Class notes· Grow up In Germany, BS philosophy, MS Japanese.docx

Class notes:
· Grow up In Germany, BS philosophy, MS Japanese, PhD
religion. Permotic technology. After half a year went back to
Northrop. Fixing problems for engineer. 3D printing, few of
them has been in it for a while. Working on the Nano level.
Self learned in engineering. Follow the bio
· First jet made out of wood. Cos radar cannot catch it.
· Reason for doing AM lightweight, elimination of secondary
processes, mass customization. Tool- less, unique consumers,
challenging( system reliability, need closed-loop, expensive,
large built volume, speed)
· SLA 1, helps to easily understand the model.
· Machine some of them using powder to drown the 3D model
and some are using iron to do that. The purposes to deliver a
heavy material to be used in an easy ways. Ex. Space shuttle
main engine.
· Company name for printers, Stratasys, FDM Maxum, FDM
titan by Stratasys. That one can resist asphalt and many harsh
materials. The largest machine is FDM foutus 900mc additive
fabrication system. The first machine is under 30 thousand
dollar. Some machines can do 3d with deferent materials in the
same time, some machine using electron beams to milt material
instead of lazier.
· New machine came out recently makes building out of sands,
emphasis on building on moon. Cost saving in custom louver
form blocks 4 HOURS VS 2 and a half weeks (96 hours) labor
saving.
· Award wining application at 2000 RP&M world conference for
rapid manufacturing aircraft locator tooling. 92% reduce of
labor works!
· Food printing for candies and chocolate has been used to
develop and grow special candy design.

· Nanotechnology is able to change the molecules of elements to
be changes for example cup of Lycurgus.
· Nanotechnology are deferent because
· Nano level so deep it even doesn’t excise any fraction in it
because you are dealing with the atomics.
· When you get to the Nano level you get self-replication. Ex
from nature is fire fuel oxygen and heat.
· No tolerance and QA issue in manufacturing on the Nano
level, all what it mater is digital and also it is identify
completely.
· Respirocytes replaces 10% of your blood. Can hold breath for
4 hours.
· Conclusion:
I personally enjoyed this lecture due to the amount of
information, which I have absorbed through class time. It is
interesting know that much of 3D printers and what are their
capabilities of capturing in producing deferent design from
aerospace repairs to food producing and candies. However in
nanotechnology I feel it is almost there to be used heavily in the
market and how it can be used starting with radio size.
Short Bio for Boris Fritz
Boris Fritz
Adjunct Professor
Loyola Marymount University
Additive Manufacturing Consultant
C: 310/850-9777
[email protected]
Boris Fritz is an adjunct Professor at Loyola Marymount
University in the Department of Mechanical Engineering,
currently teaching a course in Additive Manufacturing. He also
does consulting in Additive Manufacturing. He retired from

Northrop Grumman Aerospace a year ago as an Engineer 5,
formerly working in the Additive Mfg Technology &
Development Department and in charge of the Rapid
Manufacturing Lab for 22 years until October, 2013. He has
three patents and was also part time faculty at Loyola
Marymount University from 2001 - 2008. He has been very
active with the Society of Manufacturing Engineers (SME) since
the early nineties, founding its national Nanomanufacturing
Technical Group, being Vice Chair of the Innovation Watch
Committee, as well as having been on the board of the
Manufacturing Enterprise Council, and national Chair of the
Rapid Technologies & Additive Manufacturing (RTAM)
Community in 2003, and on their Advisory Board for 6 years.
He has also been on the Advisory Board of SME’s RAPID
Conference for the last 10 years, as well as speaking at that
conference on the State of the Industry of Nanomanufacturing
and chairing sessions for many years up to the present time. He
has published and presented many papers on Additive
Manufacturing at numerous Universities & conferences in the
US & Europe. He was also one of the subject matter experts on
5 continents who helped create the Additive Manufacturing
Technology Roadmap for Australia, 2011. Fritz was also a
member of the Foresight Nanotech Institute’s Roadmap Working
Group, 2005-2007 and the U.S. representative to GARPA
(Global Alliance of Rapid Prototyping Associations) from 2001
through 2006 (http://www.garpa.org). He was on the Editorial
Advisory Board of Time Compression Technology Magazine,
2002 -2005. He has won 4 World Excellence Awards in the
field of Stereolithography, 2 of them first place (1995 & 2001).
He also contributed to the prestigious Wohlers Report 2001 –
2003, 2007-2010, providing the section on Nanotechnology –
the annual state of the Rapid Prototyping industry book
published by Terry Wohlers
(http://www.wohlersassociates.com/). From 2003-present,
annual Speaker at USC’s Space Architecture Graduate Seminar,
for the Department of Astronautics. In 1998 he received the

Outstanding Engineering Achievement Merit Award of the
Engineers’ Council of California. Fritz has also worked as a
consultant to JPL. He is also featured in the National
Geographic documentary 'Hitler's Stealth Fighter' available now
on YouTube. In 2013 he co-authored the paper 3D Printing of
Food for Space Missions through the Dept of Astronautics at
USC, which included a write up on Wired Magazine and
presentation at AIAA in 2014. His webinar on the Silent
Industrial Revolution of Additive Mfg and its transition into
Nanotechnology is available at:
http://www.sme.org/nanotechnology-webinars/ as well as on
YouTube under ‘Boris Fritz Silent Revolution’. He spoke on
Additive Mfg and its Transition into Nanomanufacturing at the
Pacific Design & Mfg Show at Anaheim Convention Center in
CA in Spring of 2014.
He is also on the Advisory Board and faculty of Ananda College
in Northern California. Fritz also does research and teaching in
the field of archaeoastronomy & has spoken several times at the
Conference On Precession & Ancient Knowledge. He has been
married for 35 years. He practices and teaches the Filipino
Martial Arts as well as practicing Serak - an Indonesian Martial
Art.
He has a B.A. in Philosophy from Occidental College, an M.A.
in Asian Studies from Claremont McKenna Graduate School,
and is a Ph.D. Candidate in the History of Religions at UCLA.
MEMO
<indicate, First Submission, Second Submission, or Final
Submission>
FROM: <insert student name>
TO: Professor
DATE: <insert date>
SUBJECT: Memo on <insert speaker name>, <insert title of
speaker’s presentation in quotes>

On February XX, 2015 in the SELP 694 Seminar Class, Mr.
XYZ presented a lecture entitled “Systems Engineering LMU
SE Seminar Class.” Mr. XYZ is currently the Vice President of
ABC Corp. Mr. XYZ graduated from XYZ University and
joined the US Navy to work in various intelligence positions
and travelled throughout the world.
Mr. XYZ described the typical career path for a systems
engineer including the expectations and responsibilities of the
various positions. Furthermore, Mr. XYZ shared the different
aspects of business sizes and how to develop new business in
both the commercial and government arenas.
Mr. XYZ started off the seminar with a concept called
“MATTESS,” which stands for “Money, Advancement, Travel,
Training, Experience, Satisfaction, and Security.” The concept
states that an employee is motivated to do their best work by at
least one of the aforementioned items. System engineers usually
promote themselves out of a job, which includes the transition
to engineering management, then managing engineering, then
program management, and finally business development.
Transitioning to engineering management requires good
communication and motivational skills. In addition,
transitioning to managing engineering requires the
understanding of corporate goals as well as management of
budgets, schedules, requirements, and business strategy
development. Furthermore, transitioning to program
management requires successful budget, schedule, requirements,
and new business development as well as providing key
interactions with the customer. Lastly, transitioning to business
development requires a good understanding of how business is
generated, engaging customers and competitors, helping the
customer sell the solution, find funding, and finally keeping the
program sold. Mr. XYZ described the different business sizes

including the large-sized businesses such as Lockheed Martin
and Northrop Grumman, medium-sized businesses such as
Honeywell and Rockwell Collins, and finally small-sized
businesses, which are the largest growing market segments
relied upon by the government and large-sized businesses.
Mr. XYZ’s presentation made me realize that satisfaction is
what motivates me to do my best work as a subcontracts
manager at my company. Furthermore, my position allows me to
transition into my company’s business development area and I
found Mr. XYZ’s presentation useful in helping me achieve my
promotion goal into this new area.
I found the speaker very engaging and I appreciated his
openness with his personal life which allowed the audience to
connect more with him on a personal level. I also appreciated
the information he shared about the current and future financial
situation of the nation that allowed us to remain optimistic
about our future business and security.
1
The Next Industrial Revolution:
Additive Layer Manufacturing
and its Transition into
Nanomanufacturing
Part 3
Boris Fritz
Adjunct Professor
Retired Engineer 5 - Northrop Grumman Aerospace

Founder, Past-Chair: NanoManufacturing Tech Group
Vice-Chair, Innovation Watch Committee
March 12, 2015
Engineering Systems Class
nanoENGINEER-‐1
http://www.crunchbase.com/
company/nanorex
2
3
No
More
Tolerance
And
QA
Issues
4

• At Atomic Scale, All Matter Is Digital
• All Atoms Of The Same Element Are Completely
Identical! No More Tolerance Issues
• Atoms Can’t Wear Out, So Part Built At Atomic Scale
Won’t Wear Out!
• Atomic Bonds Don’t Fatigue!
• No More Go/No-go Gauges Or Tolerance Problems –
All Parts Are Perfect As Long As They Are Made Of
The Specified Atoms.
• Digital Perfection!
Secret
of
NanoTech
are
the
new
Microscopes
• Older
HRTEM
(High
Resolu3on
Transmission
Electron
Microscopes)
are
housed
in
8’
tower
plus

support
equipment
• 1981
Gerd
Binnig
&
Heinrich
Rohrer
create
the
scanning
tunneling
microscope
(STM)
for
imaging
individual
atoms
• 1993
University
of
North
Carolina
and
UCLA
devise
virtual-‐reality
system
connected
to

an
STM
which
allows
user
to
see
and
touch
atoms
• Atomic
Force
Microscope
(AFM)
allows
actual
interac3on
with
atoms.
Only
1
½
feet
high
on
a
buffered
concrete
slab
–
otherwise

a
mouse
running
across
floor
would
upset
it!
• Magne3c
Field
Microscope
(MFM)
–
it’s
sharp
3p
samples
the
magne3c
field
surrounding
each
atom
• NSOM
–
Near
Field
Scanning
Op3cal
Microscopy

–
an
op3cal
microscope
that
is
now
capable
of
going
below
the
diffrac3on
limit
of
visible
light
(200nm)
and
handle
the
resolu3on
required
to
view
nano
materials
with
all
the
advantages
of
op3cal

microscopy!!!
5
3D
printer
prints
sand
grain-‐size
cathedral
at
record
speed
A reproduction of St. Stephen's Cathedral in
Vienna, printed by the 3-D printer. It's about
50,000 nanometers, or half the width of a
human hair.
A racecar printed at the Vienna University of
Technology that's 285 nanometers long,
about 1/1000 the width of a human hair.
The
Dip
Pen
Nanolithography

Process
• Dip-‐pen
Nanolithography
from
NanoInk,
A
Layer
Addi3ve
Process
Using
An
Atomic
Force
Microscope
Tip
As
An
'Ink
Pen'.
It
Allows
The
Building
Of
Pa`erned
Nanostructures
By
Deposi3ng
Molecules

Directly
Without
The
Use
Of
Pa`erned
Masks
Or
Sensi3ve
Films.
• Pharmaceu3cal
Counterfei3ng
–
can
print
id
code
at
rate
of
1
million
capsules/hour
• 55,000
pens
in
array
w/
mul3ple

materials
7
Power
Shirt
• Fiber-‐based
Nanotechnology
in
Clothing
Could
Generate
Electricity
by
Harves3ng
Energy
from
Physical
Movement
• Electron
microscope
image
shows
two
pairs

of
fibers
coated
with
zinc
oxide
nanowires
and
alternately
with
gold
(top
fiber).
The
fibers
would
rub
together
to
produce
a
small
electrical
current.
Many
pairs
of
these

fibers
could
be
woven
into
a
garment
to
produce
a
"power
shirt."
World’s
Smallest
Petrol
Engine
Runs for two years on
a single squirt of
lighter fuel.
Produces 700 times
more energy than a
conventional battery
Glucose

Biofuel
Cell
Fourier
University
scien3sts
have
implanted
the
first
func3onal
glucose
biofuel
cell
in
a
living
animal,
elimina3ng
the
need
to
surgically
remove
and
replace
a

power-‐genera3ng
device
for
implants.
No
more
cyborgs
in
the
future
as
predicted
by
sci-‐fi!
Mother
of
all
graphi.c
forms.
Graphene
is
a
2D
building
material
for

carbon
materials
of
all
other
dimensionali.es.
It
can
be
wrapped
up
into
0D
buckyballs,
rolled
into
1D
nanotubes
or
stacked
into
3D
graphite.
(Ar.s.c
impression
of
a
corrugated
graphene
sheet:
Jannik
Meyer)

11
Graphene
• This
image
was
captured
using
a
Digital
Mul3mode
AFM.
No3ce
the
step
from
the
substrate
at
zero
height
to
a
graphene
flake
about
8
angstroms
high,

which
is
on
the
order
of
a
monolayer.
• 10
x
lighter
&
500
x
stronger
than
steel
&
superconduc3ng.
First
nanotech
synthetic
organ
transplant

• Nanotechnology
has
played
a
cri3cal
role
in
the
first
synthe3c
organ
transplant,
a
trachea
(windpipe).
• “Thanks
to
nanotechnology,
this
new
branch
of
regenera3ve
medicine
will
be
able
to
produce
a
custom-‐made
windpipe

within
two
days
or
one
week.
• They
use
a
nanocomposite
to
form
a
scaffold
exactly
the
same
size
and
shape
as
the
pa3ents
own
windpipe,
which
is
then
seeded
with
adult

stem
cells
from
the
pa3ent’s
own
bone
marrow
• It
will
soon
be
possible
to
repair
or
replace
many
other
organs
in
the
same
way.
13
"Courtesy
Ze`l
Research

Group,
Lawrence
Berkeley
Na3onal
Laboratory
and
University
of
California
at
Berkeley."
World’s Smallest Radio
This
simula3on
shows
the
electric
field
surrounding
the
nanotube
radio
during
radio
opera3on.
No3ce
how
the

field
is
strongest
at
the
3p
of
the
nanotube
and
how
the
field
varies
as
the
nanotube
vibrates.
This
effect
allows
the
nanotube
radio
to
demodulate
radio
signals.
Image:
Courtesy
of
ZeIl
Research

Group,
Lawrence
Berkeley
Na.onal
Laboratory
and
UC
Berkeley
World’s Smallest Radio
Respirocytes
• Respirocytes
-‐234x
amount
of
O2
&
CO2
Medulla
Oblongata
&
rate
of
respira3on

• Replaces
10%
of
your
blood.
Can
hold
breath
for
4
hours!
Killer
App
#1:
Programmable
Matter:
Utility
Fog
&
Claytronics
Intel
&
DARPA

Where
Are
We
Going
With
AM
&
NT?
• U3lity
Fog
Invented
By
J.
Hall
(From
Nanofuture:
What’s
Next
For
Nanotechnology),
Chief
Scien3st
Of
Nanorex
(Www.Nanorex.Com)
• 1200
Dots/Inch
Type
Nanobots

Working
As
Swarms
&
Changing
From
Simulated
Air
To
Anything
You
Need
In
Your
House
Instantly.
• U3lity
Fog
Forms
As
Bubble
Around
Your
Head-‐
Virtual
Reality-‐
To
Interact
With
Someone
Far

Away
As
If
You
Were
Really
There-‐
You
Almost
Could
Not
Tell
The
Difference.
• You’re
Virtually
In
Friend’s
House
In
Another
Country,
He
Grabs
A
Book
Called
‘I,
Robot’
And
Gives
It

To
You.
You
Take
It
Back
With
You
(In
Our
World
It’s
Called
A
‘File
Transfer’).
18
19
The Future?
• The Singularity Is Near: When Humans Transcend Biology by
Ray Kurzweil
• The Future Is A Blending Of 3 Technologies All Involving
Exponential Manufacturing (Self-replication):
• Genetics
• Nanotechnology

• Robotics
• Nanotech Effect on Man by End of Century:
• Gradual Transformation Of Technology Inside Of Our Bodies
Is
Inevitable – HUD, Nanoskin 5 microns thick.
• Next after Nanotech (10-9) But No Books On This Yet:
Picotechnology (10-12) And Femtotechnology (10-15).
How
far
out
can
we
reasonably
predict
the
Future?
• Jules
Verne’s
remarkable
accuracy
predic3ng
the
20th
Century:
• Voyage
to

the
Moon
–
correct
size
of
space-‐capsule,
launch
site
in
Florida,
length
of
voyage,
#
of
astronauts,
weightlessness
in
space,
and
splashdown
in
ocean!
• Paris
in
the
20th
Century
1863–
Jules

Verne
book
locked
away
&
found
in
1994
aser
130
years
–
remarkably
precise-‐
glass
skycrapers,
air
condi3oning,
TV,
elevators,
high-‐speed
trains,
gas-‐powered
cars,
fax
machines,
&
Internet-‐like
system.
(Michio
Kaku
–Physics
of

the
Future)
• Lensman
Series
by
Doc
Smith
• Completely
missed
computer
revolu3on
• Foresaw
highest
mental
technologies?
From
Nano
to
Femto-‐technology
20
Galactic
Civilization
• Physics
Based
Stages
of
Higher

Civiliza3ons
based
on
Energy
Consump3on
per
Russian
astrophysicist
Nikolai
Kardashev:
• Types
1
–
3
• We’re
about
Type
0.7
• Hand
labor
in
pre-‐industrial
society
about
1/5hp
and
1hp
for
horse
• Industrial
Revolu3on

hundreds
of
hp
• Type
1
is
Global
&
planetary,
and
uses
power
of
sun
1017
wa`s
–en3re
planet’s
energy
available
–
Buck
Rogers,
Flash
Gordon
• Type
2
is
stellar,
consuming
all
power

of
sun
1027
wa`s
–
Star
Trek’s
United
Federa3on
of
Planets
before
warp
drive
• Type
3
is
galac3c,
billions
of
stars
1037
wa`s
–
like
Star
Wars
Empire
or
Star
Trek’s
Borg

• Also
possible:
Type
4
Extra-‐galac3c
sources
of
energy
like
Dark
Ma`er
–
godlike
Q
of
Star
Trek
whose
power
is
extragalac3c
(per
Michio
Kaku)
21
22

“Productive Nanosystems:
From Molecules to Superproducts”
Developed by K. Eric Drexler & Nanorex– 5 minutes
Movie
Contacts
• Rapid
Technologies
&
Addi3ve
Manufacturing
(RTAM)
Community
h`p://www.sme.org/rtam
• Nano
Manufacturing
Technical
Group
h`p://www.sme.org/Rtam/nano
• RAPID

Conference
–
largest
3D
Prin3ng
conference
in
the
world
–
May
18-‐21,
Long
Beach
Conven3on
Center
• h`p://rapid.sme.org/2014/public/enter.aspx
• Boris
Fritz
at
[email protected]
23
Bibliography
• Scien3fic
American

Editors,
Understanding
Nanotechnology,
Warner
Books,
2002.
• Ivan
Amato,
Stuff:
The
Materials
The
World
Is
Made
Of,
Avon
Books,
1997.
• J.
Storrs
Hall,
Nanofuture:
What’s
Next
for
Nanotechnology,
Prometheus
Books,
2005
• J.

E.
Gordon,
The
New
Science
Of
Strong
Materials:
Or
Why
You
Don’t
Fall
Through
The
Floor,
Princeton
Science
Library,
1976.
• Ray
Kurzweil,
The
Singularity
Is
Near:
When
Humans
Transcend
Biology
• Robert

A.
Freitas
Jr.
and
Ralph
C.
Merkle,
Kinema.c
Self-‐Replica.ng
Machines,
2004
• Michio
Kaku
Physics
of
the
Future
24
1
Nanomanufacturing
Part 2

Boris Fritz
Adjunct Professor
March 12, 2015
Print
A
House,
Or
An
Entire
Neighborhood
• A
University
of
Southern
California
professor
has
devised

a
layered
fabrica8on
method
he
calls
Contour
Cra:ing
that
he
believes
could
be
used
to
print
en8re
buildings.
The
Multi
Prototyping
Lab

• h=p://www.rapidprototypingmachine.com/
• The
Mul8
Prototyping
Lab
is
capable
of
Dual
Addi8ve
3D
Prin8ng
(ABS
and
PLA),
high-‐
precision
milling,
extrusion
deposi8on,
drop-‐
on-‐demand
metal
(including
nanoscale)
prin8ng,
plus
much
more.
It
is

capable
of
producing
fully
func8onal
prototype
parts.
• The
Mul8
Prototyping
Lab
is
able
to
produce
prototypes
completely
in
one
machine.
Not
having
to
move
the
prototype
from
one
machine
to

another
provides
many
benefits
including
lower
up-‐front
cost,
faster
prototyping,
higher
accuracy,
lower
prototype
produc8on
costs,
plus
much
more.
• MPL
wins
RAPID
2013
Innova8ve
Award.
4

Materials Update
• Voxeljet800 from Augsburg, Germany is the first AM
machine to build continuously along one axis with the
build plane at a 30 degree angle.
• They use PMMA – Polymethyl Methacrylate
• Voxel8 from Somerville, MA has officially unveiled their
multi-material electronics printer. The Voxel8 Developer’s
Kit is a low-cost 3D printer capable of 3D printing in two
materials: PLA and conductive silver ink, with the PLA
stored in the base of the printer and the ink located
directly in the printhead itself. https://www.voxel8.co
Voxel8
5
• The company will be displaying, alongside their amazing
printer, a
quadcopter produced almost entirely in one piece from their
machine.
The PLA and connective circuits of the quadcopter were 3D
printed in
one go, with the electronics, battery, and motors inserted
throughout
the printing process.
• Not only does this hint at the possibility of, one day, 3D
printing
complete electronic items in one process, but, more
immediately, the
design of electronic devices becomes free from the two-

dimensional
plane of a PCB board. Instead of allowing electronic parts to
dictate
design, Oliver explains that designs will now dictate the
placement of
electronic parts. As users model new objects, they can weave
their
electronics into the design itself, allowing circuits to traverse
curves
and climb walls. Engineers will no longer need to find a
location to
situate their circuit boards, but can place them wherever they
see fit.
Voxel8
https://www.voxel8.co
First
3-‐D
Printed
Records
Sound
Awful—And
Amazing
The needle drops and a
series of high, repetitive
whines come from the
album. Then a crackling
sound, and a muffled

guitar riff. Finally, Kurt
Cobain’s voice —
audible, but distant and
hollow, like he is singing
in a tunnel with a scarf
over his mouth.
It’s about the worst
version of “Smells Like
Teen Spirit” you could
find. But it is awesome
all the same for its
totally unique medium.
This particular LP is part
of the batch of the first
records ever to be
created on a 3-D printer.
ChefJet
3D
Printer
for
Sugary
Treats
• Liz
and

Kyle
von
Hasseln
had
modified
a
3D
printer
to
churn
out
custom
sugary
treats.
• 3D
Systems
has
aquired
them
to
sell
3D
printers
for
crea8ng
custom

culinary
crea8ons.
7
ORD
Solution
s
Announces
New
Food
Printing
3D
Paste
Printer
• h=p://ordsolu8ons.com
• ORD
Solu8ons,

the
Canadian
manufacturer,
of
the
wildly
successful
5
material/color
RoVa3D
printer
that
launched
on
Kickstarter
in
July,
is
shaping
up
to
be

a
pre=y
innova8ve
bunch.
The
company
has
taken
their
flexible
RoVa3D
design
and
applied
it
to
3D
printed
food.
They
have

a
paste
prin8ng
version
of
their
original
printer,
allowing
users
to
extrude
viscous
materials,
like
food
silicone
&
other
so:
materials.

You
can
swap
out
the
plas8c
pouring
extruder
for
a
paste
extruding
syringe.
The
fully
assembled
printer
is
selling
for
$899

(Canadian
Dollars).
8
3D
Printing
of
Food
for
Space
Missions
• Last
year’s
course
included
a
project
on

this
topic
which
was
co-‐authored
as
a
paper
by
the
student
Michelle
Terfansky
along
with
Prof
Thangavelu,
Prof
Khosnevis
and
myself.
It
was

published
as
an
AIAA
Paper
early
this
year
and
we
even
had
a
write
up
in
Wired
Magazine.
• Please
see

Prof
Thangavelu
for
a
copy
of
the
paper.
9
Mathematical
Art
Project
• h=p://bugman123.com/Math/index.html
• This
rose
is
actually

a
plot
of
a
single,
con4nuous,
parametric
math
equa4on.
I
got
this
idea
while
trying
to
create
a
visualiza4on
of
a

spiraling
spin-‐la>ce
relaxa4on
for
a
physics
experiment
involving
a
Nuclear
Magne4c
Resonance
(NMR)
spectrometer.
• Here
is
some
Mathema4ca
code:

• (*
run8me:
16
seconds
*)
• Rose[x_,
theta_]
:=
Module[{phi
=
(Pi/2)Exp[-‐
theta/(8
Pi)],
X
=
1
-‐
(1/2)((5/4)(1
-‐
Mod[3.6
theta,

2
Pi]/Pi)^2
-‐
1/4)^2},
y
=
1.95653
x^2
(1.27689
x
-‐
1)^2
Sin[phi];
r
=
X(x
Sin[phi]
+
y
Cos[phi]);
{r
Sin[theta],
r

Cos[theta],
X(x
Cos[phi]
-‐
y
Sin[phi]),
EdgeForm[]}];
• ParametricPlot3D[Rose[x,
theta],
{x,
0,
1},
{theta,
-‐2
Pi,
15
Pi},
PlotPoints
-‐>
{25,
576},

LightSources
-‐>
{{{0,
0,
1},
RGBColor[1,
0,
0]}},
Compiled
-‐>
False]
10
The
world’s
Lirst
3D-‐printed
guitar,
October

12,
2012
Desktop
3D
Printers
&
3D
Systems,
Stratasys,
Bukobot
3D
Printer
Wiki
&
Airwolf
3D
Based
on

the
RepRap
tradi8on
of
self-‐replica8on
and
open
source
so:ware,
Bukobot
can
print
most
of
the
parts
necessary
to
build
a
second
printer

and
the
so:ware
is
free
to
use
and
modify
by
all.
Bukobot
also
relies
on
some
of
the
best
aspects
of
previous
RepRap

models,
while
making
some
improvements
along
the
way,
making
it
is
easy
to
build,
easy
to
use,
extremely
sturdy,
and
extremely
affordable.

Most
importantly,
Bukobot
is
designed
to
expand
to
fit
your
needs
so
that,
as
you
upgrade
your
model
to
include
more
printheads

and
a
larger
prin8ng
playorm,
you
can
easily
incorporate
new
parts
and
expand
the
printer’s
structure.
This
leaves
it
open
to
hacks

and
tricks
provided
by
Bukobot
users
from
the
Buko
community.
AirWolf
3D
is
a
new
company
that
has
a=empted

to
fix
problems
that
the
previous
desktop
printers
had.
World's
Lirst
printed
plane
The
pres8gious
'New
Scien8st'
magazine

has
featured
'the
world's
first
printed
plane'
in
its
29
July
2011
issue.
A
collabora8ve
venture
between
The
University

of
Southampton
and
3T,
the
plane
went
from
drawing
board
to
flight
in
seven
days
-‐
two
days
for
design
and
five

days
to
produce
the
component
parts
using
plas8c
addi8ve
manufacturing.
The
UAV
(Unmanned
Aerial
Vehicle)
has
a
wing
span
of
1.5m

and
was
made
of
four
parts
(two
wings,
a
body
and
a
nose
cone)
along
with
an
internal
component
tray
-‐
all
'printed'

using
3T's
AM
technology.
The
first
flight
of
the
UAV
was
captured
on
video
by
the
New
Scien8st.
h=p://www.3trpd.co.uk/news/new-‐scien8st-‐uav.htm

SULSA is the world's first 'printed' aircraft.
(Credit: Project SULSA UAV)
Heading
to
Costco?
Pick
Up
a
3D
Printer
from
ROBO
3D
• Everyone’s
favorite
warehouse

club,
Costco,
will
be
selling
desktop
3D
printers
star8ng
September
19th.
The
machine
that
the
US’s
second
and
the
world’s

seventh
largest
retailer
has
decided
to
introduce
to
their
3
million
customers
is
the
ROBO1
3D
printer
from
San
Diego-‐based
ROBO

3D.
• The
ROBO1
3D
printer
is
selling
with
two
1
kg
spools
of
filament
at
a
price
of
$729.99.

• h=p://www.robo3dprinter.com
14
SpaceX
launches
cargo
ship
with
3-‐D
printer
to
International
Space
Station
• Sept
21,
2014
Dragon
should

reach
the
space
sta8on
Tuesday.
It's
the
fi:h
sta8on
shipment
for
the
California-‐based
SpaceX,
one
of
two
new
commercial
winners
in
the
race

to
start
launching
Americans
again
from
home
soil.
• The
space
sta8on-‐bound
3-‐D
printer
was
developed
by
Made
in
Space,
another
California

company.
It's
sturdier
than
Earthly
models
to
withstand
the
stresses
of
launch,
and
meets
NASA's
strict
safety
standards.
The
space
agency
envisions
astronauts

one
day
cranking
out
spare
parts
as
needed.
For
now,
it's
a
technology
demonstrator,
with
a
bigger
and
be=er
model
to
follow
next

year.
• Made
in
Space
–
founded
in
2010,
they
have
25
employees
and
have
flown
400
microgravity
parabolas
with
30,000
hrs
of

tes8ng.
• I
have
arranged
to
have
them
as
keynote
speakers
at
the
RAPID
conference
in
May
15

16
Made in Space Latest News
After running for about three months aboard the
ISS, the first 3D printer in space has finally sent a
bit of itself back to Earth for testing. At 7:44 pm
EST yesterday, SpaceX’s Dragon cargo
spacecraft landed in the Pacific Ocean, about 259
miles southwest of Long Beach, California.
Among the 3,700 pounds of NASA cargo on
board, the spacecraft carried 3D printed samples
produced on the Made In Space Zero G Printer,
currently installed on the International Space
Station.
In addition to a number of samples, hardware,
and data from biology and biotechnology
experiments conducted on the ISS, objects
fabbed on the Zero G Printer will be returned for
study. The printer was first
installed on the Space Station last November,
where it made the history books as the first 3D
printer in space, subsequently performing the first
3D prints in space, including a wrench e-mailed
from Earth to the ISS and printed in ABS. Now

that they’ve been returned to Earth, they will be
compared to their Earth-printed equivalents, the
same CAD files manufactured as control objects
in the NASA study.
17
Made in Space Latest News
Costello continues, “Experiments
like 3-D printing in space
demonstrate important capabilities
that allow NASA and humanity to
proceed farther on the journey to
Mars.”
As braniacs on Earth apply
rigorous study to the 3D printed
parts to determine the sorts of
effects that microgravity may have
had on the printing process, the
Made In Space printer will
continue chugging away.
Comparing the materials from

space with the materials grown on
earth, will give us a better
understanding of any significant
differences.
Design for RP&M versus traditional design
• Engineers Must Learn to Design for RP Applications. This
Requires a Shift in Approaching the Manufacturing
Process. Additive Manufacturing Allows for Parts to Be
Made That Would Previously Be Considered Assemblies.
• Example: Ecs-duct, Part of an Aircraft’s Ventilation
System. Presently Made As Kevlar Lay-ups on Mandrels
As 5 Separate Pieces, With the Center Vane Embedded
in the Plies. The 5 Pieces Have to Be Bonded and
Insulated As an Assembly. Many Labor Hours & Several
Weeks to Manufacture. Nylon Part Made in 2 Days As
One Single Piece on SLS System.
19

No More Tooling
• Eventually AM will mean the end of
Tooling.
• When the final product can be grown
directly with all its inherent features, you
don’t need tooling anymore.
• This means not only the cost savings
involved with making the tooling but
maintaining it over the life of the aircraft.
That’s a lot of money!
Factory
of
the
Future

Nanotechnology:
The Race for a 2.6 Trillion Dollar Market
We can now buy over 800 products that incorporate
nanotechnology, and that number will undoubtedly grow by
the time this presentation is given. The U.S. government's
National Science Foundation estimates that within a
decade, the total market impacts of nanotechnology will
reach a trillion dollars. This market includes
nanostructured materials ($340 billion), semiconductors
and integrated circuits ($300 billion), pharmaceuticals
($180 billion), nanostructured catalysts ($100 billion) and
nanotechnology-enabled aerospace products ($70 billion).
But NSF did not even consider the cosmetics, agriculture,
textiles, non-aerospace defense, and non-pharma medical.
So their projections may be much too low--by a factor of
two and a half (according to Lux Research).
22
Nanotechnology Development

500 BC – Colloidal gold/silver
1959 Feynman – “There's Plenty of Room at the Bottom”
1981 Drexler – popularized the term “nanotechnology”
1989 Eigler – built first atom-by-atom constructed structure
Cup of Lycurgus
How
big
is
Nano?
• Nanotechnology
Deals
With
Materials
&
Systems
That
Have
At

Least
One
Dimension
Of
About
1
To
100
Nanometers
(Nm).
A
Nanometer
Is
1
Billionth
Of
A
Meter.
• Ten
Shoulder
To

Shoulder
Hydrogen
Atoms
Span
1
Nanometer
(10
Angstroms),
1000
nm
=
1
micron,
1000
microns
=
1
mm.
• A
DNA
Molecule

Is
About
2.5
nm
Wide
23
Nanomanufacturing
24
25
Why
Do
Materials
Get

Stronger
the
Smaller
They
Get?
• In
1920
A.
A.
Griffith
Wants
To
Know
Why
The
Actual
Strength
Of
Solids

Is
Between
1/50
To
1/100
Of
The
Calculated
Theore8cal
Strength.
• Strength
Of
Actual
Glass
Fibers
Was
Only
About
25,000
Psi,
While

Theore8cal
Strength
Was
2,000,000
Psi
–
What
Gives?
• Experiments
With
Glass
Rods,
Hea8ng
And
Drawing
Thinner
And
Thinner
Glass
Fibers.

At
1/10,000”
(0.0001)
The
Limit
In
His
Day,
The
Strength
Grew
To
1,600,000
Psi.
Later
Work
Of
Thinner
Fibers
Actually

Exceeded
The
Theore8cal
Strength.
Cleared for Public Release, Control No. 06-026 dtd. 3/28/06
26
Why
Do
Materials
Get
Stronger
the
Smaller
They
Get?

• Rather
Than
The
Chemical
Bond
Strength
(Theore8cal
Strength)
Normal
Size
Materials
Are
Actually
Controlled
By
Stress
Concentra8ons
On
The
Surface
Area

Of
A
Material.
One
Tiny
Scratch
Or
Crack
Is
All
It
Takes.
• Important
Fact
About
Stress
Concentra8ons:
A
Tiny
Hole
Weakens

A
Material
Just
As
Much
As
A
Great
Big
One!
Surface
Stress
Is
Where
All
The
Problems
Come
From.
Most
Of

These
Cracks
Are
Smaller
Than
An
Op8cal
Microscope
Can
See
(Half
A
Micron).
If
The
Surface
Is
Made
Smooth
&
Kept
Smooth

Large
Parts
Can
Be
Just
As
Strong
–
Which
Is
Hard
To
Do.
But
Nature
Has
Done
It
With
Abalone
Shells
Without

Needing
To
Be
Smooth
At
All!
Abalone
shells
withstand
hammer
blows,
yet
are
made
of
chalk
and
calcium
carbonate!
• At

Nano-‐scale
The
Materials
Are
At
Their
Theore8cal
Strength-‐their
bond
strength.
There
Is
No
Room
For
Cracks
between
individual
atoms!

Cleared for Public Release, Control No. 06-026 dtd. 3/28/06
27
Molecular Beam Epitaxy (MBE)
• Atomic Spray Painting On Surfaces (CVD)
• Builds Materials One Atomic Layer At A Time
• Grows Lasers That Read Compact Discs (A
Solid State Semi-conductor Laser)
• Invented in 1968 at Bell Labs
• MBE Can Grow Nearly Perfect Crystals One
Atomic Layer At A Time
28
Molecular Beam Epitaxy (MBE)

• Over 70% Of The World’s Supply Of Compact
Disc Lasers Are Made By MBE
• MBE Is Now Capable Of Creating A Square
Centimeter Of Semiconducting Laser – An
Enormous Expanse Of Over 1 Quadrillion Atoms
– With As Few As 3 Atoms Out Of Place!
29
The Varian Gen II Molecular Beam
Epitaxy system at UT-Austin
30
Self-Replication: Exponential Mfg
• Nanomanufacturing And Our Rapid Prototyping &
Manufacturing Process Have Something In Common: Additive

Layer Manufacturing
• One Ultimate Goal: Self-replication:
• Background – Descartes (1596-1650),
• Theory Of Self-reproducing Automata By John Von Neumann
(1903-1957)
• Simple Example Of Self-replication In Nature: Fire!
• From RP's Reprap Project To The Fablab At Mit Self
Replication Is Finally Taken Seriously For Near Term Results.
These Are The Full Scale Initial Attempts At Self-replication
• Greatest Payoff For Self-replication Is At The
Nanomanufacturing Level
• Software Control Of Matter: Http://
Ideasfactory.Wordpress.Com/
31
Kinematic Self-Replicating

Machines by Robert A. Freitas
Jr., Ralph C. Merkle
• Most Complete Book On Exponential Manufacturing
• SIMD (Single Instruction Multiple Data) Architecture
• One Single Data Store Records Instructions
• The Data Store Transmits Information To Trillions Of
Molecular
Sized Assemblers Simultaneously
• This Way Each Assembler Does Not Have To Store Entire
Program
For Creating Desired Product
• Includes Key Safety Concern: The Self Replicating Process
Can
Be Easily Shut Down
• While A Hard Copy Of This Book Can Be Purchased For
$142.50,
A Downloadable Version Is Available For Free At Http://
Www.Molecularassembler.Com/KSRM.Htm

32
A New Manufacturing Revolution
• Self-replication Was A Dream For Centuries
• It Is Beginning To Happen Now With Limitations But With
Rapid
Progress
• It Is Vital To Begin Educating Our Industry That This Is A
Viable
Technology That Needs To Be Implemented
Mechanosynthesis
and
CAD
33

1
Nanomanufacturing
Boris Fritz
Adjunct Professor
March 12, 2015
Overview

• Overview
of
Addi,ve
Manufacturing
(AM)
• AM
in
Aerospace
&
other
applica,ons
• Future
of
Addi,ve
Manufacturing
• Addi,ve
Manufacturing
at

the
Nanoscale
• Future
of
Technology
2
3
Rapid Technologies & Additive Manufacturing (RTAM)
Community & Tech Groups of the Society of Manufacturing
Engineers ( www.SME.org/RTAM )
3D Imaging
Direct Digital
Manufacturing

Education &
Information
Exchange
Medical
Applications
NanoManufacturing
RTAM
COMMUNITY
From
Rapid
Prototyping
to
Additive
Manufacturing

• Defini,ons
for
AM,
RP,
RM,
DDM,
SFFF,
3D
Prin,ng:
• Addi,ve
process
of
automated
part
crea,on
directly
from
CAD
model
• Differen,ated

from
NC
machining
which
is
a
subtrac,ve
process
• Simplicity
vs
Complexity:
2D
layers
vs
5
axis
NC
programming

Subtractive
Mfg
5
Why do AM?
• Part consolidation (GE Aviation fuel nozzles –
18 to 1 – so need only 1 drawing not 18.
• Lightweight
• Elimination of secondary processes
• Patient specific customization (mass customization)
• Tool-less mfg

• Unique consumer goods made possible
• Challenges: System reliability, need closed-loop controls,
expense,
larger build volume, speed.
8
SLA 1
• Chuck Hull creates the Stereolithography
process with US patent #4575330 on March
11, 1986 and the AM industry was born.
• In 1988 the first SLA1 was sold and 3
service bureaus started
• Story of Chuck’s patents
iPro8000
Stereolithography

System
Part Build Volume of 25.6 x 29.5 x 21.7”
Photopolymer Liquid Resin
SLS
(Selec,ve
Laser
Sintering)
Machine
–
Nylon
Powder
Part
Build
Volume:
12.5
x
11.0
x
16.0”

Selective
Laser
Sintering
Commercial Materials
for SLS
• Functional Models
• Polyamide
• Glass-filled Polyamide
• Thermoplastic Elastomer
• Tooling for Plastic Molding
• Stainless Steel/Bronze
• Metal Casting
• Foundry Shell Sands
• Polystyrene

Market for SLS
Applications in Aerospace and Aircraft
• Space Shuttle Main Engine (nitrogen duct)
• International Space Station (power systems)
• Environmental Control Systems (military aircraft)
• Aerodynamic modeling
• Flight test fairings for RF and EM sensors
• SLS patterns for autoclave composite construction
• Engineering mock-ups for dynamic evaluations
Cleaning a Part at the Breakout
Station
There are Build Failures

Market for SLS
Applications in Aerospace and Aircraft
• Space Shuttle Main Engine (nitrogen duct)
• International Space Station (power systems)
• Environmental Control Systems (military aircraft)
• Aerodynamic modeling
• Flight test fairings for RF and EM sensors
• SLS patterns for autoclave composite construction
• Engineering mock-ups for dynamic evaluations
Selective Laser Sintering- Oven
JSF Screen Before Furnace
Infiltration
JSF Screen after Polishing

Stratasys
• Scott Crump – CEO starts company in 1988
• FDM patent 1992
• Early 1990’s no automated supports
Company almost disappears
• Slow process, but should have been the first one – most
straightforward – not complicated like photopolymers
• Layer Thickness 0.008 larger than most systems
(standard is 0.004) – more stairstepping, but now much
better
• Research
at
Stratasys:
since
they
incorporated
in
Israel
with

their
merger
with
Objet,
they
get
a
huge
tax
write-‐off
which
allows
them
to
dedicate
a
full
10%
of
their
capital
into
R&D!

No
other
OEM
comes
close
(NGC
does
only
1or
2%).
20
Stratasys Fused Deposition Modeling FDM
Early 1990’s no automated supports
Company almost disappears
Fused Deposition Modeling, FDM

Advantages
• Functional Materials: ABS, Polyester,
Polycarbonate, PPSF
• PPSF (Polyphenylsulfone) Good to 200C
(405F), High Impact Strength & Tensile
Strength, Resists Gasoline, Sulfuric Acid, &
Antifreeze
• No Post Curing or Other Chemicals Needed
• Fast on Small, Hollow Geometries
• Office Environment Machines
FDM Maxum
• The fastest prototyping system offered by
Stratasys, operating 50 percent faster than
previous systems. Its WaterWorks™ soluble
support systems offers virtually hands-free
prototyping.
• Parts up to 600 x 500 x 600 mm (23.6 x 19.7 x

23.6 in) can be built
• Models can be produced within an accuracy of ± .
127 (± .005 in) up to 127 mm (5 in.). Accuracy
on models greater than 127 mm (5 in) is ± .0015
mm per millimeter (± .0015 in/in)
FDM Maxum
FDM Titan by Stratasys
• Parts up to 14 X 16 X 16 Inches (355 X 406 X
406 Mm) Can Be Built
• Models Are Produced Within an Accuracy of ± .
005 Inch ( ± .127) up to 5 Inches (127 Mm).
Accuracy on Models Greater Than 5 Inches (127
Mm) Is ± .0015 Inch Per Inch
(± .0015 Mm/mm)high Performance
• Engineering Materials Such As Polycarbonate,

ABS and Sulfones.
• New high temp machine for higher temp
materials like PPSF - 405F & Ultem
FDM Titan
Introducing
the
3-‐D
Printed
Bicycle
• In
2010,
Stratasys

and
Kor
Ecologic
introduced
the
first
3-‐D
printed
car.
• And
now
EADS,
the
European
Aerospace
and
Defense
Group,

has
figured
out
how
to
construct
a
3-‐D
printed
bicycle-‐-‐out
of
nylon,
no
less.
FDM Fortus 900mc Additive
Fabrication System

• Build volume of 3 ft. x 2
ft. x 3 ft.
• Speed factor goes up
by 5x with the Maxum
& Fortus & Service
Bureaus start buying
them.
• Variable velocity
scanning from 1”/sec to
10”/sec
• Solid Concepts has
over 20 Stratasys
machines
Stratasys Dimension Concept Modeler
• Stratasys New Dimension Lowers the Entry
Barrier to Rapid Prototyping to an
Unprecedented Level Below $30,000. On Top of
That the Machine Builds Out of a Fairly Tough

Plastic Material: ABS.
• The New Price Brings RP&M into the Range of
High End Printers.
Stratsys Dimension Concept Modeler
Objet 500 Connex3
• First
Shown
at
RP&M
2014.
• The
Objet
by
Stratasys
Builds
Parts

Using
Inkjet
Technology
to
Deposit
Droplets
of
Photopolymer
That
Are
Then
Cured
With
Flood
Lamps.
Two
Materials
Are
Used,
Both
Photopolymers:
a

Primary
Material
for
Building
a
Part
and
Supports
and
a
Secondary
Material
That
Is
Used
As
a
Release
Layer
Between
a
Part

and
Its
Supports.
• Builds
in
0.008-‐inch
(20-‐micron)
Layers
• Priced
at
$330,000
(20x16x8”)
• 10
color
paleees
available

Objet Quadra Tempo
Objet Quadra Tempo
Objet Multi-Material in 1 Build by
Fusion Proto/Mfg
DM3D - POM (Precision Optical Manufacturing)
In-house production now – no sale of Machines
• New DMD5000, http://www.dm3dtech.com
60x20x18” (1525x500x460mm)
• Near Net Finish: Needs Finish Machine Pass
With CNC or EDM
• Programmable for 3 Simultaneous Materials
With Gradual Change in Alloy Percentages
• Most Metals Except Titanium

• Focus on Tool Repair (E.G. 10 Days vs 10wks)
• https://www.youtube.com/watch?
v=v62EjHXcBkc
DM3D - POM
DM3D - POM
DM3D - POM
Arcam EBM
• Electron beams rapidly form metals parts
• Developer of electron beam melting systems for the rapid
manufacturing of

metal parts is offering a larger, faster machine to build parts of
200 x 200 x
350mm or 300mm diameter by 200mm high
• Arcam launches new larger EBM system for rapid
manufacturing in metal.
The Arcam A2, a rapid manufacturing system based on electron
beam
melting (EBM), produces solid metal parts larger and faster
than other
metal additive fabrication methods. Arcam celebrates its 10-
year
anniversary by launching the Arcam A2 for Rapid
manufacturing in metal,
with a significantly increased build capacity.
• The new Arcam A2 features a choice of two build tanks,
enabling the
production of 75% larger builds than the present Arcam EBM
S12. 'This is
the most significant new feature, but there are many important
enhancements improving performance and productivity,' said
Ulf Lindhe,
sales and marketing manager at Arcam. The Arcam A2 was
designed for

rapid manufacturing and is delivered with two build tanks
allowing the user
to choose between wide and high builds.
Arcam EBM
• Aerospace components in titanium aluminide (TiAl)
Arcam presents aerospace applications made in the newly
developed process for efficient manufacturing of components in
TiAl. TiAl is an intermetallic used predominantly for turbine
blades in
advanced aeroengine applications.
• MultiBeam™ HiRes
As part of Arcam’s continuous strive to reach new applications,
we
give a sneak preview of MultiBeam™ HiRes (High Resolution)
for
the EBM technology. MultiBeam™ HiRes makes it possible to
build
structures with a resolution and surface finish far beyond
EBM‘s
state-of-the-art.

MultiBeam™ HiRes extends the range of application areas for
EBM,
and will specifically be available in future products from Arcam
for
advanced Trabecular Structures for orthopedic implants.
Arcam A2
EBM
Arcam’s
New
Machines
• Q10
-‐
designed
for
industrial
produc,on

of
orthopedic
implants.
• Q20
-‐
designed
for
cost-‐
efficient
manufacturing
of
a
wide
range
of
aerospace-‐related
components
such
as

turbine
blades
and
structural
airframe
components.
Build
volume
is
380mm
diameter
x
380mm
in
Z
(13.78”
diam
x
15”

Z)
42
Fabrisonic – Solidica
www.fabrisonic.com
• Ann Arbor, Michigan. Direct Metal Parts Combining
Traditional CNC With Sonic Welding, Layer by Layer.
Build Volume: 600x900x250mm (24x36x10”). Called
Ultrasonic Consolidation (UC) with +-0.008 accuracy over
entire workpiece (+-0.002 in future).
• Bonds 1mm Thin Sheets of Aluminum Tape by Sonic
Welding, Followed by Cnc Router to Shape Each Layer.
Builds at Rate of 35 Cubic Inches/hour.
• Aluminum, Stainless, Brass, Nickel-based Alloys, Titanium
Alloys.
• Using Additive Processing Technique Combined With
High Speed Milling to Allow Customers to Produce
Aluminum Cores and Cavities in a Single Machine, With a
Single Set up.

Fabrisonic - Solidica
• Solidica’s Formation 2030 machines build parts by depositing
one-
inch-wide (25mm) strips of 0.004-inch-thick (0.10mm)
aluminum
tape. White says the company’s ultrasonic consolidation
technology
uses sound to create microfriction between the strips of
aluminum
tape. Under pressure, this microfriction causes metallurgical
bonds
to form between the tape layers. Parts built with with this
process
have densities of 98 to 99 percent with no discernable
boundaries
between layers.
• Now called UAM (ultrasonic additive mfg). EWI co-owns
Fabrisonic
now with Solidica. Faster system now – ultrasonic transducer
increased from 1.5kW to 9kW – better bonds between dissimilar

materials. Aerospace aluminum, titanium alloys and stainless
steel.
• No phase change in temperature, so no shrink, no thermal
stresses
Fabrisonic
• SonicLayer
7200
–
largest
machine
• Integrated
3-‐axis
CNC-‐machining
&
automated
metal
tape
feed

system
&
9kW
of
power
for
the
ultrasonic
transducers
• SonicLayer
4000L
has
laser
micromachining
capability
45
Fabrisonic - Solidica

EOSINT
P
800
• The
first
laser-‐sintering
system
processing
high
performance
polymers.
• High-‐performance
polymers,
un,l

now,
could
not
be
used
in
the
laser-‐sintering
process
due
to
their
mel,ng
point
between
220°C
(428°F)
and
380°C
(716°F)
degrees.

Due
to
its
capability
for
process
temperatures
up
to
385°C
(725°F)
the
new
EOSINT
P
800
is
the
world's
first
system
which

enables
the
laser-‐sintering
produc,on
process
for
this
highly
interes,ng
group
of
materials.
Direct
Part
Mfg/
Laser
Sintering
–

High
Temp
Materials
48
1st
known
computer
controlled
gradient
fabrication
by
Optomec
Ti-48Al-2Cr-2Nb Ti-6Al-2Sn-4Zr-2Mo - Ti-
22Al-23Nb
gamma titanium aluminide orthorhombic titanium aluminide

TENSILE SAMPLE
Elevated Temperature Test from Westmorland Labs
The gradient sample test was for Ti-6-2-4-2 to Ti-22-23.
The tensile strength was approximately 80 ksi with the
yield strength at 95 ksi. Elongation was 12%. Gradient Cross
Section
We’ve seen 3D printers before, but none quite this ambitious.
Italian inventor Enrico Dini’s D-Shape is on a scale
large enough to print entire buildings out of simple components:
sand and an inorganic magnesium-base binding
material.
The three-dimensional printing apparatus has hundreds of
nozzles on its underside, which spray the inorganic
binding glue that turns the sand into solid stone and builds up
objects in layers from the bottom up. D-Shape can
generate a building about four times as fast as the traditional
construction method at only half the cost — or less.
Less waste left behind also makes the 3D printing process

environmentally friendlier than conventional alternatives.
Interestingly, D-Shape’s next challenge might be building moon
bases. Its inventor is currently in talks with the
European Space Agency about creating a version of the device
that could use lunar dust to build structures on the
surface of our nearest celestial neighbor.
h"p://mashable.com/2010/04/21/d-‐shape-‐sand-‐printer/
Huge 3D Printer Makes Buildings Out of Sand
High Lift Wing (1995 First Place
Award for North America) $12K
RP Vs. $450K Conventional
Custom Louver Form Blocks
• 4 Hours versus 2 ½ weeks (96 Hours ) Labor
hour saving

• Using SLA Dies Directly to Form Sheet Metal
Louvers on Hydraulic Press Using 10 Tons of
Force.
• Experimented on Other Sheet Metal Parts With
SLA Dies With 350 Tons of Force.
• Published Findings Worldwide, Even in Brazil in
Portuguese!
Sheet Metal Forming custom louvres
Estimated
$1.1M
Saved
Rapid
Manufacturing
Aircraft

Locator
Tooling
Drill
Jig
• 72
fastener
loca,ons
• 92%
reduc,on
in
cost
• 40%
savings
in
labor
• 98%
reduc,on
in

defects
Award
Winning
Application at
2000 RP&M
World
Conference
Rapid Manufacturing – Aircraft Locator Tooling
RMST’s (Rapid Manufacturing Soft Tooling) Cost
Benefits on our Assembly Line :
56
• Over 1300 Identified on Production Assembly Line

• Implemented 488 Part Locators on Production Assembly Line
• Implemented LEAN Factory Kits with Usage Instructions &
Visual Aids
• 40% Factory Labor Reduction Demonstrated
• 80% Reduction in Tooling Implementation Cost Demonstrated
• 60% Reduction in Tooling Process Flow Demonstrated
• 90% Reduction in Sustaining Maintenance Cost & Process
Flow
Demonstrated
• 500% Improvement in Installation Accuracy (+/- 0.005 in)
• Significant Reduction in MRB (NT & RR) Cost (Quantifying)
• Reduces QA Cost by Providing Self-Inspection Features for
SLS
(Quantifying)
57
58
Mod-Repair Kit

1st Place
Excellence Award
Winning
Application at
2001 RP&M World
Conference
GE
Aviation
• This
video
shows
the
process
of
making
the
fuel
nozzles
for

their
jet
engine:
• hep://www.mmsonline.com/blog/post/video-‐addi,ve-‐
manufacturing-‐at-‐ge-‐avia,on
• By
using
AM,
GE
Avia,on
made
the
fuel
nozzles
25%
lighter
and
consolidated
18

parts
into
1
single
part,
along
with
being
5x
more
durable
plus
it
reduces
coking
(build
up
of
carbon).
They
need
19

nozzles
per
jet
engine
and
will
be
making
1,700
engines/year!
They
are
making
32,300
nozzles/year
now.
They
expect
to
make
over

100,000
AM
parts
by
2020.
GE
Avia,on
will
invest
$3.5
billion.
Introducing
the
3-‐D
Printed
Bicycle
• In
2010,

Stratasys
and
Kor
Ecologic
introduced
the
first
3-‐D
printed
car.
• And
now
EADS,
the
European
Aerospace

and
Defense
Group,
has
figured
out
how
to
construct
a
3-‐D
printed
bicycle-‐-‐out
of
nylon,
no
less.

DSM Contributes To
First Chicago City Model
•
In recognition of the centennial anniversary of Daniel
Burnham’s
first architectural Plan of Chicago (1909), and to help promote
Chicago’s bid to host the 2016 Olympic Games, the Chicago
Architecture Foundation unveiled the first large-scale model of
the
city of Chicago, created largely via the stereolithography (SL)
process using SOMOS® resins exclusively from DSM Desotech.
• Each of the more than 1,000 building structures included in
the
“Chicago Model City Exhibition” were made from SOMOS®
high-
performance stereolithography resins, including
WaterShed® XC 11122, ProtoGen™ Gray 18920, and SOMOS®
14122.
SLA model of City of Chicago

Mass Customization using RP&M
The Invisalign Braces process
To ensure a high
degree of
accuracy
throughout the
process,
impressions are
taken of your
teeth by your
doctor.
Your doctor sends
Invisalign® your
impressions which are
used to make plaster

models of your teeth.
Using advanced imaging
technology, Invisalign® transforms
your plaster models into a highly
accurate 3-D digital image.
A computerized movie - called
ClinCheck® - depicting the
movement of your teeth from the
beginning to the final position is
created.

Using the Internet, the
doctor reviews your
ClinCheck file - if
necessary, adjustments to
the depicted plan are
made.
Invisalign
From your approved ClinCheck file,
Invisalign® uses laser scanning to
build a set of actual models that reflect
each stage of your treatment plan,
using SLA7000 Stereolithography
Machines. They own 20 and are

buying 30 more, at $¾ million per
machine. They own more SLA
equipment than the rest of the world
put together. This will gradually be
the new trend in RP.
Your customized set of aligners are
made from these stereolithography
models, sent to your doctor, and
given to you. You wear each aligner
for about two weeks.
After wearing all of your aligners
in the series, you get the beautiful
smile you’ve always wanted.

This revolutionary process and the
hearing aid process which actually
uses the SLS nylon parts as the
final product are the way of the
future – mass customization!

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