3D Printing

ATOA Scientific Technologies | Multiphysics CAE | Engineering Apps | 3D printing
ATOA: PUBLIC
3D Printing
Multiphysics CAE for The First Time Right
Dr Raj C Thiagarajan
12 Aug 2015
Webinars

ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |2
ABSTRACT
• 3D Printing is projected as the next industrial revolution and it can potentially influence almost every aspect of our
daily life in some way. The missing link or bottleneck in computer aided product development is prototyping or
product manufacturing. New development in 3D printing such as digital material takes product development to newer
heights. Functional 3D products with complex shapes for novel functionality can be manufactured right at your
desktop. Self-replicating 3D printing machines can revolutionize the industrial manufacturing from linear to nonlinear
growth. For end customers, 3D printing technology enables complex, intricate design and high cost production
products, custom made.
• This webinar will start with an overview of 3D printing technology. The parametric CAD model design methodology in
COMSOL for 3D printing will be given. Material modelling for evaluating various materials such as polymers,
composites, metals, ceramics and hybrid materials, suitable for 3D Printing will be detailed. Resistive, laser and
inductive heating simulations for effective thermal processing will be highlighted. A wide range of 3D printed products
from molecular models to consumer products which are engineered using Multiphysics CAE will be showcased.
CAD CAE CAM of Product development, 3D Printing, Multiphysics CAE of 3D printing.

3D Printing
The fabrication of objects through the deposition
of a material using a print head - ASTM.
3D printing technology foundation comes from, more than two decades old Rapid
Prototyping, CNC, Robotics and Material Processing Technologies.
Current excitement is due to, technology maturity, open source electronics hardware,
crowdsourcing, digital fabrication, advancements in CAE, history free CAD, the maker’s
community, the availability of low cost printers, multi material technology, low cost laser,
the internet economy, all that propels 3D printing into an exciting future and possibility.
Faster Product Development, CUSTOM, Bottom up, Disruptive Business Model

Simulation based Product Development
Simulation based Computer Aided Product development for faster,
Individual: Idea to Physical Prototype
Industry: Concept to Market
Advantages of Virtual or simulation based product development is proven.
Virtual Product Development : Concept - CAD - CAE - CAM
CAD: Digital 3D Design
CAE: Engineering Design and Analysis, Virtual Testing, product performance, Process design, life
cycle evaluation.
CAM: Rapid Prototyping (RP), 3D Printing, Additive Manufacturing (AM), Direct Digital
Manufacturing (DDM), Solid-Freeform Fabrication (SFF)

PRODUCT DEVELOPMENT CYCLE
● Product Development is long
Cycle process.
● Cost of Design changes increases
exponentially with product
development cycle.
● 80% of the product cost is
determined or committed at the
concept design stage

First Time Right Product Design
Design Change Cost in product development
•Cost of fixing = Stages X Times
•Cost of Design changes increases exponentially with
product development cycle.
•Multiphysics CAE + 3D printing for the first time
right product development

First Time Right Development Cycle
PREFERED CONCURRENT ROUTE for FIRST TIME RIGHT PRODUCT DEVELOPMENT

3D Printing : Conversion of Concept to Physical Product
CONCEPT
2D Sketches,
Drawing
CAD
3D Digital Model
iges, step
MESH
Triangular Tessellations
STL file
SLICE
2D layer by layer
Gcode
3D PRINT

3D Printing Technologies
Additive Manufacturing
ASTM F42 – Classification
1. Photopolymerisation:liquid photopolymer selectively cured by light activation
2. Material Jetting:droplets of build material are selectively deposited
3. Binder Jetting:a liquid bonding agent is selectively deposited to join powder materials
4. Material Extrusion: material is selectively dispensed through a nozzle
5. Powder Bed Fusion:thermal energy selectively fuses regions of a powder bed
6. Sheet Lamination: sheets of material are bonded to form an object
7. Directed Energy Deposition: focused thermal energy is used to fuse materials by
melting as they are being deposited

3D Printing Material and Methods
Materials
● Solid Thermoplastics
● Liquid photopolymers
● Polymer,metal, ceramic powders
Methods
● FD (Fused Deposition Modelling)
● SL (Stereolithography Apparatus)
● LS (Selective Laser Sintering)

3D Printing and Multiphysics CAE
Material
Product
Process
and
System
Trial and Error
vs
Physics based
modelling
For the first time right

FD (Fused Deposition Modelling)
A material extrusion process used to
make thermoplastic parts through
heated extrusion and deposition of
materials layer by layer –ASTM
•Thermoplastic filament
•XY motion extruder, heater head
•Z motion support bed.
•Sensor, control, interface system
Polymer wire
X-Y movement
Extruder
Heater
Object
Build platform
Z movement
Schematic Illustration of FD 3D printer

FD Physics
Thermomechanical + Phase change + Flow process
Pressure Flow (Poiseuille Flow)
dP= 2 η L Q / π d4
Viscoelastic Material behaviour,
Power law, Carreau - Yasuda, ..
Print Resolution
= f(d, L, T, P, η), Extruder, Process and Material Parameters
d
D
alfa
M
F
Solidification
P - Plunger
Melting
Polymer
liquid
dP
L
Die Swell
Solid polymer wire

FD : Multiphysics CAE
Viscoelastic material modelling, Process
flow, Part warpage and residual stress,
Part performance
Extrusion die Design
Effect of die angle on exit pressure and
velocity
Process optimization
Effect of pressure on shear rate of a
viscoelastic material

SL (Stereolithography)
a vat photopolymerization process used to
produce parts from photopolymer materials in
a liquid state using one or more lasers to
selectively cure to a predetermined thickness
and harden the material into shape layer upon
layer -ASTM
Photopolymer
Laser source and mirror control
Z motion support bed.
Sensor, control, interface system
Mirror
Laser beam
Laser Source
Platform
Z move
Photosensitive Resin
Part

SL Physics
Laser Radiation exposure
Size, time and intensity
Photoinitiation
Photopolymerisation
Monomer
Oligomer
Photoinitiator
+ UV Radiation = Cure Reaction
Heat transfer
SL performance f(Resolution, Speed, Temp, degree of cure)
A Gaussian laser and a resin obeying Beer’s Law.
E, exposure at y, z, PL , laser power, w0 beam
radius, Vs scanning speed, Dp , Penetration depth
hν
Photoinitiator Oligomer Monomer

SL : Multiphysics CAE
Photopolymerisation chemical reaction modelling
Laser Optics Ray tracing
Laser Radiation heating process modelling.
Scanning of the laser
Laser radiation heating
Conduction, convection and Radiation heat
transfer
Coupled to Photopolymerisation chemical
reaction for the degree of cure.

LS (Laser Sintering)
A powder bed fusion process used to
produce objects from powdered
materials using one or more lasers to
selectively fuse or melt the particles at
the surface, layer by layer, in an
enclosed chamber.
LS – Selective Laser Sintering / Melting
(SLS/SLM)
Sinters Fuses or melts powdered
material (polymer, metal, or ceramic)
laser or electron beam.
Mirror
Powder
Roller
Laser
Source
Build
Platform
Z move
Powder
Bed
Laser beam
Part
Powder
Stock

LS Physics
Granular/ powder material
sintering, fusion or melting
Laser heating
Heat transfer
Phase change
Coalescence
Frenkel’s relation, t~ηD / σ
Solidification,
Densification
Solidified Layers
Sintered Layers
Laser Beam
Melting and Coalescence
Powder layer
Scan Direction
D

LS : Multiphysics CAE
Laser Heating
Granular material fusion:
Coalescence of viscous particles
due to Surface forces,.. Two phase
level set method
Phase transition by a moving
boundary interface according to
the Stefan problem as a function
of process parameter gradients

3D Printing and Multiphysics CAE
Product Design
Process modelling
Overhang and support
Warpage and Shrinkage
Residual stress
Part performance for First Time Right

3D Printed Part Performance
Additive manufactured Materials Property prediction
Microstructure is starting point for part performance
Schematics of Microstructure and sample micromechanics results.
FD
Transverse isotropic X, Z
Lower transverse properties
SL
Transverse isotropy, X, Y
Properties are inherited from
the photopolymer
LS
isotropic, X ,Y, Z
Property reduction due to
porosity
X
Z
Y

Molecular to CAD to 3D Prototypes
Molecular model with atomic
level properties.
Conversion of atom data into
solid model
CAD model to STL file and 3D
printing.
Molecular structure inspired
ultra lightweight macro
materials and structures.

Future of 3D Printing
Multi material
Polymer, Metal, Ceramic, Natural, Bio… all in one
Multi functional
Material (engineering) + Electronics (semiconductor)
Industrial scale 3D printing Machines
Heavy Industrial Machines, Residential home, Infrastructure
Innovations
Nanomaterials, 4D printing, Self assembling systems,...
will enable breakthroughs in 3D printing

CAD CAE CAM of 3D Printing
@ 3d.atoa.com
This webinar
is from
atoa.com

3D Printing

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