Additive Manufacturing 101

Advanced Applications

Presented by:

James Janeteas,
Cimetrix Solutions Inc,

Who we are

Founded in 1993
Full Line Stratasys Partner for Canada
Strong Design / Manufacturing background
Service Commercial and Academic verticals
Business based exclusively on Stratasys Products

Who we are

Dental
Specialize: High Requirement Driven Applications

Automotive

Dimensional properties
Mechanical properties
Process repeatability
Predictability
Hot/Cold operating conditions
Long product service life

Aerospace

Defense

Medical

Terminology
Known by many names
3D Printing

Advanced Manufacturing

Rapid Prototyping

Additive Fabrication

Rapid Tooling

Additive Layer Manufacturing

Rapid Technologies

Direct Digital Manufacturing

Rapid Manufacturing

Direct Manufacturing

Terminology
Additive Manufacturing
Term covering all technologies
Term covering all applications
Replacement for RP and Additive
Fabrication
Definition:
Collection of technologies, directly driven
by CAD data, to produce 3-Dimensional
physical models and parts through an
additive process.
Defined by ASTM : As the process of joining materials to
make objects from 3D model data. Usually layer upon layer as
opposed to subtractive methodologies.

Solution Classification

ADDITIVE MANUFACTURING

3D PRINTERS

3D PRINTERS

3D PRODUCTION
SYSTEMS

Most Affordable
Hobby Grade Solution

Professional Grade
Solution

Professional Grade
Highest Performing Systems

$2k - $7k
Simple and easy to use
Optimized for form

$7k - $50k
Simple and easy to use
Optimized for form, fit and
function

$50k - $500k & up

Optimized for performance
Broad application solution
High performance materials

Solution Classification

3D PRINTERS

3D PRODUCTION SYSTEMS
Performance Requirements Increase

Conceptual
Models

Functional
Prototypes

Manufacturing
Tools

End-Use
Parts

Technology Assessment

Production Series

Differentiators

Enablers

Envelope size
Materials
Accuracy
Throughput
Resolution

Customization
Repeatability
Flexibility
Complex Part Fabrication

Typical Build Process

Pre-Process

Manufacture

Remove Supports

FDM Process
Fused Deposition Modeling : FDM
Dual extrusion head technology
Deposit liquefied build and support
Precise Additive Fabrication
Advanced materials
Advanced mechanical properties
Safe, Simple, Clean process

Pre-Process

Manufacture

Remove Supports

FDM Materials
Engineering Grade Thermoplastics
Material Options
ABS-M30
ABS-M30i
ABS-ESD7
Nylon 12
PC-ABS
PC (Polycarbonate)
PC-ISO Class 6 :
Pharmaceutical
Ultem 9085 *
Polyphenylsulfone PPSF
Support Material
*Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV.

Technology Assessment

POLYJET- Polyjet Matrix

Multiple extrusion head technology

Deposit liquefied build and support

Precise , High Resolution
Advanced photo cure materials
Composite Material Capability
No Post Curing
Safe, Simple, Clean process

Material Options
Vero Family Rigid Opaque
FullCure 720 - Rigid
Transparent

Durus White - Polypropylene

like
Tango Family - Rubber Like
RGD5160-DM - ABS Like
RGD525 High Temp
VeroDent Dental
MED610 Rigid
Biocompatible

FDM Materials

ULTEM 9085

Aerospace & Defence Grade

*Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV.

SABIC Engineered
Certificate of Conformance available
FDM Material Properties
High tensile and compressive strength
High operating temperature
Passes FAR 25.853

FDM Materials
Ultem 9085

Aerospace Grade Thermoplastic

Passes FAR 25.853
Vertical burn test
FST zero rating
UL94 V0
Radiant Heat OSU 55/55 PASS
Result

Off Gassing
ASTM E595

Limit

PASS

Total Mass Loss (

TML)

0.41 %

1.00 %

Collected Volatile
Condensate
Material (CVCM)

<
0.01%

0.10 %

Water Vapour
Recovery Report
(WVR)

0.37

Report

Functional PrototypesEnd Use Parts

Czech Aircraft Company Saves up to 80% of

Prototyping and Production Costs Using Fortus

With Fortus, we can now develop and test innovative designs - and if
necessary change them quickly without halting the production process.
This means we no longer need to make functional compromises.
Igor Mega, Evektor

Conceptual Models Functional Prototypes

Needed time-to-market reduction
CNC Process added too much time to
design and prototype process
Outsourced parts were big and costly
Process did not allow for unplanned
projects
Fortus for in-house prototypes
Large capacity required
Ultem 9085 for end use part production
such as blow pipes

Development Costs reduced up to 80%

Accelerated product development
Prototyping costs also substantially reduced
Can develop more complex and innovative
designs make changes without halting
production

Primary Applications

Additive Manufacturing

Established / Traditional

Direct Digital Manufacturing

(Design)

(Manufacturing)

The Sweet Spot

Additive Mfg.

Specialty End Use Parts

Rapid Tooling
Low Volume Production

Sweet Spot

Complexity

High Complexity, Low Quantity

Conventional Mfg.

Quantity

Manufacturing Tools
Direct benefits
Financial gain
Lowering costs
Increasing profits

Time advantages
Decreasing time-to-market
Decreasing cycle time

Indirect benefits
Design freedom
Product redesign frequency
Rapid response

Manufacturing Tools

Assembly Aids
Examples:
Jigs
Fixtures
Check gauges
Drill / rivet guides
Go / No-Go gauges
Alignment tools & guides
Robotics- End of Arm
Shot Peen, Grit Blast, Paint
masking tools
Surrogate Parts

Manufacturing Tools
Assembly Aids
Benefits:
Custom interfaces for complex surfaces
Minimize part handling damage
Optimized for access without increased
costs
Light weight ergonomic
Enables: Emblem
Reduced dependency on external suppliers
Overnight fulfillment of new tooling
requirements
Lights out fabrication
Digitally mastered coordinated tooling
Resulting in:
Reduced cycle times up to 85%
Improved
Cubingquality
Device

Headlight Alignment

Gage Checker

Manufacturing Tools

Manufacturing Jigs and Fixtures with FDM

FDM is taking on increasing importance as an alternative manufacturing

method for components made in small numbers
-Gunther Schmid, BMW

Manufacturing Tools

Conventional fixture making

Cost and time requirements were high
Lack of design freedom reduced productivity

FDM used to produce fixtures

Have over 400 assembly fixtures
Several built on Fortus system

FDM enhances ergonomics

Organic shapes maximize performance
Sparse fill cut weight 72%

Time and cost savings

Typical cost reduced from $420 to $176
Typical lead time reduced from 18 to 1.5 days

Method

Cost

Time

CNC
Machining
Aluminum

$420

18.0 days

Fortus
system
ABS-M30

$176

1.5 days

Savings

$244
(58%)

16.5 days
(92%)

Manufacturing Tools

Fabrication Tools

Sheet Metal Forming

Composite Tooling
Fibre Winding
Coordinated Tool Families
Thermoform Tools
Pulp Mould Tooling
Tooling Masters & Patterns
Injection, Blow Moulds
Sand Casting
Investment Casting

Manufacturing Tools

Piper Reduces the Cost and Leadtime of

Hydroforming Tool to Build a personal Jet

I can program an FDM part in 10 minutes while typical CNC

program takes four hours to write
-Jacob Allenbaugh, Manufacturing Engineer, Piper Aircraft

Manufacturing Tools
Producing hundreds of aluminum structural components
Inner frame components, gussets, brackets, skins etc.
FDM as the manufacturing process
PC Material 3000 to 6000 psi
Ultem 9085 for up to 10,000 psi
Hydroform Tooling
Produce route , drill and trim fixtures with FDM
Program FDM part 10 min vs. 4 hrs CNC
No operator attendance
Less material waste

Aluminum Window Pan (left) FDM Tool

Aluminum Window Pan on top of FDM Tool

End Use Parts

Direct benefits:

Lower cost
Shorter lead time

Indirect benefits:

Design freedom
Change freedom
Mass customization
Weight reductions
Part consolidation
Supports lean initiatives
True JIT (just-in-time)
manufacturing
Reduced warehouse
space/inventory cost

End Use Parts : Case Study

FDM End use parts allowed for:

Flexibility when designing complex parts

Manufacture of less expensive part
Weight saving solutions
Production of parts that meet FAA
regulatory requirements to be installed on
aircraft
Low volume production
No tooling required

End Use Parts

Best fit when:

Relatively low volumes
Short run production
Bridge to tooling
High part complexity
Eliminate expensive tooling
Reduce long lead times
Part acceptable
Aesthetics not critical
Finishing processes feasible
Physical properties acceptable

End Use
Parts
: Case Study
Applications:
End Use
Parts

To the best of my knowledge, the only additive fabrication technology

that meets the stringent requirements for MRI equipment is FDM,
Tramm.

Virtumed

LLC

End Use Parts

Virtumed

LLC

Accelerate Design & Manufacturing

Design complexity high

Cost of tooling would be very high

MR Instruments invested in Fortus system

FDM used to build the plastic housings

Builds custom appliances to secure patients
head

Elimination of tooling saves time & money

71% reduction in time vs. CNC

62% reduction in costs vs. CNC
74% reduction in time vs. RTV Moulding
84% reduction in costs vs. RTV Moulding

What

inspires you is your business

How you make it real is ours.

THANK YOU