Polymer AM for end-use applications with focus on Vat Photopolymerization - Jasper van Dieten-Blom Marketing Manager Somos® - DSM

1. Jasper van Dieten-Blom
Marketing Manager Somos®
December 1st, 2015
Polymer AM for end-use applications with focus on
Vat Photopolymerization

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DSM’s global presence
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Latin America: *
~1,000 employees
North America:
~5,000 employees
Europe:
~13,000 employees
China:
~3,500 employees
India:
~500 employees
2014:
9,2 Bio€
24000+ people

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TU Delft Nuna solar team 2015
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Somos team 2014, 2015 +5, 2016 +5

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In 3DP from day 1…
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The first Somos®
material and machine
commercialized in 1992.
early 3D Systems Inc.
SL prototype
Back in the days…

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Market Application Mix
Functional parts have grown at the cost of
prototypes, but mix is steadying
Direct & indirect manufacturing have grown
in relative size, market growth >30%
10% 10% 9% 10%
8% 10% 9% 9%
31%
18% 20% 18%
12%
11% 11% 10%
9%
11% 10% 9%
3%
5% 6% 5%
19%
28% 29% 29%
7% 6% 6% 9%
2% 1% 2% 2%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2011 2012 2013 2014
Other
Education / research
Functional parts
Tooling components
Patterns for metal casting
Patterns for prototype tooling
Prototypes for fit & function
Presentation models (incl
architecture)
Visual aids (engineers, medical
professionals, etc.)
61%
49% 48% 47%
12%
16% 15% 14%
19%
28% 29% 29%
9% 8% 8% 11%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2011 2012 2013 2014
Other
direct manuf
indirect manuf
prototype
Source: Wohlers Reports 2012, 2013, 2014, 2015

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Since 1992, vat photo has come a long way
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• Clear transparency
• Fast
• Excellent surface quality
• Highly accurate large parts
• Good mechanical properties
• Good temperature resistance
— Monochrome
— Not the ‘real’ thermoplast
Acrylate-Epoxy
Hybrid technology

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The only 3D printing technology to
produce optically clear durable parts
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Images courtesy of
Malcolm Nicholls Ltd
Clearest materials – prototyping lights

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Clearest materials – see-through-metal?
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Images courtesy of Promethech Software Inc
and Fiat Chrysler
Moisture and temperature resistant
enough for running engine tests

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F1 and WEC windtunnel models
Increased output for winning teams
Toyota Motorsport GmbH won the 2014
Manufacturer's Title in the World
Endurance Championship
Stiffness - mimics carbon
Smooth surface

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AM technologies increasingly used for
manufacturing of end-use parts
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tooling
Casting
patterns
Prototyping
Indirect
manufacturing
Direct
manufacturing
1 part 1 tool 100s parts

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Accelerate verification for white-good product
Images courtesy Wehl & partner
Composite SL material
Tensile Modulus 10 Gpa
HDT 268°C
80 parts PC GF20%

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Cost-effective molding for small series
• 2 glass filled nylon parts for industrial tool
• Quick test for potential design fix
• RP parts or cast urethane would not resist high heat required
• Molded using SL Rapid Tooling > well within the 0.005” spec
• Part size is relatively small, <125 mm
• Part or tooling design still needs iterations
• Verification of design requires final material
• Testing for compliance (UL, CE)
• Quantity of parts is low (less than 100 is ideal)
Current fit for rapid tooling
• Thermally conductive molds with conformal cooling channels
• Software to help print molds ‘easily’
Tomorrow’s solution?

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Investment casting
1. Speed up development of casting design and
casting process by 3D printing prototype
patterns
2. Avoid expensive wax tooling step by printing
each pattern for short series
3. Enable complex designs in casting not
achievable with lost wax method
Material development to assure:
- Cleanest burnout > minimal scrap/rework
- Dimensional stability > accurate large casts
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Image courtesy of Niagara investment castings

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AM technologies increasingly used for
manufacturing of end-use parts
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tooling
Casting
patterns
Prototyping
Indirect
manufacturing
Direct
manufacturing
1 part 1 tool 100s parts

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SL parts in end use applications
Image courtesy Magestic systems inc.
Accurate
Air-tight

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SL parts in end use applications
Image courtesy Toyota Motorsport group
Durable
Smooth

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The part we play…
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19. Jasper.Dieten-van@DSM.com
jasper-van-dieten-blom
www.dsm.com/somos