Additive mfg (3D Printing) technologies are evolving so rapidly that one needs to stay on its toes to follow all new leads. Many researchers are focused on developing new technologies while others working tirelessly to improvise the existing ones. Follow my blog if you want to witness the unfolding of next industrial revolution.
In this process objects are created by a 3D printer that uses a digital light projector (DLP) as the light source for curing photo-reactive polymers.
Simplified
Advantage over Stereolithography (SLA)
DLP is generally considered to be faster than SLA, and here’s why:
With SLA, the laser has to individually cure the resin in a “point to point” technique. On the other hand, a DLP projector screen flashes an image of a layer all at once! Thus all points of a layer can be cured simultaneously. In this way, the print speed is increased in comparison to SLA since it takes less time to cure a single layer.
XYZ 3D Printers
A Taiwanese 3D printers company launches a new DLP printer PartPro 120 xP
Connected to my previous Blog, today we are looking at few Additive Carbon-Fiber applications from the Industry.
Carbon Composite Tooling
Dash-CAE an English auto parts manufacturing company, making use of Fortus450mc and Fortus900mc machines to manufacture Tooling, Jigs and Fixtures for Rapid Prototyping and Composite services.
Finished Composite Automotive parts
Ducting for Supersonic Cars
Graphite AM another British engineering service bureau and consultancy firm has confirmed that it is an official 3D printing partner of the Bloodhound LSR supersonic car project. Applying its SLS expertise, the company is supporting the team’s ambitious goal of breaking the land speed record by supplying lightweight and high strength parts for the vehicle.
Carbon Composite Connector Rods
An Athens Greece based Machine Shop Extreme Tuners has created 3D printed carbon composite connector rods for the Mitsubishi Lancer Evolution car.
These Rods according to the company:
Weighs 10 times less than steel rods
Weighs 6.5 times less than Aluminum rods
Can withstand 3000 HP and approximately 15000 RPM
References: Dash-CAE Graphite AM Bloodhound LSR eXtream Tunners Stratasys
Light weight. 70% lighter than steel and 40% lighter than Aluminum.
Highly Strong and Stiff.
Heat resistant.
Posses very low coefficient of thermal expansion.
Highly corrosion resistant.
Resistant to chemicals.
Conductor of heat and electricity.
Challenge in Additive Manufacturing of Carbon fiber Parts
Because of very high melting temperature (around 3600 C) of the Carbon Fiber material, generally used mass manufacturing methods like Injection molding, Blow molding and Die-casting can not be used for Carbon fiber products. The same applies in Additive manufacturing as well. Currently used technologies in additive manufacturing are not capable of handling materials with such a high melting temperature. We can not process carbon fiber the conventional way (Extrusion or Binding and sintering).
Additive Solutions for Carbon Fiber Parts
Composite Parts by ExOne Washout Tooling
ExOne can print on-demand composite parts by their 3D Printed washout tooling.
3D printed soluble support materials are designed to create hollow
tooling and composite parts with trapped geometries. You can order parts
on demand developed with washout tooling for aircraft ducting, pressure
tanks, mandrels and more.
Currently, ExOne only offers printed and coated cores. Composite layup,
curing and washout is completed by our customers using filament winding
or application of prepreg woven fabric. Common layup materials that can
be applied to our cores are: carbon fiber, fiberglass, aramid fiber or
ceramic matrix composites (CMC).
Printing is performed with one of the thermoplastic material by FDM method. During the printing layers of FIBER are laid in certain area of the print to improve tensile strength.
Desktop Metal AFP machines
The company revealed Fiber HT and Fiber LT machines recently. The world’s first desktop 3D printer to fabricate high resolution parts
with industrial grade continuous fiber composite materials used in
automated fiber placement (AFP) processes. Based on a new process called
micro automated fiber placement (μAFP), users can now print parts with a
superior level of strength and stiffness, and in a broad range of
materials, that traditionally required million dollar AFP systems. More can be red about the release here.
Advancement by Anisoprint
Anisoprint CCF (Composite Carbon Fiber) and CBF (Composite
Basalt Fiber) are a composite reinforcing fibers in the form of a tow made of thousands of
ultrathin carbon or basalt monofilaments, impregnated with a special polymer composition
ensuring high-quality adhesion between the polymers and the fiber. Composite fiber is used to
reinforce the plastic during fabrication of the part.
Learn more about Anisoprint products and technology here
Markforged Mark Two
Print composite parts as
strong as aluminum on our top-of-the-line desktop machine. The Mark Two
combines Markforged’s unique continuous carbon fiber reinforcement with
workhorse reliability for the strongest, most versatile parts. As an
industrial 3D printer in a desktop form factor, the Mark Two delivers
high-performance parts straight off the print bed.
Chopped Fiber Filament
In this process shredded bits of carbon fiber are mixed with PLA or ABS or Nylon Or another 3D printing plastic. The filament is manufactured of this mixture of plastic an carbon fiber. In the 3D printing process plastic will be melted and extruded but shredded carbon fibers will be extruded un-melted and will be embedded within the plastic. Carbon fiber enforces the plastic and printed products are many times stronger.
Hobbyists
Can take advantage of open source carbon fiber filaments. There are plenty of brands available on amazon These materials works fine on most personal FDM machines.
Industrial Users
Fortus 380mc and Fortus 450mc industrial FDM machines are able to print high quality and high resolution parts with their Nylon12CF materiel. Find out more about these machines here
Fortus systems are based on Stratasys FDM
technology, so you can build durable parts in production-grade and
high-performance thermoplastics. The Fortus 380mc gives you the option
of up to eight different materials*. The Fortus 450mc lets you build
larger parts with those familiar materials, as well as high-performance
thermoplastics* such as FDM Nylon 12CF (carbon fiber) and ULTEM™ resins,
for specialized industries like medical, aerospace, research and
defense. Create high-performance and complex parts without the need for
additional employee training, as the Fortus systems come equipped with
an intuitive touchscreen interface for an efficient workflow.
*Standard and engineering thermoplastics: Both the
Fortus 380mc and 450mc. High-performance thermoplastics and sacrificial
tooling material: Fortus 450mc only.
ACCIONA, a leading company in sustainable infrastructure solutions,
inaugurated last night in Dubai a new global 3D printing center to meet
the growing demand for 3D printed infrastructure.
Please read more about the project at the link below Acciona 3D Printing Center Dubai
Melbourne based Australian startup developed Titomic Kinetic Fusion (Cold Spray of powder)) to produce load-bearing 3D forms from metallic and
non-metallic powder feedstock. The 2 co-inventors, Mr. Jeff Lang and
Professor Richard Fox, explored IP spraying metal powders at supersonic
speeds onto a scaffold to build a 3D object. This was found to be a
patentable application. The CSIRO patent was licensed and a new company,
Titomic, was established to commercialize this technology.
Why Titomic Kinetic Fusion
At least 5 times faster than fastest Metal AM method out there.
Fuse dissimilar metals for large seamless structures with enhanced engineered properti.
Stronger structures without welding, folding or bending weak points.
Production volumes without extensive production tooling.
Industry-leading build rates, faster manufacturing time & speed to market.
More efficient use of energy and resources, saving production costs.
Observations
As this is a cold-welding operation, it is to be seen that what is the smallest feature it can print.
Accuracy of manufactured parts.
Extensive post processing may require.
More accurate features may require machining.
Company is targeting large size parts specific to Aerospace applications where cost of Titanium is a concern. Big portion of the metal is lost when applying subtractive methods for manufacturing.
Tool manufacturer SANDVIK COROMANT showcased a Milling cutter body (Light Weight CoroMill 390) manufactured by additive.
Advantages:
Light Weight.
Shorter tool body length.
Better tool life.
Silent Tools™ damping technology offers high productivity when machining with long overhangs.
According to Sandvik "When designing lightweight CoroMill® 390, material has been
tactically removed to create the optimal cutter design for minimizing mass. This makes it more compact and significantly lighter than a conventional cutter"
Applications:
Lightweight CoroMill® 390 is designed for long reach face milling, deep shoulder and side milling, cavity milling and slot milling.
To be used at depths more than four times the cutter diameter combined with Silent Tools™ milling adaptor.
