Sintering / Melting (SLS &SLM)
in vacuum or inert gas
Titanium bracket is 30 percent lighter Valve block for a A380: 35% lighter
(titanium alloy)
layer thickness of 15 – 500 μm
Critical process parameters: Metals:

Aluminum, stainless steel,
• Laser power
titanium, nickel, CoCr , Cu, alloys,
• Scan speed + others
• Layer orientation
• Hatch distance
affect solidification conditions: System: X LINE 2000R Similar systems:
- Microstructure
- Size of dendrites and grains Build volume: 800 x 400 x 500 mm3
(2 x 1kW fiber lasers) + others
Source: www.concept-laser.de; www.eos.info; www.slm-solutions.com
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Support-free Metal AM by Laser Powder Bed Fusion
Intelligent Fusion™ corrects deformation issues and allows true print-to-design
In-situ metrology sensors Software corrects for deformation Non-contact powder bed re-coater
Support-free laser fusion
Bottle opener
Sample: Aerodef 2019 Unsupported inner areas!
• Simpler design process

• Less post-processing
VELO3D Sapphire
Two 1kW lasers

Source: www.velo3d.com
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Rapid Metal Printing
Multi-Layer Concurrent Printing (MCP)
metal
recoater “World’s fastest and largest direct metal 3d printer”
powder
laser cascading layers
of metal powder
~55 times the market speed

6 5 4 3 2 1
(identified as 1.96 kg of Titanium per day)
substrate
Print speed of 113 kg per day
(target of 1000kg!)
recoater Target industries:

oil & gas, mining, shipping
Novel recoating tool: lasing during recoating process

Other approaches:
multiple layers deposited and fused in a single pass 4 laser scan heads
Bi-directional binder jet printing
(single pass jetting)
Source: www.auroralabs3d.com
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Electron-beam Melting (EBM)
Advantage: void-free deposition of metals
Lattice skull implant
Spectra H
TiAl turbine blades

(for new GE9X engine)
Build volume:
- 250 mm diameter
- 430 mm height Optimized roughness for bone in-growth
~62 EBM machines operated by GE Aviation (2019)
Source: www.arcam.com
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FDM Extrusion Process of Metals
Bound Metal Deposition™
Print Media
not filament!
example
316L steel
Bound metal rods
(high metal ratio) • No lasers, no powders!
• Sparse infills possible
Studio System ~$120,000 • Ceramic support release layers
• Safe for office environment
Related processes:
Ultrafuse
(Metal X) 316L filament
Printer Debinder Furnace
CEM (composite extrusion modeling)
Office-friendly metal 3D printing system - uses injection molding pellets
Water-based binder – no de-binding step

Source: www.desktopmetal.com; markforged.com; www.aim3d.de; www.rapidia.com
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Binder Jetting of Metals
Process
Binder jetting onto layers of powder (~30-60 sec per layer) De-powdering For metal parts: with or w/o infiltration
(e.g. bronze infiltration)
Binder curing between layers Sintering
Examples of metal parts
+ Suitable for large parts (e.g. sand molds for casting) Stainless steel
+ No heat applied during printing (less stress)
+ Often more cost effective than other additive methods
+ Parts are supported by loose powder
- Sintering process can cause deformation
With infiltration
Powders: sand, ceramics, plastics, metals 3-20 µm particles
Binder: phenolic, aqueous, silicate, etc. Without infiltration
Similar process:
Process for high volume low-cost parts
(<1% latex binder;
no de-binding needed)
Source: ExOne
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DED (Directed Energy Deposition): Powder-fed
Focused thermal (laser) energy is used to fuse a metal powder
Repair of worn shaft seal
(powder size: 45-75µm)
5 axis of freedom to build/repair

components layer by layer without
the need for support structures
Similar concepts:
Wire & powder-fed
Source: www.beam-machines.com
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DED: Wire-fed e-beam Metal AM
Electron Beam Additive Manufacturing (EBAM®)
Titanium dome for satellite fuel tanks
Part requires finish-machining
Source: www.sciaky.com; Lockheed Martin

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DED: Metal Arc-welding
Wire Arc Additive Manufacturing (WAAM)
• FAA-certified process
Rapid Plasma Deposition (RPD): • 50–100 times faster than powder-based systems
similar to • Deposition rate: up to 10kg/h
Tungsten Inert Gas (TIG) welding
Similar concepts based on Metal Inert Gas (MIG) welding:
Source: Aviation Week (Oct 2015) and www.norsktitanium.com

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Cold-Spray Metal Printing
Titomic Kinetic FusionTM printer
Deposition speeds of up to 45 Kg of material per hour

(compare to E-beam melting: 9.07 Kg/hr)
• Mitigate oxidation issues - titanium particles

1.8 m titanium drone
impact to mechanically fuse (no melting)
• No heat-related distortion
• Extremely fast build rates Similar Concept:
Supersonic 3D Deposition (SP3D)
Source: www.titomic.com, www.spee3d.com
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Jet-printing of Nanoparticle Inks for Metals
Nanoparticle JettingTM (NPJ) – metals and ceramics
Metal Ceramic
• Powderless (greater safety!)
• High speed (~5x of SLS)

Carmel 1400 system
• Smooth surface finish
• Extremely low shrinkage (~8x less than MIM) Printing at ~500degC
Support removal
• Isotropic uniformity (water soluble material)
• 99.9% density Final sintering

Source: xjet3d.com
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Jet-printing of Molten Metal
Printing of liquified metal (e.g. Aluminum)
acquired by Xerox (2019)
Magnet-o-Jet™: electromagnetic pulsing

of molten metal 1000 droplets per second
Melting point comparison:

Al - 660.3°C
Ti - 1,668°C
Fe - 1,538°C
Cr - 1,907°C
Cu - 1,085°C
Source: vadersystems.com/
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Joule PrintingTM of Metal
Precise closed-loop control of melting at the voxel level
Process
Metal wire
Fast and low cost:

• prints at 5-10 kg/hour at very low power (<1 kWh per kg)
• uses commodity wire as the raw material
Unlike a direct energy deposition system (e.g. arc welding), there is

no dripping or splashing
Source: www.digitalalloys.com
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MELDTM Metal AM
MELDTM makes the material malleable without melting
Build Rate (cm3/h)

Al Steel
MELD 1020 61
SLS 2.5 5
Additive manufacturing
Coating
Metal joining Open atmosphere operation
Component repair Large parts
Metal Alloy/Composites Fast process
Unweldable materials
Materials without porosity or hot-cracking
Source: meldmanufacturing.com
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Ultrasonic Welding
• Functionally Graded Laminates
• Embedded electronics/sensors
• Metal matrix composite (MMC)
20kHz
Rolling ultrasonic welding

Aluminum-Titanium
process Laminate
CNC contour milling
Alumina fibers in
Aluminum (MMC)
SiC fibers embedded in

Source: fabrisonic.com metal laminate
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MICA Freeform Process
Layering process using plating and planarization
formerly Memgen
SLS
MICA
Laser sintering vs MICA freeform

Materials:
Similar process:
Fabrication of parts in assembled state Polystrata by
Source: www.microfabrica.com
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Ceramic Structures
Source: Xjet
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Direct Writing (Extrusion) of Clay Paste
3D PotterBot Clay printer
Scara Mini V1
Source: www.deltabots.com, www.instagram.com/explore/tags/potterbot

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Fused Deposition Modeling (FDM)
FDM followed by sintering
parts which contain more

than 80%w of ceramic Oxide ceramic filament: Alumina, zirconia, ZTA (ZrO2/Al2O3)
Carbide: Silicon carbide (SiC)
Nitride: Silicon nitride (Si3N4)
Metals: Stainless steel and Tungsten carbide
Debinding in acetone and sintering between 1200°C and 1500°C:

plastic is removed and a pure ceramic remains Related processes:
Water-based binder
Source: zetamix.fr; www.rapidia.com
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Inkjet Printing of Ceramics
Nanoparticle JettingTM (NPJ) followed by sintering
Multimaterial print
Steel-and-ceramic (un-sintered)
Ceramic drill bit with 2400 connected cooling channels
Image: Fabbaloo
Source: xjet3d.com, Fabbaloo

Alumina and Zirconia ceramics
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Stereolithography (SLA / DLP) of Ceramics
Resin is a ceramic-filled photopolymer Many ceramic photoresins for SLA /DLP processes
Example: Investment Casting

slurry
foil
un-sintered
DLP engine sintered (~ 15% - 20% shrinkage)

Castalite® resin molds
Admaflex 130 after Bronze casting
Similar processes:
Sintered ceramic parts
(also sintered metal possible)
Source: Formlabs, Tethon3D, Admatec
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LCM (Lithography-based Ceramic Manufacturing)
High performance and bioresorbable ceramics by DLP* *digital light projection
Example: Ceramic static mixer

Photocurable slurry
DMD light exposure
Debinding
Sintering
CeraFab 7500
Materials
Aluminum oxide
Zirconium oxide
Silicon nitride
Hydroxyapatite
Tricalcium phosphate
Silica-based ceramics
… Bone augmentation Dental restoration
(Bioresorbable implants: (Zirconia crowns, implants)
Tricalcium phosphate, Hydroxy apatite)
Source: www.lithoz.com
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Binder Jetting of Ceramics
Examples:
Binder
Jetting
(Debinding)
CERAMO TWO (by EVERYTHING ELEVATED)

Ceramic cord box with holes Juicer
Sintering
Silicon Carbide
Alumina
Zirconia
Boron Carbide
Example: Supports for catalytic applications (high surface area) Similar processes:
MJF
Source: www.voxeljet.com, matthey.com, kwambio.com, www.exone.com
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Laser Powder-Bed Processes for Ceramics
Selective Laser Sintering / Melting (SLS / SLM)
Direct SLS: e.g. used in Si-SiC ceramics (with infiltration)
Indirect SLS: laser melting of a sacrificial organic

Si-SiC part by
binder phase in the polymer-ceramic composite Direct SLS
(resulting in ’green’ parts)
Alumina part with
Indirect SLS
SLM: higher laser energy; lower porosity materials

– but so far limited success in ceramics
Canon’s new ceramic process: “materials suited to

selective laser melting” (SLM)
Source: www.mtm.kuleuven.be; global.canon; pdfs.semanticscholar.org

Alumina-based ceramic material
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Directed Energy Deposition of Ceramics
Laser Engineered Net Shaping (LENS)
LENS process
Source: www.optomec.com
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Composite Structures
Source: Airbus
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Fiber Layering / Weaving
Carbon / Ceramic Fiber-reinforced Composite Materials
- layered or 3D woven structure -
LEAP fan blade

Carbon fiber is braided onto High-strength break levers:
an aircraft component 3D composite FDM printer embedding
continuous carbon fiber
Related process:
3D-woven composite and resin transfer
molding (RTM) process
Sources: www.airbus.com; www.compositesworld.com/articles/albany-engineered-composites-weaving-the-future-in-3-d; markforged.com
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Composite-based AM (CBAM)
Stacking and bonding of fiber sheets
CBAM 2 printer
Process
1. Printing onto fiber fabric sheets 2. Heat compression
Related process:
3. Removal of unbonded areas SLCOM
Source: www.impossible-objects.com
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- Mechanical Structures -
with Full Color
Source: Phoenix Children’s Hospital

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Selective Deposition Lamination (SDL)
Build material: paper
X,Y,Z resolution: 0.1mm
Photorealistic color
Mcor ARKe
Removing excess paper
Process
Source: www.mcortechnologies.com/
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PolyJet Printing
Inkjet printing of UV curable polymers
J750 3D printer from Stratasys

(360,000 colors: CMY, white, black, transparent)
Similar technology:
3D printer jets and instantly UV-cures tiny

droplets of liquid photopolymer
over 10 million colors and translucent
– rigid or elastomeric polymers – objects (but different materials properties)
Source: Stratasys; Mimaki
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ColorJet Printing (CJP)
Solidifying and coloring a powder with a binder
formerly: Z Corporation
• Uses thin layers of white support powder (gypsum)

• Inkjet printed color binder material
• Powder bed helps to avoid the need for printing supports
• Requires post-processing (clean up of excess powder)
ProJet CJP 660Pro
Source: www.3dsystems.com & www.3dnatives.com

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Multi-Jet Fusion (MJF) 3D Printing
DA FA
Similar to binder jetting

(however not binder but fusing agent)
process • Black fusing agent (FA) for light absorption
• Detailing agent (DA) prevents capillary spreading
• Color only around edge
Strong thermoplastic
chain link
• Average printing cost per part is half the average
cost of comparable FDM & SLS printer solutions
• 10 times faster than FDM and SLS
• Very strong and durable parts
HP Jet Fusion 500/300 Series 3D
Now also metal parts via sintering! with up to 8 agents for color 3D
(HP Metal Jet) Price: >$50k - 100,000 Phoenix Children’s Hospital
Heart of Jemma
Source: www8.hp.com/us/en/printers/3d-printers.html
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Inkjet Printing of Color Surface layer
3D PLA FDM printer plus color inkjet
Xyz print da Vinci and XYZmaker modeling software; Similar process:

- process uses special filament to which ink adheres -
Source: www.xyzprinting.com
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Color Surface by Hydro-dipping
Adding graphics to 3D parts: by inkjet printing onto water transfer
paper (PVA based) and hydro dipping
Source: learn.adafruit.com/hydro-dip-3d-prints/overview
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3D Color Parts by Thermoforming
Computational Thermoforming (ETH Zurich, Disney Research)
process
Gypsum mold because of thermoforming process (PLA would melt)
Example: Plastic food

process (side-view)
Source: C. Schueller, et al. , Siggraph 2016

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Applications
Examples
(emphasis on 3D printing)
Source: Widex
TM
Application Areas
Replacement Functional Tooling, Jigs, Branding /
Parts Prototypes Fixtures Promotion
Concept Models End-Use Parts Visualization Aids Molds / Castings
Area Benefit Example

Prototyping Faster, less expensive, allows complex designs Maker community, R&D, product design
Aerospace Light weight, complex design, spare parts, … GE fuel injector nozzle for LEAP engine
Automotive Faster design cycles, Cost & time savings for small Turbine for Koenigsegg sports car,
series production, spare parts for rare vehicles Customization (Mini)
Medical / Dental Patient-specific design, optimized textures for Transparent Invisalign braces, hearing
bone ingrowth,… aids, implants
Military Simpler logistics, spare part availability in remote USS Essex printer installation
areas or on-ship
Jewelry Faster design cycles, unique and complex designs Many examples of jewelry designers
Industrial Faster and less expensive, complex designs Turbine blades for generators by
possible Siemens; Tools /fixtures
Construction / Architecture Logistics, simplified transport, unique designs Metal bridge by MX3D in Amsterdam
Sports / Clothing Individualization, exclusive fashion design Personalized shoe soles (e.g.Nike, Adidas)
Electronics Conformal design, potentially less expensive, large Antenna and sensor prototypes
area electronics, improved performance, …
Source: ultimaker.com; Teclination + others
TM
Electronics - RF Antennas
Ka-band 4×4 monopulse phased array (1 -100GHz)
metal
1part
100 parts
brazing and EDM 3D laser fusion
(~8months to develop and 3 to build) ( ~a few weeks to complete)
• 95% weight reduction

• 20% reduction of production cost e.g. for low SWaP radar on High
Altitude, Long Endurance
• 75% of non-recurring costs eliminated (HALE) platforms
Source: 3dprint.com/178724/3d-printed-antenna-one-component/
TM
Aerospace - Aviation
3D printed fuel nozzle for CFM LEAP engine for Airbus A321 neo
19 nozzles per LEAP engine

5X increase in durability
25% weight savings
20 parts replaced with one
Reduced weight of components by “bionic” design
3D printed bionic spacer panel

15% lighter through use of
internal lattice structures
Source: www.ge.com; www.cfmaeroengines.com; www.materialise.com

TM
Aerospace - Rockets
Monolithic Thrust Chamber with Internal Cooling Structure
Selective Laser Melting:

• Nickel superalloy IN718
(difficult to CNC machine)
• Minimum post processing needed
Combined fuel injector and

thrust chamber
Complex lattice structure:

Ø Improved cooling
Ø Light weight
Source: www.slm-solutions.com, cellcore3d.com

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Heat Exchange
Novel complex (bio-inspired) & more efficient designs
Complex heat exchanger concept in Al

Pure copper heat exchanger:
• spiral design (0.5mm wall thickness)
• >30% lighter
• 35% cost reduction
• 22% lighter
• 55 mm smaller
than traditionally
manufactured parts
Lung-inspired Heat exchanger
Source: www.metal-am.com; www.3t-am.com (ARPA-E HITEMMP)
TM
Automotive
US$148 billion in AM product value forecasted for 2030 (Feb 2019)
Spare parts • On demand production of spare parts, e.g. for old-timers
Small series • Parts for special and exclusive car series & motorsport
Customization • Exclusivity /personalization
Tooling • Tools/jigs for test & assembly (Cost/time savings )
Quality Enhancement • Testing of prototypes before production
Design cycles • Accelerated design cycles & lowering costs of new products
Small series variable turbo Customization Rapid development

Source: 3dprintingindustry.com; yours-customised.min; www.hrewheels.com
TM
Industrial Casting
Sand and plastic molds (for investment casting) via binder jetting
Sand mold and metal part Investment casting:

Plastic model and metal part
plastic metal
VX4000 PRINTER
Plastic mold will burn out completely

without any residue at 700°C or more
3D PRINTING SAVES UP
TO 75 % IN SAND
CASTING COSTS • build space: 4000 x 2000 x 1000 mm (LxWxH)
• Layer height: 300 micron
Cooling of ceramic casting die
Source: www.voxeljet.com
TM
Tooling for Composite Lay-up
e.g. carbon fiber composite
ULTEM
FDM printed in ULTEM 1010 polymer
3D printing tools (for composite lay-up) offer savings in time and material over more
traditional methods
- but processing conditions are critical: Coefficient of thermal expansion (CTE), curing temperature and pressure -
Source: www.stratasys.com
TM
Medical
Implants Surgical Planning
Phoenix Children’s hospital
OsseoTi
Porous Metal Software requires FDA
(for bone in-growth) clearance!
Ti chest implant Spinal wedge implants Patient-specific pediatric heart model
Orthopedic Casts Personalized Medicine
Light-weight patient-specific 3D-printed cast Printlets™ technology

Source: www.anatomics.com; www.zimmerbiomet.com ; www.rapidreadytech.com; www.materialise.com
TM
Clear Dental Aligners
3D printing of dental molds for thermoforming
Medical-grade polymer (SmartTrack) is thermoformed around 3D mold
• ~50-60 stereolithography (SLA) 3D printers from 3D Systems

• >220,000 custom-made clear aligners produced per day (~8 million p/year)
• Align Technology: ~$1.3B in sales (91% of revenue from aligners) (Forbes, Sept. 14, 2017)
SmileDirectClub uses HP’s Multi Jet Fusion to make dental molds

Sources: www.invisalign.com, www.forbes.com
TM
Hearing Aids
CAMISHA (Computer Aided Manufacturing of Individual Shells for Hearing Aids)
- scanning, modeling, and printing -
Example: SLA parts by Danish hearing aid manufacturer Widex
Source: www.widex.pro
TM
3D Bioprinting
Printed biopolymer (hydrogel) and live cells
Polycaprolactone construct with Printed ‘heart’

bone, muscle and tissue cells (with cardio muscle cells)
Fine 3D Vascular bundles

• Vascular structures for oxygen and nutrient delivery (holographic SLA)
(for tissue thicker than 250 µm – oxygen diffusion limit) Similar concepts:
Source: www.wakehealth.edu; organovo.com; biolife4d.com; www.prellisbio.com

TM
3D-printed Optics
A revolutionary new approach to lens manufacturing
No need for polishing

Inkjet based fabrication
Source: Luxexel.com
TM
Jewelry
Wax 3D SLA printing and lost-wax casting
SLA mold
Lost-wax casting process
wax plaster burnout metal metal
model mold part
High wax content SLA photopolymer

for clean burnout
DNA India
Source: envisiontec.com, i.materialise.com; www.dnaindia.com

TM
Textiles, Fashion, Footwear
Personalized shoe soles 3D printed dresses
Laser-sintered airy midsoles in

thermoplastic polyurethane (TPU)
– one size fits one –
Gabi Asfour & Stratasys: BIOMIMICY collection (2016)
Source: ceramics.org/ceramic-tech-today/innovation-on-the-ground-3-d- Source: www.wired.com/2017/05/the-shattering-truth-of-3d-printed-clothing/

printed-shoes-offer-custom-fit-perfect-cushion
TM
Art (Example: 3D printed Ceramics)
Unique Ceramic objects
Extrusion printer
Adaptive Manufacturing
Image: Galerie VIVID
Sensory Printing Machine that

feels the environment
Source: oliviervanherpt.com/
TM
Culinary Printing
3D printed chocolate 3D printed sugar Pixilated sushi
Pixel food printer: 3D printer capable of

producing edible and pixelated 8-bit sushi
Source: www.miamfactory.com/ Source: www.3dsystems.com/culinary Source: http://open-meals.com/

TM
Materials
(emphasis on FDM)
TM
Variety of Materials
Manufacturing process determines materials choice
Source material
liquid powder filament sheet

Process
SLA
FDM
Jet-Printing SDL
SLS Wire-Fed E-beam
Plating (Polystrata, MICA) Ultrasonic Welding
E-beam Rapid Plasma Deposition
CLIP Composite Layering
Composite Weaving
2-photon Polymerization
Jet Fusion
SLA: Stereolithography
Binder Jetting SLS: Selective Laser Sintering
Aerosol FDM: Fused deposition modeling
Extrusion SDL: Selective Deposition Lamination
CLIP: Continuous Liquid Interface Production
Metals, ceramics, polymers, composites, biomaterials,…

TM
FDM Filament Materials
Carbon fiber, metal, ceramic
Acrylonitrile Butadiene
ABS Styrene filler or magnetic particle filled
polymer
Nylon
for high temperature PC, Polycarbonate, PC/ABS blend
applications, e.g. in cars PC/ABS - High impact strength
Oxygen absorption
Polyetherimide (ULTEM) – Micro-porous, e.g. for filters
PEI high performance polymer
porous
or bio- applications can affect print quality!
Poly Vinyl Alcohol - for

Polylactic Acid –
PLA biodegradable PVA support structures – water
soluble (but hygroscopic)
High Impact PolyStyrene -

Polyethylene Terephthalate,
PET also PETG HIPS soluble in limonene (not
hygroscopic)
Thermoplastic Polyurethane - Glass, pH sensitive,

TPU flexible novel antibacterial material, … +
others
Sources: www.matterhackers.com; www.stratasys.com/materials/fdm; www.esun3d.net/index.aspx

TM
FDM Materials - Examples
Flexible, TPE, TPU, TPC Nylon 12 Carbon Fiber (Stratasys)
HIPS Wood / Metal PLA
Source: all3dp.com/best-3d-printer-filament-types-pla-abs-pet-exotic-wood-metal/; www.stratasys.com

TM
Exotic FDM Filament - Examples
• Debinding
• Sintering (~1300C)
• ~20% shrinkage
Ultrafuse 316LX 316L steel
Source: www.formfutura.com; 3dprintmagazine.eu

TM
Materials Safety – Fumes in FDM
Volatile Organic Compounds (VOCs) & UltraFine Particles (UFPs)
- released by FDM extrusion process -
• PLA – regarded as safe • UL study (2017) identified nanoparticles and

• ABS – releases carcinogens (styrene) VOCs (styrene, caprolactam, lactide,…)
Feb 2019
Caution should be used when operating a 3D printer in small office spaces

and hazardous filaments should be avoided!
Source: ulchemicalsafety.org/initiatives/3d-printing/
TM
Materials in Non-FDM Processes
Metals
Binder jetting: Metals, Ceramics,
Plastics, elastomers, (ceramic) filled polymers Sand (ExOne)
Ceramics
Inkjet Silicones (Wacker ACEO)
Biomaterials, food
Electronic functionality Printing of living cells (Poietis)
Important materials factors in power-based processes such as SLS:

• Oxygen content of particles (causing reduced strength of parts)
• Spherical shape and size distribution (flowability and part porosity)
• Particle recyclability (e.g. plasma conditioning) 3D-printed photodetectors for ‘bionic
eye’ (U. Minnesota)
TM
Metal Powder for AM
Gas atomized powder
For powder bed & blown powder AM processes
Important Powder Properties

• Spherical morphology & high packing density: for good flow
properties
• Low oxygen content: for clean microstructures & lower sintering

temperatures in binder jetting
• Particle size distribution: for good flow and reduced voids

- SLS: ~40-90 micron powder
- Binder jetting: ~9-20 micron metal injection molding (MIM) powders ("Powder Metallurgy Science",
R.M. German, MPIF)
Available AM Powders (Examples):

Ø Titanium, (stainless) steel, aluminum, (pure) copper
Ø Al alloys (Scalmalloy: Al, Mg, Scandium – strong and crack-free)
Ø Cobalt chrome
Ø Titanium and nickel-based alloys
Ø Gold, platinum, palladium, silver
Concerns: Health, safety (explosion hazard), waste/recycling

Ti-6242 particles (45-106 micron)
Sources: www.materials.Sandvik; www.ge.com; tekna.com; www.mimete.com; www.oerlikon.com
TM
Diamond Composite
SLA* printed diamond composite
*stereolithography
SLA with diamond particles in polymer binder

- then binder removal and infiltration with molten Si to form SiC matrix
- possibly also HIP process for densification
Source: www.home.Sandvik; www.freepatentsonline.com

TM
Amorphous Metals (Metallic Glasses)
Extreme hardness - High yield strength - High elasticity
2kg
irregular, non-crystalline structure
requires high cooling rates of

over 1000 Kelvin/second (50% weight reduction through design)
Selective Laser Melting (SLM)

• corrosion resistance (Zirconium-based alloy)
• excellent wear resistance
• elasticity Large components enabled
• (biocompatibility) by SLM 3D printing
Source: www.heraeus.com;3dprintingindustry.com
TM
Novel Multi-Material Objects
Graded composition alloys Ceramic-reinforced metal matrix composites
Gradient alloys Metal-matrix composites
Ti-6Al-4V to V Gradient Alloy
Laser Deposition process
Related process:
Laser Metal Deposition
Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357); (LMD) / powder nozzle
authors.library.caltech.edu/50785/1/S0884291414002088a.pdf
TM
Novel Ceramics Research
Silicon oxycarbide ceramic (SLA* & Pyrolysis)
*Stereolithography
high hardness, strength, temperature capability &

resistance to abrasion and corrosion
• 10 times stronger than ceramic foam

• withstands temperatures up to 1700C
Source: Zak C. Eckel, et al. (2016) “Additive manufacturing of polymer-derived ceramics” Science 351 (6268), 58-62
TM
Materials Selection Database
Database for AM materials and machines
Search for
• Materials
• AM Process
• Properties
- Mechanical
- Physical
- Thermal
• Certifications
Related products:
AMRS
Granta MI
Source: senvol.com
TM
Design
Source: Teclination
TM
AM Design Process & Tools
3D Model Slicer
CAD Design Mesh repair
capture Software
Kinect Fusion Blender Netfabb Cura,
Autodesk Recap AD Fusion 360 AD Meshmixer Repetier Simplify 3D
… Meshmaker Meshlab Slicer for Fusion
Rhino … …
…
Ansys SpaceClaim, Autodesk Inventor, Siemens NX, SolidWorks …
Design libraries of existing 3D models, e.g.:
For added Color and Texture:

e.g. Blender or proprietary software such as Stratasys GrabCAD
TM
Example – Coil Structure for FDM
Design and modeling
Autodesk Fusion 360
Print conversion (mesh repair, support structures, slicing)
Source: Teclination Consulting

TM
3D Design File Formats
3D design files may contain data about geometry, color,
texture, and materials
• old and simple format: describes anl object as a

Tesselation: .STL
.STL series of linked triangles (Tesselation)
• no info regarding color, texture, material, file
security
• best for color and high precision printing;

.OBJ tessellation or free form curves/surfaces
• color and texture stored in a paired .MTL file Free form curves: .OBJ
.AMF • potential new format (ASTM)
.3MF • potential new format (Microsoft)

Encoded colors and textures: .MTL
Source: all3dp.com
TM
Slicer Software
Slicer
.stl, .obj, .x3D, 3MF, … .gcode .gcode example
Slicer creates:
1. a toolpath (more or less intelligently) based on the geometry of the design-file
2. a percentage of infill to save 3D printing time and material
3. support structures, if the geometry is difficult to print
Examples
SliceCrafter
Z-Suite
Source: all3dp.com, ultimaker.com

TM
Support Structures in AM
Printed support structures are needed in FDM, SLA, etc.
(processes without a supporting solid powder bed such as SLS)
• General rule of thumb: most extrusion-based printers can

support overhang angles less than 45 degrees.
• Adding support structures with specialized software
Example:
Source: www.simplify3d.com
TM
DfAM (Design for Additive Manufacturing)
Parametric and generative design, topology optimization,
lattice structures and biomimicry (bionic design)
Examples:
Fusion 360 Ultimate generative design
CogniCAD™: Cognitive Computer Aided Design

Platform For Ultimate Lightweighting
Generate (TM) topology optimization
Element design optimization software
Altair InspireTM topology optimization /

generative design
Also: Compensation for shrinkage & warping (e.g. part orientation) and adding support structures
TM
AM Build Simulation Software
Multiphysics Multiscale Modelling of AM Processes
Example
Model distortions & residual stresses for processes
Suggest distortion compensation
Model optimal support structures
Minimize risk of printer damage (e.g. re-coater damage)
Minimize number of build tryouts

Predict impact of postprocessing (e.g. heat treatment, HIP,
support removal)
Optimize build-up orientation, support configuration

Verify influence of operating conditions on distortions, plastic strains and residual stresses
NX & Simcenter
+ others
Source: www.geonx.com; www.3dsystems.com; www.ansys.com; www.alphastarcorp.com; www.e-xstream.com
TM
Fabrication Process
Source: i.materialise.com
TM
3D Fabrication Services
HP Digital Manufacturing Network
+ many others
TM
Cost Example - Shapeways
Mosaic Egg
Not a photo (model)

2.41 x 1.96 x 1.96 inches
Natural Sandstone: $29 Natural Silver: $1,155

Orange Plastic: $34 18k Gold: $26,896
Polished Nickel Steel: $187 Platinum: $61,802
Natural Brass: $596 (prices as of Sept, 2018)
Source: www.shapeways.com
TM
3D Printing with Support Structures
Cut-away Support Structures
General recommendation
450 <450
No support needed Support needed

Needed in FDM, SLA, jet-printing and metal SLS (metal SLS: for heat distribution and stability during cool-down)
Soluble Support Material

HydroFill water-soluble FDM support for ABS and PLA parts
ABS
FDM printing
Source: pixelpractice.nyc; airwolf3d.com
TM
Post Processing - Examples
~70% of part cost can come from post process in (SLS or binder jetting)*
• Cutting / dissolving of support

FDM • Solvent vapor, sanding, bead blasting, tumbling, coating
• Removal from powder bed (+ remove support)

SLS • Bead/sand blasting, tumbling, machining
• Washing, post-cure
SLA • Removal of support, coating
• Poly-jet: Dissolution of support material

Jetting • Binder-jet: de-powdering, (de-binding & sintering)
ABS plastic
SLS: removal of part from powder bed FDM: solvent vapor smoothing FDM: removal of support structures
Source: www.3dnatives.com; www.3dprinterworld *Wohler report
TM
Simplified Post-processing
Augmented Deposition: material extrusion (FDM) and jetting
RIZE™ ONE
Part extrusion Special ink (color)

Release ink
Support
extrusion
support structures are quickly, easily and cleanly removed

Source: www.rize3d.com
TM
Automated Post Processing
Support removal and surface finishing
FDM part
Hybrid DECI Duo
two perpendicular, single-axis jet streams

comprised of compressed air, detergent, and
suspended solids providing targeted blast
SLS part
Related processes:
(Automated
powder removal)
Source: www.postprocess.com; solukon.de
TM
Surface Finishing
Importance
Examples:
Corrosion/oxidation Surface friction and

Tensile strength
resistance wear
Cellular and biofilm

Bending fatigue Appearance
adhesion
before
Methods
after finishing
Sanding/polishing/machining Vibratory grinding
Abrasive flow machining Shot peening / blasting
Chemical etching Electro-polishing

color variety
Vapor smoothing Electrodeposition
Dyeing Spray/dip-coating + others

Source: www.metal-am.com; www.belairfinishing.com; dyemansion.com automotive colors
TM
Surface Finishing – novel Approaches
Dry Electropolishing Laser-polishing
Ra < 0.1 µm Polished: Ra <0.3 µm
SLS: Ra < 7 µm
Titanium spinal implant with a smooth surface SLS CoCr knee implant, partially laser-polished
finish (right) achieved using DryLyte Technology
• Complex geometries • Selective

• Micro-scratch free • Micro-scratch free
• Preserves geometry • Fast
• Reproducible • Particle-free
• Reproducible
• Surface densification
Source: www.metal-am.com; www.dlyte.es; www.ilt.fraunhofer.de

TM
Surface Smoothing – Example: RF Antenna
FDM printed RF horn antenna
Solvent-vapor
smoothed VSWR
PLA plastic coated with
conductive paint
Surface smoothing improves antenna performance

Source: Microwave & RF, October 2018, (Glenn Robb, Antenna Test Lab Co.)
TM
Defect Reduction (Material Densification)
Hot Isostatic Pressing (HIP) for SLS or EBM + other processes
HIP can achieve 100% of

maximum theoretical density
Eliminate microporosity
Remove (printing) defects
Remove micro-cracks
Schematic of a SLS or EBM
printed part
Part has to have a gas- Improves the ductility and fatigue
tight surface! resistance of critical, high-
Typical: 5,800 to 30,000 psi performance materials
and up to 2,000°C
Challenge: Defect elimination without coarsening the microstructure (lowering yield strength)
Source: quintustechnologies.com
TM
Fabrication Challenges
Standardization of processes (machine-to-machine and run-to-run variability)
• Consistency of source material
• Process control and error correction
Post processing requirement
• Impact on cost, time and quality )
Certification of parts
• How to distinguish a good part from a faulty one
New potential health hazards to operators

• e.g. particulates, VOCs
Integrity of digital data

• E.g. employ blockchain technology to secure data (‘Cubichain Technologies’)
Protection of Intellectual Property

TM
Process / Quality Monitoring
Starting Material
(Specification and Quality)
Post Process Materials

Process Environment
Quality Testing
(e.g. moisture, airflow)
(NDT, DT)
Machine Parameters Dimensional Accuracy and

(e.g. laser power, nozzle monitoring, Surface Finish
temperature) (Measurement and post-processing)
In-situ Part Monitoring

(Melt Pool, Heat Map)
TM
Process and Quality Control Solutions
Process control for metal AM Product Lifecycle Management &
Workflow Optimization
Examples:
Product Lifecycle Management (PLM)
for simplicity and traceability
Workflow optimization
Workflow Software
data analytics: PrintRite3D ANALYTICS®

TM
Artificial Intelligence Supported AM
3D Printing Enhanced by Machine Vision and AI
Inkjet printer
Multi-material inkjet printing:

• Digital print record for each layer
• Data used to train a machine learning algorithm
• Voxel-level real-time feedback control
Related approach:
Blacksmith
Source: www.inkbit.xyz; markforged.com
TM
Data Security and Virtual 3D Printing
MAY 14, 2018
JUNE 30, 2018
Virtual Secure Manufacturing Space
• Software to manage and protect IP

(shared with vendors during design and manufacturing)
• Enable simpler, secured and more

efficient production process
• Rent virtual printers (representing real physical
printers, or portions thereof)
Source: www.assembrix.com
TM
Testing and Standards
Source: ASTM
TM
Materials Testing
Non-destructive (NDT) and destructive (DT) methods
Testing of starting materials quality
• e.g. powder flow, particle size, contaminants, moisture content in plastics
In-situ: e.g. Melt Pool Monitoring (MPM), heat mapping

• MPM: In-process monitoring of SLS melt plume via light beam; spectroscopy of the
plume
Ultrasound and eddy current
• Trusted methods; Eddy current is simple and better at depth than ultrasound
X-ray or CT inspection
• Currently used for critical parts because it can detect internal defects
Penetrant Dye testing

• Standard method to find surface cracks
Process Compensated Resonance Testing (PCRT)

• To identify defective parts (tests part’s resonance frequency)
Fatigue, toughness, shear, tensile tests Melt-pool monitoring

• Destructive methods
+ other test methods
Source: Chris Hole (Technology Partnerships) – SpaceTechExpo 4/12/2017; www.testia.com
TM
Standardization Efforts - Examples
America Makes & ANSI ASTM (American Society for Testing and Materials)
ASTM Committee F42 on Additive Manufacturing Technologies

and focus areas (sub-committees)
Source:www.ansi.org; www.astm.org
TM
AM Standards Structure
Source: ASTM
TM
Additional
Technology Examples
Source: Advanced Materials / ETH Zürich

TM
Small-Scale AM
e.g. Two-photon Polymerization
Photonic Professional GT2
Similar concepts:
Source: www.nanoscribe.de & www.laserfocusworld.com; www.microlight.fr; www.nano-fabrica.com

TM
Microprinting
3D Microprinting of Metals Using a Force-Controlled
Nanopipette for Layer-by-Layer Electrodeposition
Deposition by FluidFM technology

(e.g. www.cytosurge.com) Volume 28, Issue 12, March 23, 2016 ~50µm
Pages 2311–2315
Hollow atomic force microscopy (AFM) cantilevers locally supply metal

ions (e.g. copper) in an electrochemical cell
Source: www.ethz.ch; L. Hirt, et al., Jan 2016, Advanced Materials (ETH and University of Zurich, Zurich, Switzerland)
TM
Large Industrial 3D Printing
Selective Lamination Composite Object Manufacturing (SLCOM)
industrial thermoplastic reinforced woven composite 3D printer
SLCOM 1
Build envelope: 762 x 610 x 610 mm
(Sand) Molds for casting Gel Printing (photo polymeric acrylic gel)
saves up to 75% in sand casting costs build up rate of 14 in/hr for super-size parts
3D retail displays
up to 4,000 x 2,000 x 1,000 mm
Source: envisiontec.com, massivit3d.com, www.voxeljet.com

TM
Combined Additive and Subtractive Systems
Laser build-up process with 5-axis milling
5-axis powder laser 5-axis milling

deposition
FDM process with 5-axis milling
Other concepts:
Lumex Avance
Print an object to near net shape and trim the part to net shape with CNC router
SLS and machining during the AM process
Source: us.dmgmori.com; www.thermwood.com; matsuurausa.com
TM
Free-form Additive Manufacturing
Robotic multi-axis 3D printing technology
Wire Arc Additive Manufacturing (WAAM)
Playhouse structure
Metal bridge
Source: www.branch.technology; mx3d.com
TM
Cooperative Mobile Print Robots
Robots that can 3D print and move around
Nanyang Technological University, Singapore
Build structures that are more or less arbitrary in size
Source: spectrum.ieee.org
TM
‘Open-ended AM’ Concept
3D printing using Unmanned Aerial Vehicles (UAVs)
UAVs as the print extrusion units to break the limitation of size
Source: www.dedibot.com; gxn.3xn.com

TM
Concrete Printing
Contour Crafting
USC Viterbi (Prof. Khoshnevis)

Source: contourcrafting.com
TM
Printed Textiles
Layered Fabric 3D printer
Laser cutting and bonding with

heat-sensitive adhesive
April 2015
Felting printer
Feeding yarn and attachment with

felting needle
April 2014
Source: www.disneyresearch.com
TM
4D Printing
Shape-shifting 3D printed parts (Smart memory polymer)
Objects transform
with heat
Science Advances 12 Apr 2017:

Source: gatech.edu Vol. 3, no. 4, e1602890
TM
Resources
TM
Additive Manufacturing News
www.metal-am.com wohlersassociates.com
all3dp.com www.tctmagazine.com
www.3dmpmag.com
3dprint.com
www.3dprintpulse.com
www.rapid3devent.com
additivenews.com
www.manufacturingtomorrow.com
www.printedelectronicsworld.com
advancedmanufacturing.org
www.sme.org home.liebertpub.com
www.printedelectronicsnow.com
www.additivemanufacturing.media
www.3ders.org
3dprintingindustry.com additivemanufacturingtoday.com
www.3dnatives.com
www.3dprintingmedia.network
www.3dprintforums.com www.compositesworld.com … and many more
additivemanufacturing.com
TM
AM Conferences and Tradeshows
formnext.mesago.com
rapid3devent.com
www.amug.com
www.additivemanufacturingforum.de
inside3dprinting.com
www.3dprint-exhibition.com
www.rapidtech-fabcon.de www.mpif.org
www.additiveconference.com
www.tctasia.com.cn
www.am-ceramics.dkg.de + others
TM
AM Patents
TM
“Additive Manufacturing” Patents
Patents/applications (‘publication date') with “Additive Manufacturing” in title, abstract or claims
2005-2018
Top applicant companies
Source: www.lens.org
TM
“3D Printing” Patents
Patents/applications (‘publication date') with “3D Printing” in title, abstract or claims
2005-2018
Top applicant companies
Source: www.lens.org
TM
AM Investments
TM
AM Landscape
Source: amfg.ai/
TM
US Government Investment
Program operated by the interagency AMNPO
(Advanced Manufacturing National Program Office)
Operates in partnership with the DOD, DOE, NASA, NSF, and the
Departments of Education, Agriculture, HHS, and Labor
national accelerator and the nation's leading

collaborative partner for technology research,
in additive manufacturing and 3D printing
furthering U.S. development and adoption of

the flexible hybrid electronics
encourages factories across the United

States to deploy digital manufacturing and through
design technologies FFRDCs,
Government
… Labs,
Agencies
consists of multiple linked
Manufacturing Innovation Institutes
(14 institutes / public-private partnerships)
TM
Public AM Corporations - Examples
NYSE: DDD NASDAQ: DDYD

NASDAQ: XONE
EPA: PWG
NASDAQ: ALGN NYSE: HPQ
NYSE: ARNC
NASDAQ: ADSK NYSE: VJET

NASDAQ: MTLS
NYSE: PRLB NYSE: GE

FRA: AM3D NASDAQ: ONVO
see also e.g. (ARK Invest) ETF: PRNT + others

TM
Corporate Example 1: GE
2016: GE acquired
ARCAM and Concept Laser
Example - LEAP engine parts:

• 2016: $39 million Center for Additive Technology 19 printed fuel nozzles in the
Advancement (CATA) in suburban Pittsburgh combustion system (Co-Cr alloy)
• 2017: became Customer Experience Center (CEC) • 25% lighter
• Replaces ~20 parts
– in addition to CEC Munich ($15M)
• ~5x higher durability
Source: GE, Bloomberg, tctmagazine
TM
Corporate Example 2: Siemens
~$30M
Example: 3D printed blades for gas turbines
New manufacturing facility of Materials

Source: www.siemens.com Solutions Ltd., Worcester, UK
TM
Corporate Example 3: Arconic
2016
Metal powder
• Arconic Technology Center near Pittsburgh (focus is on

wire or powder for 3D printed aerospace parts)
• AmpliforgeTM Process (combines additive and traditional
manufacturing)
3D printed hinge
November 15, 2017
Alcoa Technology Center, Pittburgh

Source: www.arconic.com
TM
Corporate Example 4: HP
“Most advanced research and development facilities

for the next-generation technologies powering
the Fourth Industrial Revolution”
• Large scale factory environment for customers and partners to

collaborate on digital manufacturing
• More than 150,000 square feet of cutting-edge innovation space
Source: www.press.ext.hp.com
TM
Contact:
www.teclination.com
daniel@teclination.com
TM

Additive Manufacturing For 3-Dimensional (3D) Structures: (Emphasis On 3D Printing)

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Additive Manufacturing For 3-Dimensional (3D) Structures: (Emphasis On 3D Printing)

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TECHNOLOGY OVERVIEW Update - Summer 2019

Source: www.geaviation.com, cessna.txtav.com

Development started in 2015

1/3 of engine parts are 3D printed

Structures carry the same

Conventional bicycle frame AM bicycle frame

High cost for prototyping and small runs

Long design / setup time (Tooling, etc.)

Materials waste in subtractive methods (milling)

Complex assembly required for complex designs

Limited materials combinations

Freedom of complexity (designs difficult to do conventionally)

On-demand production (reduced inventory)

Cost and time savings (for prototyping and small runs) -

Example: aerospace bracket

Reduced waste material

3D printing market is expected to grow from

IDTechEx, March 2018

Global 3D printing revenues: $3.1B in 2020

Predictions heavily depend on assumptions and included technologies

3D Systems: DDD Example:

ExOne: XONE Stratasys: SSYS

LOM • Laminated Object Manufacturing

FDM • Fused Deposition Modeling EPD • Electrophoretic Deposition

SLS / SLM • Selective Laser Sintering / Melting

EBM • Electron Beam Melting PNP • Pick and Place

SLA / DLP • Stereolithography / Digital Light

PVD • Physical Vapor Deposition

Plus: *Information Services (Conferences / Journals)

Source: am.vdma.org and Teclination (*)

Digitalization of physical products

Issues in supply chain

Reliability of mechanical structures

Source: DuPont, TaktoTek

LDS (Laser Direct Structuring)

laser activation and plating

Using stretchable conductive ink from DuPont

Sensor Structures via

printed smartphone antennas

Source: www.optomec.com & www.neotech-amt.com

3D printed signal conditioning circuit Source: Science, 30 Sep 2016

Hybrid of AM, robotic component placement and

FDM nozzle (source:3dnatives)

e.g. Marlin firmware control:

Example: Laser galvo-scanning &

CLIP (Continuous Liquid Interface Production) CLIP process

Adidas Futurecraft 4D midsole

Oxygen Dead zone

Lubricant Sublayer Photo-curing (LSPc)

Intelligent Liquid Interface (ILI)

Breathable ankle orthosis Nylon duct

Typical powder particle size:

Polymers 1 million diode laser array

Build volume: 700 x 380 x 580 mm ProX SLS 6100, …

Infrarded Inkjet IR light

“10 to 100x faster than current

Build volume: 290 x 140 x 180 mm Multijet Fusion (MJF)

spun out of Stratasys

Partnership with Kodak

US Patent 8488994 B2 (2013)

3D printing alternative to injection molding

Addresses issues of vat-based systems (e.g. SLA process):

Qualified material: Ultracur3D