State of the art

of 3D printing/additive manufacturing technologies

and their possible application in

buildings/curtain wall/construction industry

Natasa Mrazovic, M.Arch.Eng., lic.arch., M.CE.

Permasteelisa, Middelburg, 14/08/26
I STATE OF THE ART OF THE INDUSTRY
1) 3D PRINTING GENERAL INFO, DEFINITIONS, THE BIG PICTURE
2) COMPARISON OF EXISTING AM TECHNOLOGIES
3) STATE OF THE ART OF THE INDUSTRY
4) STATE OF THE ART IN SCIENTIFIC RESEARCH (MATERIALS,
SIMULATIONS, ETC.)
5) RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION
IN BUILDING DESIGN / CONSTRUCTION INDUSTRY

II AM FOR CURTAIN WALLS

1) AM SYSTEMS AND MATERIAL POSSIBLY APPLIED FOR CURTAIN WALLS
2) WHAT IS POSSIBLE TODAY
3) WHAT IS POSSIBLE WITH EXTENDED KNOWLEDGE
4) POSSIBLE NEW FUNCTIONS AND APPLICATIONS
5) BRAINSTORMING .

CONTENT
3D PRINTING - THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
ASTM (2009): 3D Printing can be defined as joining materials to make objects from 3D model
data, usually layer upon layer []

CONTROLLED DEPOSITION OF MATERIAL, usually layer by layer

Courtesy of Buswell, Soar, Gibb and Thorpe

3D PRINTING THE BIG PICTURE
3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
 Courtesy of dr Martin Baumers

MAJOR ADVANTAGES GENERIC DISADVANTAGES-DUE TO TECHNOLOGY IT WILL

CHANGE
1. COMPLEX GEOMETRY 1. LIMITED MATERIALS
2. OPTIMIZATION 2. LOW PROCESS PRODUCTIVITY
3. CUSTOMIZATION 3. PROBLEMS WITH DIMENSIONAL ACCURACY
4. POOR SURFACE FINISH
4. TRIGGERED REVOLUTION IN 5. REPEATABILITY ISSUE
MANUFACTURING AND DESIGN 6. UNCOMPETITIVE PRODUCTION COST AT MEDIUM AND
LARGE VOLUMES

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE
 Courtesy of John Hornick / Finnegan/ Inside 3D Printing Conference in
San Jose, 2013

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

 Courtesy of John Hornick / Finnegan/ Inside 3D Printing Conference in
San Jose, 2013

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

Engineering Implications

More complex geometries

- internal features
- parts consolidation
- designed internal structures
- material design - NO WASTE
- special geometries and functions not considered before
No tools, molds or dies
- direct production from CAD
Unique materials
- controllable microstructures
- multi-materials and gradients ; new products emerging
- embedded electronics / Integrated functional new structures
- commercialization expected to be 10-15 years away
- substantial technological hurdles need to be overcome

Business implications

- Enables business models used for 2D printing, e.g. photographs, to be applied

in 3D - Print at home, at local FedEx Kinkos, through Shapeways or at local store
- Removes the low-cost labor advantage
- Entrepreneurship
- Patents expiring (new machines); Software tools; Service provides
- User-changeable web content plus a network of AM producers already
enables new entrepreneurial opportunities (Shapeways.com, Freedom of
Creation, FigurePrints, Spore, etc.)
Courtesy of Prof Brent Stucker and dr. Martin Baumers

3D PRINTING BIG PICTURE

Impact on logistics

- Eliminate drivers to concentrate production

- design and manufacture anywhere is now possible
- Manufacture at the point of need rather than at lowest labor location
- Changing Just-in-time Delivery to Manufactured-on-Location Just-In-Time
- Make local manufacturing of products normative
- Small business can compete with multi-national corporation to produce goods for
local consumption
- Parts produced closer to home cost the same as those made elsewhere;
minimizing shipping drives regional production
- Reverse increasing urbanization of society, e.g. No need to move to the big city if I
can design my products and produce anywhere
- Make jobs resistant to outsourcing , e.g. Creativity in design becomes more important
than labor costs for companies to be successful

The future
- The industry will grow significantly (according to predictions)
- Estimated market penetration now 1-8%
- Current global growth rate : 30 % p/a

- New products, new designs, new design systems

- New business models will emerge
- Industrial 3D printing will become cheaper
- - faster build speed
- Process innovations needed
- Current hype around amateur (low cost) 3D printing will be reduced
Courtesy of Prof Brent Stucker

3D PRINTING BIG PICTURE

 Courtesy of dr Martin Baumers

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

 Courtesy of dr Martin Baumers

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

 Courtesy of John Hornick/ Finnegan/ Inside 3D Printing Conference in
San Jose, 2013

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

 Courtesy of dr Martin Baumers

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

 Courtesy of dr Martin Baumers

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

COMPARISON OF EXISTING AM TECHNOLOGIES
Technology Vat Material Binder Material Powder Bed Sheet Directed
(Categories Photopoly Jetting Jetting Extrusion Fusion Lamination Energy
ASTM F2792) merization Deposition

Definition/
Major
Characteristics
Market
known/Patent
names
Developments
/State of the
art
Characteristics/
Disadvantages/
Secrets
Materials in ...

What is the Courtesy of dr Martin Baumers

technology best
for?

COMPARISON OF EXISTING AM TECHNOLOGIES

Technology Vat Material Jetting Binder Jetting Material Extrusion Powder Bed Fusion Sheet Lamination Directed Energy
Photopolymerization Deposition

Definition/ - an additive
Major manufacturing
Characteristics process in which
liquid photopolymer
in a vat is selectively
cured by light-
activated
polymerization
- Projection systems :
a) use a projector (LED
or DLP) to illuminate the
cross-section
b) resolution limited by
pixels of projector
c) typically faster per
layer d) common for
micro-Stereolithography
-an additive -an additive an additive - an additive an additive - an additive
manufacturing manufacturing manufacturing process manufacturing process manufacturing process manufacturing process
process in which process in which a in which material is in which thermal energy in which sheets of in which focused
droplets of built liquid bonding agent selectively dispensed selectively fuses regions material are bonded to thermal energy is used
material are is selectively through a nozzle or of a powder bed form an object to fuse materials by
selectively deposited deposited to join orifice - SLS, SLM, DMLS, Paper (LOM) using melting as they are
powder materials it is based on Stratasys EBM, BluePrinter, DMD glue, being deposited
-Wax or FDM machines; it is etc. Plastic using glue or - Wire & Powder
Photopolymers; - office friendly; DIY - Polymers, metals and heat Materials
Multiple nozzles; community; bestselling ceramics Metal using welding or - Laser & Electro Beams
-Single nozzles platforms, etc. bolts; ultrasonic AM, ... - Great for feature
addition & repair

Single-Droplet : Solidscape
Modelmakers; 0.0005 layers
small, accurate parts made
slowly

Multi-droplet: Thermojet and

Actua from #D Systems; prints
waxy-like materials no longer
in production, but still serviced
Market known/ Stereolithography , Objet; 3D systems Zcorp; Voxeljet; SLS, SLM, DMLS, EBM,
Patent names Envisiontec DLP , Micro-SLA Projet; Stratasys ProMetal/ExOne , BluePrinter, Lase
, 2-photon lithography etc. Solidscape etc. Cusing, etc.
machines; Several
Direct Write
machines , etc.

COMPARISON OF EXISTING AM TECHNOLOGIES

Technolo Vat Material Jetting Binder Jetting Material Extrusion Powder Bed Fusion Sheet Lamination Directed Energy
gy Photopolymerization Deposition

Develop - increased - New Stratasys/Objet - 3D Systems - expiration of initial FDM - the most used platform - Renewed interest in - Electron Beam with
ments / proliferation of Connex 500 ; purchased Zcorp and patents has led to a vast for functional parts paper-based machines wire seems to be
State of DLP/LCD/LED multimaterial & Multi- has changed proliferation or personal 3D - significant R&D at the low-end by Mcor leading for part
the art technology to cure color marketing to Colorjet: printers investment and others production currently
entire layer at once - Many traditional 2D a) printing sugary food - more personal machines - many metal laser - Fabrisonics sells 3 - DoD is interested in
- new printing companies are and ceramics (pottery sold at $1k-2k than industrial sintering machine platforms based upon laser powder deposition
photopolymer investigating 3D printing: & art) machines for $10k-$200k manufacturers; SLM metal ultrasonic AM for repair (America
materials which a) thermoplastics are b) Announced a color - lots of new materials, Solutions, ConceptLaser, Other solid state AM Makes project)
mimic engineering difficult (viscosity issues) personal 3D printer competitors EOS, Phenix, Renishaw, methods are being - manufacturers are
photopolymers b) metals are starting to - ExOne is pushing - many ways for consumers to Realizer investigated (friction stir marketing laser
- expiration of initial be publically discussed sand printing and access & buy these machines - Starting to see new AM, etc.) deposition heads as
Stereolithography - significant interest in builds metal parts for - 3D Systems and Stratasys polymer machine add-ons to existing
patents are printed electronics; Shapeways offer personal 3D printers in manufacturers; several machine tools
opening up the major industry interest at -Voxeljet, fcubic, etc. addition to their industrial companies entering the
marketplace the intersection between make marketplace offerings marketplace to compete
- renewed interest 2 1/2D & 3D geometries dynamic: - renewed interest in with 3D Systems & EOS
in 2-photon a) continuous build manufacturing parts via - open vs. Closed machine
polymerization for platform design has extrusion architecture battles
nano-scale major ramifications - high-temperature materials, - GEs purchase of Morris
components concrete, fiber-reinforced Technologies (2012) is still
composites, etc. having major ramifications
- people seem to be taking it on the metal laser sintering
more seriously than a few marketplace
years ago
Character - always need always need supports; 1) parts from - always needs supports - an expert user is the - Getting rid of excess - Material needs
istics/ support ; thus, we 1) thus we must remove starch/plaster look a) thus we must remove them most critical aspect of material is difficult something to land on
Disadvan must remove them them; pretty but are quite b) downward facing surfaces getting a good part cut then stack vs. (supports)
tages/ and downward 2) downward facing brittle are inferior - user-selected trade-offs Stack and cut - we dont typically make
Secrets facing surfaces are surfaces are inferior - post-process - secondary support material between speed, accuracy - Mechanical properties 3D complex parts, just
inferior (particularly true if infiltration of these make support removal easier and strength in polymer are typically quite poor complex parts with
- photopolymers do secondary support materials by (water soluble, easier to laser sintering mostly upward- facing
not have long-term materials are not used) cyanoacrylate or remove etc) - takes about a year to features
stability in the - secondary support another material - fundamental tradeoffs in learn enough to - there is a direct
presence of light materials make support needed for strength build style mean you can consistently make good correlation between
they continue to removal easier: (infiltration makes NEVER be fully dense and parts in metal processes feature size and build
react and degrade a) different strength, these parts very simultaneously achieve - polymers are not 100% speed
overtime b) water soluble heavy) maximum accuracy without recyclable - accurate processes
c) different melting 2) metal parts are not post-processing - metal supports are a are painfully slow
temperature engineering-grade: huge problems - fast process is very
-mostly applicable to - $50k-$100k/year per inaccurate
art machine waste is common - surface finish &
-need infiltrated (blade crashes and/or accuracy requirements;
(highest accuracy) or over-supporting) almost always require
http://www.isis3d.net/pages/isisone- sintered (shrinks) finish machining
features

COMPARISON OF EXISTING AM TECHNOLOGIES

Technology Vat Material Jetting Binder Jetting Material Extrusion Powder Bed Fusion Sheet Lamination Directed Energy
Photopolymerization Deposition
Materials in Materials in VP: -only commercial - majority of the - Commercial - Polymer Materials in PBF - Paper is used for - most metal alloys can
... - over 20 years of materials are wax- build material is materials include you can use any material you want as long proof of concept parts be deposited with some
photopolymer like materials or powder (- makes easy to extrude as its nylon (or if it meets the cooling color printing on the success
research, including photopolymers the process very, engineering curve) paper gives color parts - rapid cooling affects
by major chemical a) need low very fast) polymers: opposite of injection molding (fast heating, - Metal sheets can be properties
companies, has viscosity - materials are by a) ABS, PC, slow cooling) cut and stacked for - polymers and ceramics
led to many resins b) waxes melt at nature composite PC/ABS, PPSF, etc. tooling and other rarely used, but possible
which you can buy low temperature, - gradients in b) Chocolate and applications
- no materials are but solidify quickly color/properties meltable food - Ceramic tapes can
standard c) photopolymers possible by printing products be cut and stacked
engineering-grade are cured using different binders c) many DIY and then fired for
polymers they light just after - any powder materials being - Metal material in PBF ceramic parts
are just specially- deposition which can be explored most casting and welding alloys can be - Polymer sheets (such
formulated to - no materials are spread and then - Syringe & pumped processed using metal laser sintering as Solido) can be
mimic engineering standard glued, reacted, nozzles also very fast melting & solidification times bonded and cut to form
polymers engineering-grade catalyzed, or available gives unique properties & challenges prototypes
polymers they otherwise fused a) pastes, glue, high reflectivity, high thermal conductivity
are just specially- using a binder is a cement materials are difficult to process (copper,
formulated to candidate b) frosting and other gold, aluminum, etc.
mimic engineering - living tissues and food products - Titanium is the sweet spot for EBM
polymers dental ceramics - Need materials - Other materials in PBF
are promising which soften under Ceramics are difficult, but possible to
shear load and directly process
maintain their shape Green parts are easy to process
after deposition powder metallurgy, sand casting, etc.
What is the - high accuracy -smooth, accurate - color parts used - inexpensive - Paper machines - Adding features to
technology parts that dont parts that dont for marketing or prototypes make cheap physical existing structures;
best for? have stringent have stringent proof-of-concept - functional parts representations of your replace complex ; -
structural structural - metal parts for without stringent design forgings with sheet
requirements requirements artistic purposes or engineering - Original LOM-like structures that we build
- patterns: - -mixing of stiff and with limited constraints (limited machines can be used up near-net shape parts
investment casting, flexible engineering fatigue strength) Manufacturing end-use products: like wood as patterns on
RTV molding, etc. materials/colors functionality - great platform on - polymer parts from Nylon 11 or 12 for sand casting, or as - Repair & refurbishment
gives tremendous - powder metal which to try lots of (including glass filled nylons) topographical maps, of existing components;
variability in green parts things: - metal parts from Titanium, Stainless etc. - qualified for many
design: - sand casting a) living tissue Steel, Inconel super alloys, tool steels and - Metal laminated high-performance
a) artwork molds b) food more tooling reduces the applications
b) full-color mock- c) toys - Prototyping components where functional time to build large
ups testing is required on prototype molds such as for
c) gradient material stamping
assemblies, etc. - micro-fluidic ceramic
parts can be made
using ceramic tapes

COMPARISON OF EXISTING AM TECHNOLOGIES

Technology Vat Material Jetting Binder Material Powder Bed Fusion Sheet Lamination Directed Energy
Jetting Extrusion
Photopolymerizat Deposition
ion
Special info Electron Beam Melting (EBM) Arcam
- electrons are emitted from a heated filament >2500
deg C
- electrons accelerated through the anode to half the
speed of light
- a magnetic lens focuses the beam
- another magnetic field controls deflection when the
electrons hit the powder, kinetic energy is transformed
to heat
- the heat melts the metal powder

EBM vs. Laser Processes:

- EBM Benefits :
energy efficiency
high power (4kW) in a narrow beam
incredibly fast beam speed (no galvanometers) POWDERS:
fewer support - small powder particles
- EBM drawbacks: give better feature resolution, surface
only works in a vacuum (gases, even inert, deflect the finish, accuracy and layer thicknesses
beam) are difficult to spread and/or feed
does not work well with polymers and ceramics become airborne easily (repel in EBM)
(needs electrical conductivity) react with oxygen easily
needs larger powder particles
- spherical powders with a tight PSD are
best
- powder morphology, packing density,
fines, etc. make a HUGE difference in
some processes

Courtesy of Prof Brent

Stucker, Founder and
CEO of 3DSIM LLC,
Professor of Industrial
Engineering Edward Reep
Clark Chair of Computer
Aided Engineering,
Department of Industrial
Engineering, University of
Louisville
Reshaping Manufacturing;
Understanding 3D Printing
Processes, Inside 3D
Printing, New York, 2014

COMPARISON OF EXISTING AM TECHNOLOGIES

Technolog Vat Material Binder Material Powder Bed Sheet Directed Energy
y Photopolymerizati Jetting Jetting Extrusion Fusion Lamination Deposition
on

video https://www.yout https://www https://www Aluminum Arcam EBM : https://www.y Optomec

ube.com/watch?v .youtube.co .youtube.co extrusion: https://www.you outube.com/w LENS
=vHg0-nZK2P4 m/watch?v m/watch?v https://www.yo tube.com/watch atch?v=YmX3 systems:
=lgcKYjq- =NVJifm2b utube.com/wa ?v=lUIipa3AgN qKJdqvA https://www.yo
nMs 6-c tch?v=QMMSr g utube.com/wat
hhaj1s ch?v=mkUVU
RLkxS4
Stereolithograph Objets https://www Stratasys https://www.you https://www.y
y: PolyJet: .youtube.co FDM tube.com/watch outube.com/w
m/watch?v technology: ?v=jqjD- atch?v=Z1WN
=TQgbMM FWMexo A6tdfWM
w1GHo
ZPrinter FDM: https://www.you Mcor
line: https://www.yo tube.com/watch Technologie
utube.com/wa ?v=dpL0Y2l_B s printers
tch?v=dpL0Y2 SI
l_BSI
FDM: https://www.you
https://www.yo tube.com/watch
utube.com/wa ?v=E7--
tch?v=SPtkO ZWPVVdQ
mP_HoA
EOS direct Source:
metal laser various online
sintering websites
https://www.you
tube.com/watch
?v=iLndYWw5_
y8
COMPARISON OF EXISTING AM TECHNOLOGIES
STATE OF THE ART OF THE INDUSTRY
STATE OF THE ART OF THE INDUSTRY
 http://www.solidconcepts.com/

Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

 PolyJet Technology https://www.youtube.com/watch?v=Som3CddHfZE
Stereolithography (SL) Technology
https://www.youtube.com/watch?v=NM55ct5KwiI
Laser Sintering (LS) Technology
https://www.youtube.com/watch?v=9E5MfBAV_tA
Fused Deposition Modeling (FDM) Technology
https://www.youtube.com/watch?v=WHO6G67GJbM
Metal Laser Sintering (MLS) Technology
https://www.youtube.com/watch?v=bgQvqVq-SQU
Cast Urethane Technology https://www.youtube.com/watch?v=rjFdbhCjKPY

http://www.solidconcepts.com/

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

 Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

 Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

 Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

 Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

 Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY: AN EXAMPLE; SOLID CONCEPTS

Solid Concepts : Hybrid projects

Courtesy of Chuck Alexander , Solid Concepts Ins; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

http://www.materialise.com/, Belgium

Courtesy of Materialise; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

http://www.materialise.com/, Belgium

Courtesy of Materialise; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

http://www.within-lab.com/UK
https://www.youtube.com/watch?v=22Gb0PbmZYU
Video : EOS M270 + Within technologies + design
https://www.youtube.com/watch?v=k-wMKnjGa4Q
2.46 - 5.00; lattice structure 5.37 6.50, 9.40 FEA software;
e.g. Orthopedic implants 12.50-15:35 if time
Or 24:07; 26:17 shoe; 39 future 39- 42:06
Special designs of heat exchangers

Courtesy of Within-lab; conference: Inside 3D printing

STATE OF THE ART OF THE INDUSTRY

 Courtesy of Rupert Soar and Farid Fouchal
Construction Processes for the Digital Trinity (2008)

DIGITAL TRINITY
http://vimeo.com/80893331 0:20-2:20

STATE OF THE ART OF THE INDUSTRY

A) 3D scanning B) 3D modelling C) 3D printing

123Dcatch/ Mudbox/AutoCAD Rhino/Grasshopper

Kangaroo FEA of structural Symvol : Adding new function

performance of the object (pressure) e.g. hygroscopic performance of the bulk material

DEVELOP PLATFORM FOR ANY PURPOSE

 MATERIAL BASED DESIGN COMPUTATION

SUBTERRAINS RAYCOUNTING

MIT MediaLab: 3-D printing with variable densities

https://www.youtube.com/watch?v=0nFyuxGEhzY

BEAST

CARPAL SKIN

Courtesy of Neri
Oxman; various sources and presentations;
Thesis: Material-based design computation
http://hdl.handle.net/1721.1/59192

RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
STATE OF THE ART IN SCIENTIFIC RESEARCH (MATERIALS,
SIMULATIONS, ETC.)
Materials are key to the future success of 3D printing
Wohlers Report

Examples of special cases materials:

Washington State University : bone-like material (support for new bone growth)
University of Glasgow: organic compounds and inorganic clusters (customized medicines)
University of Warwick : Carbomorph conductive plastic (functioning electronic device)
Carbomorph
Cambridge University & PARC: thin film transistors
Xerox PARC: Chiplets
- grain of sand
- containing intelligent data
-microscopic electronic building blocks
Tsinghua University & Chinese Academy of Sciences : Self forming Metal
North Caroline State University: Liquid metal
- flexible, stretchable, alloy of gallium and indium Thin film transistors
- liquid at room temperature
- self-healing mechanically and electrically

NASA/ Ames Research Center: Bio- Composites

- in-situ, on demand printing of advanced bio-composites
- 3D printing cells from molecules in surrounding environment into usable material
- 1 billion European Commission Initiative /75 institutions and partners/17 EU countries: Graphene flagship
- Graphene: flexible, transparent, conductive, harder than diamond, 200x stronger than steel
- Graphene 3D Labs/Lomiko Metals
- University of Pittsburgh, Harvard School of Engineering, University of Illinois / US Army Grant: 4D materials
- materials that modify their own structure at the macro level; adaptive, biomimetic composites that
reprogram their shape, properties or functionalities on demand, based upon external stimuli

3D PRINTING/ ADDITIVE MANUFACTURING THE BIG PICTURE

Materials in general, 3000 common types Thermoplastics

Material demands for 3DP

- Form proper feedstock
- Fabricator processability
- Post - procesabillity as needed
Polymers in general - Acceptable Service Properties

Materials grand challenge in AM

- Quality
- Process consistency
- Reliability
- Wide diversity of compositions
- Superior structure and properties
- Low (feedstock and processing) cost
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS

Materials for AM

Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS

Mechanical properties POROSITY : Processing Effects on Porosity in SLM Processed 17-4 Stainless Steel
- Stress or Strength (take a load without failing)
- Ductility (permanent elongation at failure)
- Stiffness (Measure of Springiness)
- Fracture Toughness (Ultra-strong or ultra-brittle)
- Fatigue (Elastic cyclic loading)

Strength
<0.5 ksi A part falls apart
20ksi Most Wood/Plastic A.B. Spierings, K. Wegener, G. Levy, Designing Material Properties Locally with Additive
Manufacturing technology SLM , Proc. SFF Symposium (2012), pp. 447-455.

80 ksi Structural Steel/Aluminum

POROSITY : Examples of Porosity in EBM Ti-6AI-4V
400 ksi High-Strength Steel

Summary of AM Mechanical Behavior

Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for Khalid Rafi. H, Karthik N.V, Thomas L. Starr*, Brent E. Stucker, Defect formation in EBM parts
Freeform Fabrication: Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013 built in horizontal orientation, Proc. SFF Symposium (2012), pp. 456-467.

STATE OF THE ART OF THE INDUSTRY&RESEARCH / MATERIALS PROPERTIES

STRENGTH STRENGTH : Modulus of Elasticity

316L Stainless Steel SLM, As

Processed

J. P. Kruth et al, Binding mechanisms in selective laser sintering and selective

laser melting, Proc. SFF Symposium (2004), Univ. Texas at Austin, pp. 44-58.

STRENGTH: SLM 316 Metals

Majewski C & Hopkinson N (2011) Effect of section thickness and build orientation on tensile properties and
material characteristics of laser sintered nylon-12 parts. RAPID PROTOTYPING JOURNAL, 17(3), 176-180
or on, Proc. SFF Symposium (2010), Univ. Texas at Austin, pp. 422-34.

STRENGTH : Modulus of Elasticity

Unpublished results,
Tom Starr, U. Louisville

STRENGTH: SLM of Ti-6Al-4V

S. Rusenberg, L. Schmidt, and H.-J. Schmid, Mechanical and Physical Properties

Table for AM Ti-6Al-4V;; A Way to Asses Quality of Laser Sintered Perts, Proc. SFF Symposium (2011),
Unpublished results, Univ. Texas at Austin, pp. 239-51.
Tom Starr, U. Louisville

SCIENTIFIC RESEARCH / MATERIALS PROPERTIES

STRENGTH AND DUCTILITY STRENGTH

66Co-28Cr-6Mo
EBM, HIP,
Homogenized
Yasa E., Kempen K., Kruth J.-P.
R.S. Kircher, A.M. Christensen, K.W. Wurth Electron Beam Melted (EBM) Co-Cr-Mo Alloy for Orthopaedic Catholic University of Leuven, Dept. of Mechanical Engineering
Implant Applications MICROSTRUCTURE AND MECHANICAL PROPERTIES OF MARAGING STEEL 300 AFTER
Mechanical behavior of LS Nylon
, Proc. SFF Symposium (2009), Univ. Texas at Austin, pp. 428-36. SELECTIVE LASER MELTING
, Proc. SFF Symposium (2010), Univ. Texas at Austin, pp. 383-96.

Mukesh Agarwala, D. L. Bourell, B. Wu and J. J. Beaman,

An Evaluation of the Mechanical Behavior of Bronze-NI Composites Produced by Selective Laser Sintering
193 ; Proc. SFF Symposium (1993), Univ. Texas at Austin, pp. 193-203
D.K. Leigh, Harvest
Technologies, priv. comm., 2011.

http://utwired.engr.utexas.edu/lff/symposiu
Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for m/proceedingsArchive/toc.cfm.
Freeform Fabrication: Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

SCIENTIFIC RESEARCH / MATERIALS PROPERTIES

MECHANICAL PROPERTIES OF AM PARTS: SLM Ti-6Al-4V (BASED ON POST-PROCESS ANNEALS
DUCTILITY (FURNACE COOLED)

M. Thne, S. Leuders, A. Riemer, T. Trster, H.A. Richard;

Influence of heat-treatment on Selective Laser Melting products e.g. Ti6Al4V
Proc. SFF Symposium (2012), Univ. Texas at Austin, pp. 492-498.

Ti DUCTILITY

D.K.Leigh, D.L.Bourell, J.J.

Beaman, Basis for Decreased
Mechanical Properties of
Polyamide in Selective Laser
Sintering, Proc. SFF
Symposium (2011), Univ. Texas Ben Vandenbroucke and Jean-Pierre Kruth,
at Austin,
Selective Laser Melting of Biocompatible Metals for Rapid Manufacturing of
Medical Parts 148,
Proc. SFF Symposium (2006), Univ. Texas at Austin, pp. 148-159

Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication: Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

SCIENTIFIC RESEARCH / MATERIALS PROPERTIES

MECHANICAL PROPERTIES OF RM PARTS: MECHANICAL PROPERTIES OF RM PARTS:
FATIGUE / FRACTURE FATIGUE

Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing

Center, LFF; Laboratory for Freeform Fabrication:
Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

P. A. Kobryn and S. L. Semiatin:

MECHANICAL PROPERTIES OF RM PARTS: Mechanical Properties of Laser-Deposited Ti-6Al-4V 179

Proc. SFF Symposium (2001), Univ. Texas at Austin, pp. 179-186
FRACTURE TOUGHNESS

MECHANICAL PROPERTIES OF RM PARTS:

FATIGUE

Reid, Fatigue of Fused

Deposition Modeled
(FDM) Acrylonitrile
Butadiene Styrene
(ABS) Stage Three
Individual Project MEC
3098, Newcastle
University School of
Mechanical and
Systems Engineering
2011.

P. A. Kobryn and S. L. Semiatin:

Mechanical Properties of Laser-Deposited Ti-6Al-4V 179
Proc. SFF Symposium (2001), Univ. Texas at Austin, pp. 179-186

SCIENTIFIC RESEARCH / MATERIALS PROPERTIES

AGING EFFECTS ON MECHANICAL PROPERTIES OF SL POLYMER
SUMMARY OF AM MECHANICAL BEHAVIOR

Mechanical behavior is predictable based on the traditional understanding

of microstructure and processing
Porosity has a strong influence on the mechanical behavior
Anisotropy is not an issue if parts are built with low porosity and good
layer interface
Polymer produced using best practice have isotropic strength and anisotropic
ductility

Karina Puebla, Dissertation:

OVERALL SUMMARY
Effects of build orientation, aging, and pre-conditioning on mechanical properties for
Stereolithography-manufactured ASTM type I specimens using a design of experiments 3DP is here to stay and the market is developing explosively
approach;
Karina Puebla, Karina Arcaute, Rolando Quintana, Ryan B. Wicker: Effects of environmental Materials for 3DP offer an opportunity for business venture
conditions, aging, and build orientations on the mechanical properties of ASTM type I
specimens manufactured via Stereolithography, Market timing is a factor entry into 3DP materials
Rapid Prototyping Journal 07/2012; 18(5):374-388.
3DP fabricators will continue to proliferate driven by expiration of founding
patents over the next 1-5 years
ASTM STANDARDS wrt MATERIALS/PROPERTIES
There is not much brans loyalty of materials among users of 3DP materials

Courtesy of Prof D.L. Bourell, University of Texas, Austin, Advanced Manufacturing Center, LFF; Laboratory for
Freeform Fabrication:
Materials for 3D Printing,, Inside 3D Printing, San Jose, 2013

ALL RELEVANT SCIENTISTS IN THE FIELD:

SFF SYMPOSIUM AT THE UNIVERSITY OF TEXAS AT AUSTIN
ALL UP TO DATE PROCEEDINGS AND THE INFORMATION ABOUT THE SCIENTISTS:
http://utwired.engr.utexas.edu/lff/symposium/proceedingsArchive/toc.cfm

SCIENTIFIC RESEARCH / MATERIALS PROPERTIES

State of the art in SIMULATIONS related to AM technologies

It is still NOT POSSIBLE to:

- Efficiently represent multi-scale geometry in a CAD environment

- Efficiently optimize multi-scale features
- Efficiently simulate the link between AM process parameters and microstructure
- Efficiently compute the effects of changes in microstructure on part performance

It IS NEEDED:
- Improved computational design tools for additive manufacturing
- like those used for injection molding and casting/forging
- Physics- based tools are inefficient when applied to AM
- Requires dramatic simplification of the process and/or geometry
- AM industry software focuses primarily on geometry and not process control or performance/quality
- forces the AM industry to continue to Build/Test/Redesign cycle of traditional manufacturing
- Process simulations that are faster than an AM machine builds a part
- predict residual stress and distortion so we know how to place support and how to pre-distort
our CAD model
- Material simulations which can predict crystal level details and the resulting mechanical properties
- Lighting fast solutions on GPU-based platforms
- We simulate only what we need to get a practical answer as FAST as possible

Courtesy of Prof Brent Stucker, Founder and CEO of 3DSIM LLC, Professor of Industrial Engineering Edward Reep Clark
Chair of Computer Aided Engineering, Department of Industrial Engineering, University of Louisville
Reshaping Manufacturing; Understanding 3D Printing Processes, Inside 3D Printing, New York, 2014

STATE OF THE ART OF THE INDUSTRY & RESEARCH IN SIMULATIONS

 PRICING?

IMPOSIBLE TO GET CREDIBLE QUOTES FROM SPECIFIC SERVICE PROVIDERS

http://gpiprototype.com/blog/dmls-in-aluminum-inconel-or-titanium-is-it-worth-it.html

http://pencerw.com/feed/2014/1/6/dmls-pricing

PROTOTYPE A SEGMENT OR A POLIFUNCTIONAL CUSTOMIZED UNIT OF A CURTAIN WALL

Courtesy Adam Cohen, Principal Consultant and CEO of Additive Insight LLC

STATE OF THE ART OF THE INDUSTRY

 Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK

RESEARCH/ MATERIALS: ENERGY CONSUMPTION

 Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK

RESEARCH/ MATERIALS: ENERGY CONSUMPTION

 Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft and R. Hague:
ENERGY INPUTS TO ADDITIVE MANUFACTURING: DOES CAPACITY UTILIZATION MATTER?
Additive Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering,
Loughborough University, Loughborough, LE11 3TU, UK

RESEARCH/ MATERIALS: ENERGY CONSUMPTION

 Courtesy of M. Baumers, C. Tuck, R. Wildman, I. Ashcroft, E. Rosamond, and R. Hague
COMBINED BUILD TIME, ENERGY CONSUMPTION AND COST ESTIMATION FOR DIRECT METAL LASER SINTERING
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham,
NG7 2RD, UK

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Courtesy of M. Baumers
Production cost, machine productivity and the emergence of an Additive Manufacturing
industry

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Courtesy of M. Baumers
Production cost, machine productivity and the emergence of an Additive Manufacturing
industry

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Courtesy of M. Baumers, C. Tuck, P. Dickens, and R. Hague
HOW CAN MATERIAL JETTING SYSTEMS BE UPGRADED FOR MORE EFFICIENT MULTI-MATERIAL ADDITIVE MANUFACTURING?
Additive Manufacturing and 3D Printing Research Group (3DPRG), Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

RESEARCH: BUILT-TIME, ENERGY CONSUMPTION, PRODUCTION COST

 Specifications Profile

Cm3 / cm2x1cm 96.645 20.618 16.05 16.8

(3mm thick) (2mm thick)
AM tech AM machine
DMLS EOSINT M270 Build rate
g/h : 37.58
Energy 205.98 43.94 34.1865 35.784
MJ/cm3 : 2.13 MJ/part MJ/part (x100/m) (x100/m)

Cost 990.61 211.33 164.51 172.2

$/cm3 : 10.25 $/part $/part (x100/m) (x100/m)

Material Object Build rate

Jetting Connex 260 cm3/h : 17.75
Energy 10.63 2.27 1.7655 1.848
MJ/cm3 : 0.11 MJ/part MJ/part (x100/m) (x100/m)
Cost 247.41 52.78 41.088 43.008
$/cm3 : 2.56 $/part $/part (x100/m) (x100/m)

EBM S12 EBM Build rate

g/h : 69.24
Energy 45.42 9.69 7.54 7.90
MJ/cm3 : 0.47 MJ/part MJ/part (x100/m) (x100/m)
Cost 384.87 81.85 63.72 66.70
$/cm3 : 3.97 $/part $/part (x100/m) (x100/m)

PROTOTYPE A SEGMENT OR A POLIFUNCTIONAL CUSTOMIZED UNIT OF A CURTAIN WALL

 SYSTEMS ASSEMBLY

http://www.projectara.com/
http://gigaom.com/2014/04/16/googles-project-ara-still-has-a-
long-way-to-go-before-modular-smartphones-become-a-thing/

STATE OF THE ART OF THE INDUSTRY

 SYSTEMS ASSEMBLY

https://www.tno.nl/am
https://www.tno.nl/downloads/LR%20Leaflet%20
Fast%20and%20Flexible%20production21.pdf

STATE OF THE ART OF THE INDUSTRY

 RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY
APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
 3D printing IS COMPETITIVE
with traditional processes and products

Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED

Courtesy of Buswell, Soar, Gibb and Thorpe

3D PRINTING - BENEFITS FOR THE INDUSTRY

 3D printing IS COMPETITIVE
with traditional processes and products

Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED

Courtesy of Buswell, Soar, Gibb and Thorpe

3D PRINTING - BENEFITS FOR THE INDUSTRY

Pilot studies show three key issues that affect how Freeform
Construction impacts traditional methods:
1) COST
2) TIME
3) VALUE ADDED

Courtesy of Buswell, Soar, Gibb and Thorpe

3D PRINTING - BENEFITS FOR THE INDUSTRY

 General Problems Possible Approaches to Solutions

1) Delivery components large enough for building structures = not scaled up RM

segments new systems and processes

2) Material cost and its heterogeneity integral part of new delivery systems

3) Construction speed is not greater than in traditional approaches the

automation process should be re-designed

4) A greater performance of building elements, build-in materials and

specialists applications clever innovative design

3D PRINTING - BENEFITS FOR THE INDUSTRY

 DUS Dutch architects/ KamerMaker XL

http://vimeo.com/80355705 0:13 1:07

RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
 Mbius, Landscape House Janjaap Ruijssenaars
Universal Architecture
D-shape Dini + Rinus Roelofs

Enrico Dini The Man Who Prints Houses

http://vimeo.com/29984723# 00:39-1:34

RESEARCH/ CURRENT PROJECTS OF THE TECHNOLOGY APPLICATION IN BUILDING DESIGN / CONSTRUCTION INDUSTRY
 Courtesy of Joris Laarman Lab Courtesy of Berok Khoshnevis, USC
http://www.youtube.com/watch?v=NFF0QQIQDXE 0:07-1:00 Contour Crafting: Automated Construction: Behrokh Khoshnevis at TEDxOjai
Sciaky http://www.sciaky.com/additive_manufacturing.html 0-1:27 https://www.youtube.com/watch?v=JdbJP8Gxqog 6:45 8:09

AUTOMATION IN CONSTRUCTION / RESEARCH PROJECTS