Addictive manufacturing

Manufatura aditiva: o presente e as necessidades
futuras
Addictive Manufacturing: present and future
necessities
Rudi Pivetta

Stereolithography (SLA)
 Polymerization of a layer
(Hatching Strategies).
 Drop down of the mobile
platform. Cover and
leveling.
 Polymerization of next
layer.
An overview of additive manufacturing
technologies and their evolutions

Laminated object
manufacturing (LOM)
Progressive collage of
sheets of paper.
Removal of excess of
the material.

MCOR Technology
 Uses sheets of A4
paper is true color.
 Requires manual
removal of excess
material.

SonicLayer 4000R has a 3-
Axis CNC Module with a
table of 40 х 24 Inches,
(101.6 х 60.96cm) and a
spindle with 8000 rpm.

Selective laser sintering (SLS)
 Deposition of a thin layer of
powder.
 Melting and solidification of
a specific area.
 Drop down of the work plan,
Start of new cycle.

LUMEX Avance-25V
Laser oscillator Yb fiber laser
Laser Power : W 400
Max. Work Size :
mm
W250 x D250
Spindle Speed:
min-1
45,000
60,000
Travel (X/Y/Z) :
mm
260/260/100
Feed Rate (X/Y/Z) :
m/min
60/60/30
NC System

Fused deposition modelling
(FDM)
 A thread of thermoplastic
material is heated to its melting in
a head that deposits the material.
 The head can be moved in two
spatial axes constructing the layer
of the part.
 Drop down of the work plan, Start
of new cycle.

Stratasys provides fused
deposition modeling
technology (FDM) and its line
of equipment “Fortus 3D” can
generate parts up to 3x2x3 ft.
Using materials such as (ABS),
polycarbonate, engineering
thermoplastics such as
ULTEM polyetherimide,
thermoplastic preferred by
the aerospace industry.

Several 3D printer
using the same
technological concept
(FDM) appeared for
personal use.

Powder bed and
inkjet 3D printing.
Powder bed and
inkjet 3D printing,
also known as "drop-
on-powder" - or
simply "3D printing"
(3DP).

Multijet Modeling or Polijet
Modeling
 Reduced size of equipment
that allow a use desktop
type.
 Models with high
dimensions quality.
 Process quickly and silent.
Build
Material

Eletron Beam Melting (EBM)
 ARCAM EBM machine use a high
power electron beam that
generates the energy needed for
high melting capacity of metal
powders.
 The vacuum system provides a
base pressure of 1×10-5 mbar or
better throughout the entire build
cycle.

Electron Beam Melting (EBM)
Orthopedic area
Aerospace area
Low pressure turbine
blade in y-titanium
Courtesy of Avio S.p.A

NASA is studying the use of
"addictive manufacturing"
technology using compound of
lunar rocks to build a lunar
settlement
 Berok Khoshnevis is developing a
system called "contour crafting"
designed to build 3D structures of
large dimensions.
 Like all 3D printing, the system builds
layer by layer. It consists of a nozzle
and spatulas computer controlled.
The nozzle deposits a concrete
compound, and the paddles smooth
surface, layer by layer.
Recent project for Aerospace area
Rendering courtesy of de Behnaz
Farahi e Connor Wingfield.

On November 19, 2013 The University of Kentucky
and the State University Moorehead along with
Kentucky Space, launched KySat-2 into orbit as part
of NASA's mission "Elana IV de Wallops " at the
launch base of Virginia.
 USA CRP with CRP Technology produced using SLS
technology pieces in Windform XT 2.0 which are
incorporated into solar panels KySat-2; Support
camera, lens cover, detachable extensions, clips
antennas and battery holders.
 Windform XT 2.0 Polyamide-based materials filled
with carbon fiber HDT (1.82 Mpa) 173.4 ° C 83.84 Mpa
UTS Elastic Modulus 8928.2 MPa.
Recent project for Aerospace area

Recent project for automotive area

Nokia 3D printing community
The project Nokia's 3D printing community
is offering to customers the ability to
create your own skins. Nokia has released
files for 3D printing for the Lumia 820. This
smartphone with Windows 8 features has
an interchangeable cover that users can
not only exchange with cover produced by
Nokia in different colors as well as printing
your custom covers.
This development kit contains printing 3D
file for 3D printers as well as tutorials and
tips on how to create your own custom
cover for Lumia 820 files including 3D
model, specifications etc..
Recent project for
consumer goods area

Sarah Silbert post on 08 /03/2013
 Earlier this week, a man "unnamed" in
the United States had 75% of Its cranium
replaced with a plastic prosthesis
produced by "addictive manufacturing".

 It is the first known surgery of this type.
 Oxford Performance Materials: OXPEKK
®-IG was designed to meet the standards
of the U.S. FDA and European standards
for use and implantable devices for long
time periods.
Recent project for medical area

Livrea 26, the future of boat design
uses 3D Printing technology
Febbraio 14, 2014 4:29 PM
Federico Maselli
 Miami, USA on days when the
attention of the nautical world's
looks Progressive Insurance Miami
Boat Show , one of the few Italian
exhibitors and Francesco Belvisi,
General Manager of YAM-Marine
Technology.
 In the most important trade fair for
boating in the U.S., the Italian
manager shows the prototype
Livrea 26. Built in Modena in
collaboration with industry and
Windform CRP Technology, the boat
brings inspirations Lancia pantesca
typical for the island of Pantelleria.
Recent projects for nautical area

Analyzing the market we can identify the following topics:
 The additive manufacturing technology had evolved in
construction speed, in the geometry definition and now is
possible use the part.
 Several hybrid machines appeared using the concepts of
additive manufacturing and traditional subtractive
manufacturing like milling.
 The maturity of additive manufacturing is confirmed by the
appearance of traditional suppliers of milling machines with
hybrid construction.
Conclusions

Speaking about materials we can identify a big developments
in applicability:
 Whereas metallic materials, advances in the SLS process, the
appearance of EBM and use of ultrasonic welding process applied
to the additive process LOM can generate parts with very
complex geometries and use them with little need for rework,
while maintaining the same mechanical characteristics parts
produced with traditional process.
 The same does not apply to plastic materials due to lack of new
usable materials in processes such as SLS and FDM.
Conclusions

New plastic materials for additive manufacturing:
 ULTEM (PEI polyeterimida) ULTEM amorphous thermoplastic resin
provides exceptional heat resistance, high strength and stiffness, and
broad chemical resistance developed by Stratasys.
 Oxford Performance Materials: OXPEKK ®-IG was designed to meet the
standards of the U.S. FDA and European standard for use by
implantable long time periodes appliances.
 Windform 3D printing is a line of materials that after 3D printing can be
machined on CNC or conventional procedures if necessary, plans for
the geometries with tight tolerances developed by the R & D
department of CRP Technology.
 During EuroMold, Stratasys announced a new material for the FDM
machines high end, Nylon 12 one of the most used materials in
industrial applications.
Conclusions

The market of plastic materials for additive manufacturing:
 The market for plastic materials for 3D printing was $ 70.5
million in 2012. According to "Markets and Markets Report"
reached U.S. $ 209.6 in 2018.
Conclusions

New suppliers of plastics for additive manufacturing:
Conclusões

Thank you!
Rudi Giovanni Pivetta
Rudi.pivetta@gmail.com

Addictive manufacturing

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