1:30 pm – 6:30 pm:
T10-Additive Manufacturing: Design, Test, and 3D Print for Production
(Moderators: Albert McGovern and David Tucker)-Room S320E
1:30 pm – 6:30 pm:
KEYNOTE: Design, Engineer, Test, 3D Print for Production-In That Order
Albert McGovern, Shure
2:00 pm – 2:30 pm:
3 Your Mind: To Print or not to Print, that is the Additive Manufacturing Question
Jim Allen, Vice President – North America, 3YOURMIND
Additive manufacturing (AM) is becoming a larger part of manufacturing, particularly plastics and metals. New technologies and new materials are being introduced on a regular basis. In a few short years, AM has become a more accepted way of producing end use parts and not just prototypes. How can companies that produce plastic parts stay ahead of the curve? How do you know when to produce a part additively versus injection molding or other more traditional technique? What if there was a tool that did this automatically? 3YOURMIND has developed the first automated AM analysis platform. Now decades of AM experience are available in a streamlined platform to inform smart 3D production decisions. We will talk about: • The use of quantitative methods for evaluation as a key turning point in AM production • How early adopters are actively integrating this new technology • The potential savings in time and money by automating this process • How we envision automated AM evaluation will shift in the industry in the next 3-5 years.
2:30 pm – 3:00 pm:
Protolabs: Designing for Industrial 3D Printing
Thomas Davis, Applications Engineer, Proto Labs
Additive manufacturing (3D printing) offers tremendous freedom of design with organic geometries, complex features, and internal channels that can be easily created. In order to take full advantage of the benefits, designers must also account for different considerations than with traditional manufacturing. Resolution, surface finish, feature size and build orientation can significantly impact part cost and performance. It is important to first understand the limitations of the processes in order to design accordingly. This presentation will go into detail on the design considerations for direct metal laser sintering (DMLS), stereolithography (SL), and selective laser sintering (SLS), polyjet, and multi jet fusion (MJF) 3D printing.
3:00 pm – 3:30 pm:
Altair: Effective Subtraction before Additive Manufacturing: The Art of leveraging Constraints
Ravi Kunju, Altair
For highly engineered components, the topological shapes that are generated based on the loads and boundary conditions, can be impacted by the many choices of constraints that are set. Over the years Altair’s Optistruct has developed the broadest set of constraints, and has recently introduced ‘overhang’ constraints for 3D printing so the resulting structure is grown to avoid a specified overhang angle (example: of 45 degrees typically), to minimize areas requiring support. Before embarking on creating a topological shape it is necessary to identify the direction of print, which is a sensitive variable by itself. With a variety of constraints available to a designer, a holistic approach needs to be developed wherein the entire process of manufacturing the part, including post processing operations, are carefully considered including the entire geometry that is printed along with the support structure. A fine balance between the interplay of choosing the right constraints, defining design & non-design space, and the right penalty factors, are critical for generating optimal topological shapes that accommodate, for example: areas for holding the 3D printed part for post-processing; or effectively evacuating the powder in plastic printing; or remove supports in metal printing. In this presentation, examples will be highlighted to showcase how to leverage the latest computational methods to efficiently subtract as much before additively manufacturing components, with a goal to develop an effective and repeatable product design strategy.
3:30 pm – 4:00 pm:
Siemens: Best Practices for Design of Plastic 3D Printed Parts
Ashley Eckhoff, Siemens PLM Software
When designing plastic parts that are to be 3D printed, the designer must consider certain unique characteristics of the plastic printing process. These characteristics imply that different techniques must be used during design of 3D printed plastic parts than what might be used during design of injection molded plastic parts and design of 3D printed metal parts. This session will discuss some of the unique aspects of designing plastic parts for 3D printing as well as unique aspects of the preparation for printing these parts.
4:00 pm – 4:30 pm:
Fathom: The Opportunity with Direct Digital Manufacturing
Tomeo Wise, FATHOM
3D printing is often thought of only during the prototyping phase of product development, but designers and engineers should expect more from the additive technologies and materials available today. By embracing a direct digital manufacturing (DDM) strategy, companies are driving greater innovation, mitigating risk, lowering costs, and gaining agility. DDM enables design freedom, reduces lead times, and allows for more decentralized production, which will have significant impacts on communities across the globe. Ultimately, less rigid development and manufacturing means that more optimized, customized, and specialized products suddenly become viable as the barriers of scale are torn down. In this session, FATHOM will discuss why companies are opting for tool-less manufacturing for end-use products with real world application examples.
4:30 pm – 5:00 pm:
Veryst: Ensuring Mechanical Reliability of Additively Manufactured Parts Through Testing and Simulation
Mark Oliver, Veryst Engineering
Additively manufactured polymers are increasingly being used in mechanically demanding applications. As this trend accelerates, engineers will need to be able to better predict the deformation and failure of polymeric AM materials in service. This involves understanding the properties that often govern failure (fracture, fatigue, creep, etc.) as well as being able to accurately simulate part deformation using finite element analysis. In the first part of this talk, I will discuss how to predict mechanical behavior of polymeric AM parts using non-linear finite element analysis. I will discuss how to measure mechanical behavior, calibrate anisotropic material models, and validate those models using a case study of simulating the strength of a polymeric AM part designed using topology optimization. The second part of my presentation will focus on fatigue and fracture of AM polymers. These properties are not often listed on data sheets but are critical to engineering reliable parts for structural applications. I will present some of the unique attributes of fracture and fatigue in various AM polymers and share new data on materials processes using MJF, CLIP, and SLS.
5:00 pm – 5:30 pm:
3Degrees: How to Approach Material Validation for Production Parts
Mike Vasquez, 3Degrees
As more organizations incorporate additive manufacturing systems to produce production parts, it is becoming clear that successfully moving beyond prototyping requires a more advanced and thoughtful material’s strategy. To achieve the desired outcomes, organizations now need to learn how to build a methodical and scalable system for measuring and characterizing materials that are going into your processing systems. This talk will discuss best practices and standards for developing and executing a successful strategy for both metals and polymers — from benchmarking properties, to creating appropriate operating/storage instructions, to testing and then ultimately tracking the lifecycle of materials throughout your production workflow.
5:30 pm – 6:00 pm:
Case Study: The HP Printer that Prints Itself
Michael Shannon, HP
The case study will provide the roadmap as to how HP’s MJF technology will be used to manufacture components for manufacturing. This case study will go through the different phases of the process that enabled 3d Printed content for the next series of MJF 3d Printers. Including the steps of Assessment, Design, Economics, and manufacturing.