Advanced 3D Printing Materials

Advanced Applications of 3D
Printing
Panel Discussion from Mark Burhop, Boris Fritz, and Erick Wolf

Siemens AG 2013 All rights reserved.

Smarter decisions, better products.

Our Three Presentations
• Exploring new materials and their applications for design and
manufacturing
• Mark Burhop, Director of 3rd party Ecosystems for Mainstream
Engineering, Siemens PLM Software
• The new industrial revolution: additive layer manufacturing and its
transition into nanomanufacturing
• Boris Fritz, Engineer 5- Prod Ops Manufacturing Technology
Development, Northrop Grumman Aerospace Systems
• Applications of desktop 3D printers for rapid prototyping
• Erick Wolf, President, Airwolf 3D
We will do a Q&A at the end for all the panelists

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Siemens PLM Software

“Material Changes” in Additive
By Jason Newell
(Content update by
Manufacturing Mark Burhop)

Smarter decisions, better products.

Agenda for Today
Exploring new materials and their applications for design and
manufacturing
• Why are new materials key to additive manufacturing growth.
• Skipping the prototype phase using materials that can be taken straight to the
manufacturing
• How composite materials are allowing sturdier items to be produced whilst
using reduced material volume

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Introduction
Mark Burhop - Siemens PLM–
Programs Director, Mainstream
Engineering Technology Ecosystem

• Works with companies that
provide complementary
technology to our design, analysis
and manufacturing software tools.
• Closely following the AM industry
and technology.
Globally, Siemens is also a user of
these technologies.
Also active on social media.
@burhop on twitter
http://siemens.com/plm/blog
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Why are new materials important
• Today‟s prototypes are easy. Just
save an STL file and give it to the
shop guy or service bureau.

• Accuracy. Not a big concern.

Use

• Color. Pick one.
• Material. Pick a “plastic”.

Today

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New materials increase the scope of additive
manufacturing
Tomorrow‟s Additive Manufacturing
•

Demand won‟t be for just prototypes.

•

We will need accuracy in
manufacturing
(tolerance, strength, predictability)

•

Software that can help create
precisely (additive) manufactured
parts.

Use

New materials are key!
•
•

Mixed materials and material
properties that can be tuned at any
place in the model.

•

Reinforced materials

•

Future

A bigger pallet of materials.

Materials that last

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3D printing for final part production up 23%
Aerospace, jewelry, and medical/dental are among the industries using 3D
printing for final parts.
3D printing for final part production up 23%
On the eve of the 3D printing industry‟s largest conference, a leading analyst firm
in the industry says the use of 3D printing for the production of parts for final
products is getting close to 30% of all 3D printing.
http://gfxspeak.com/2013/11/18/3d-printing-for-final-part-production-up-23/#sthash.gfR74APf.dpuf

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Direct to Part Manufacturing
• The use of 3D printing for final
part products continues its
long-term growth trend.
(Source: Wohlers Associates)
• “final part production created
by 3D printing processes rose
to 28.3% of the $2.2 billion
spent last year on 3D printing
products and services
worldwide”.
http://gfxspeak.com/2013/11/18/3d-printing-forfinal-part-production-up23/#sthash.CaXFEBHn.dpuf

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Growing industry

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Existing materials form 3D Systems

http://www.3dsystems.com/materials/Production
3D Systems

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EOS materials

https://www.eos.info/material-p
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Expanded use of additive manufacturing because of
newly supported materials
“The strength of the technology is that it can
be used to produce complex individual pieces
or parts that are needed in small quantities,”
says Krüger. “A classic example from our own
product development is a new duct
system, known as a „transition duct‟, for gas
flows in gas turbines,” says Martin
Schäfer, who has been working with this
technology at Siemens CT since the late
1990s. “This curved, thin-walled part has
very small channels, and it’s extremely
difficult to make it with conventional
technologies such as casting and milling.
But with additive manufacturing, these metal
parts can be produced right from a computer in
just a few days, instead of weeks,” says
Schäfer. All rights reserved.
Siemens AG 2013
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Worlds Hardest Christmas Tree
Siemens uses 3D printing processes to
speed up gas turbine repair. For certain
types of turbines, defective burner parts
are simply reprinted, reducing repair times
by as much as 90 percent. Olaf Rehme of
Siemens Corporate Technology also uses
one of the super-hard special steels that
can withstand extreme conditions.
http://www.siemens.com/press/en/presspicture/pictures-photonews/2013/pn201317.php

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Siemens: Gas Turbine Burner Repair

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

Aluminum

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Nickel Alloy and Titanium

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Hot isostatic pressing (HIP)
•

(HIP) is a manufacturing process used to reduce the porosity of metals and
increase the density of many ceramic materials. This improves the material's
mechanical properties and workability.

• The HIP process subjects a component to both elevated temperature
and isostatic gas pressure in a high pressure containment vessel. Pressure is
applied to the material from all directions (hence the term "isostatic").
• When castings are treated with HIP, the simultaneous application of heat and
pressure eliminates internal voids and microporosity through a combination
of plastic deformation, creep, and diffusion bonding; this process improves
fatigue resistance of the component.
http://en.wikipedia.org/wiki/Hot_isostatic_pressing

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Carbon Fiber
The properties of carbon fiber,
• high stiffness
• high tensile strength
• low weight
• high chemical resistance
• high temperature tolerance

• low thermal expansion

http://www.hotrod.com/techarticles/body/hrdp_1212_how_to_lay_up_c
arbon_fiber_at_home/photo_05.html

Popular in aerospace, civil
engineering, military, and
motorsports, along with other
competition sports.

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critical length, lc,

The Fibers do not have to run the entire length. They just have to be “long
enough.”

The minimum fiber length for a continuous fiber composite lc= critical length
sf= tensile strength of the fiber
d = diameter of the fiber
tc = shear strength of the bond between the matrix and the fiber

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Carbon Fiber in 3D printing
• “Short Chopped Carbon Fibers” to reinforce PLA. Proto-Pasta on
KickStarter (FDM/FFF process)
• As the nylon is melted by the laser it encapsulates the carbon
fibers, leaving very tiny ends of the fiber protruding from the nylon.
Next, the machine applies another layer of nylon over the just-melted
layer: As the laser melts the subsequent layers of nylon the carbon
fibers become interwoven from layer to layer – creating a very strong
composite. http://nwrapidmfg.com/blog/2012/06/25/carbon-fiber-fillednylon-a-material-alternative/ (SLS process)

Getting fibers running in all directions would be
very valuable.
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Carbon Fiber Printers
• The MarkForged Mark One Carbon
Fiber printer.
• “continuous Fiber” printer.
• Just announced so I do not have a lot
of information.
http://markforged.com/

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Graphene
Graphene can be described as a one-atom thick
layer of graphite (carbon).
High-quality graphene is strong, light, nearly
transparent and an excellent conductor of heat and
electricity.
adding graphene to polymers which are
conventionally used in 3D printing improves the
properties of the polymer in many different ways; it
improves the polymers mechanical strength as well
as its electrical and thermal conductivity
Graphenea found that the addition of as little as
0.22 percent of graphene to alumina made it 50
percent more resistant to the propagation of cracks
under strain

Source: http://www.graphenea.com/blogs/graph
ene-news/8689765-graphene-reinforcedalumina-tougher-and-more-conductive-thanplain-a

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Homogeneous Material in a Square Rod

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Homogeneous Material in a Square Rod

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Heterogeneous Material in a Square Rod

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Stress Distribution is Heterogeneous Square Rod

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Professor Yong Chen and his team at the university
of Southern California (USC) Viterbi School of
Engineering

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http://vimeo.com/79412743

What is next?

Materials beyond manufacturing…

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Paper
Mcor Technologies
Full-Color 3D Printing with standard paper
http://www.mcortechnologies.com/

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Concrete

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Source: UC Berkeley
Department of
Architecture and Software
Siemens PLM Luxology

Sugar

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Photo by Zach Burhop – at CES 2014

ChefJet line of 3D printers from 3D Systems

Chocolate

Examples of chocolates created by the 3D chocolate printer (Photo: EPSRC)
http://www.gizmag.com/3d-chocolate-printer/19121/picture/137279/
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Conclusion
• Ability to print in a growing number of materials will expanding additive
manufacturing reach, especially for “direct to part” 3D printing.
• Composite materials are becoming important to addressing many of the
limitations of existing materials used in additive manufacturing.
• Mixed materials have the potential to allow designers to create entirely new
products, especially where tuning of material properties is key.

Finally!
As this is February 13, Be sure to
take home sample materials,
preferably in a heart shaped box.
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Advanced 3D Printing Materials

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