1. Additive Manufacturing
ADDITIVE
MANUFACTURING
What is it?
Why is it such a “hot” area?
How is UL involved?
Brent Stucker, Ph.D.
Clark Chair of Computer Aided Engineering
Professor of Industrial Engineering
Mechanical Engineering Associate Faculty Member
University of Louisville
2. Additive Manufacturing
What is Additive Manufacturing?
(3D Printing)
• The process of joining materials to make objects from
3D model data, usually layer upon layer, as opposed
to subtractive manufacturing methodologies
3. Additive Manufacturing
Vat Photopolymerization
• An additive manufacturing process in which liquid
photopolymer in a vat is selectively cured by light-activated
polymerization.
– Stereolithography
– Envisiontec
– Micro-SLA
– …
4. Additive Manufacturing
Material Jetting
• An additive manufacturing process in which droplets
of build material are selectively deposited
– Wax or Photopolymers
– Multiple nozzles
– Single nozzles
– …
5. Additive Manufacturing
Binder Jetting
• An additive
manufacturing process
in which a liquid
bonding agent is
selectively deposited to
join powder materials.
– Zcorp
– Voxeljet
– ProMetal/ExOne
– …
6. Additive Manufacturing
Material Extrusion
• An additive
manufacturing process in
which material is
selectively dispensed
through a nozzle or orifice
– From microns to meters
– Stratasys FDM machines
– Office friendly
– DIY community
– Best selling platform
– …
7. Additive Manufacturing
Powder Bed Fusion
• An additive manufacturing process in which thermal
energy selectively fuses regions of a powder bed
– SLS, SLM, DMLS, EBM, etc.
– Polymers, metals & ceramics
8. Additive Manufacturing
Sheet Lamination
• An additive manufacturing
process in which sheets of
material are bonded to form an
object.
– Paper (LOM)
• Using glue
– Plastic
• Using glue or heat
– Metal
• Using welding or bolts
• Ultrasonic AM…
9. Additive Manufacturing
Directed Energy Deposition
• An additive manufacturing
process in which focused
thermal energy is used to
fuse materials by melting as
they are being deposited
– Wire & Powder Materials
– Lasers & Electron Beams
– Great for feature addition & repair
10. Additive Manufacturing
Engineering & Business
Implications
• More Complex Geometries
– Internal Features & Structures
– Parts Consolidation
• Enables business models used
for 2D printing, such as for
photographs, to be applied to
physical components
– Print your parts at home, at a
local “UPS Store” or “Lowes”
or order through “Amazon-like”
website like Shapeways.com
11. Additive Manufacturing
Web 2.0 + AM =
Factory 2.0
• User-changeable web content plus a network of
AM producers is already enabling new
entrepreneurial opportunities
– Shapeways.com
– Freedom of Creation
– FigurePrints
– Spore
– …and more
11
12. Additive Manufacturing
Impact on Logistics
• Eliminates drivers to
concentrate production
• “Design Anywhere /
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”
13. Additive Manufacturing
AM is Hot This Year…
• Newspapers, magazines, TV shows and technical
publications have all discovered 3D printing via additive
manufacturing
• President Obama & Vice-President Biden have spoken
about the potential:
– The first Institute within the National Network for Manufacturing
Innovation is focused on Additive Manufacturing
• DoD (DARPA), DOE, DHHS, DOC (NIST), NSF and
other agencies funding R&D
• Mergers & acquisitions are in full-swing
• Most major manufacturers are spinning up R&D
14. Additive Manufacturing
University of Louisville’s
Involvement in AM
• One of the best equipped additive manufacturing
(AM) facilities in the world
• Performing federally-funded basic and applied
research, technology transfer and industry-funded
projects in AM since starting with SLS in 1993
• Over 20 people focused on AM
• Partner of leading AM users
– Boeing, GE, EWI, Integra, service bureaus, etc.
• Over 70 member organizations in our RP Center
– Includes Haas Technical Education Center
15. Additive Manufacturing
AM Equipment at UL
• Polymer Laser Sintering (LS)
– 3D Systems (DTM) 2500 plus
(with Multi-zone heating)
– 3D Systems (DTM) 2500CI High
Temperature Research Platform
• Multi-zone heating
• High Speed Scanning
• Direct Metal Laser Sintering
(DMLS)
– EOS M270 Dual Mode
• Electron Beam Melting (EBM)
– Arcam S400
• ExOne 3D Printing
– Dental machine
• Ultrasonic Consolidation (UC)
– Fabrisonic R200 High Power
– Solidica Formation Beta Machine
• Laser Engineered Net Shaping
– Optomec LENS 850
• Fused Deposition Modeling
– Stratasys uPrint
– Several desktop, educational
“material extrusion” machines
• Stereolithography
– 3D Systems SLA 250/30
• Direct Write
– nScrypt Direct Write head
16. Additive Manufacturing
Why Additive
Manufacturing in Kentucky
• U of L has a world-leading capability in additive
manufacturing
– Laser and electron beam powder bed processes for
metals, plastics and ceramics
– Ultrasonic additive sheet lamination and more…
• U of L and other KY institutions can educate &
train the needed workforce
– Entrepreneurs, designers, engineers, doctors, dentists,
technicians, etc.
• The proposed Louisville/Lexington advanced
manufacturing corridor can be a catalyst
17. Additive Manufacturing
Other Louisville/Kentucky
Benefits
• UPS could be a key enabler to the
distributed, on-demand manufacturing
model enabled by AM
• Louisville is a great hub for locating
new AM companies and U.S.
headquarters for foreign companies
• Louisville is a center for medical
innovation
• Northern Kentucky is part of greater
Cincinnati’s aerospace infrastructure
18. Additive Manufacturing
Additive Manufacturing
Research at UL
• Office of Naval Research Direct Digital
Manufacturing – $2.45M grant over 4 years
– Investigating Material Properties of parts made using
AM
• Office of Naval Research Cyber-Enabled
Manufacturing Systems – $1.05M over 7 years
– Ultrasonic Consolidation–related funding
• Multi-functional, multi-material parts
– Dislocation Density based Crystal Plasticity Finite
Element Modeling (DDCP-FEM)
19. Additive Manufacturing
UL Research continued
• Military SBIR/STTRs – over $500k in subcontracts
– High-temp SLS work in support of JSF and more
– Naval scale models (magnetic signature)
– Modeling of metal powder bed fusion
• Industry-funded projects
– 70 members of our Rapid Prototyping Center consortium (19
years of continuous funding)
– Boeing has funded us for more than 10 years
• Dental projects
– Porous titanium implants & new materials
20. Additive Manufacturing
UL Research continued:
• GE Aircraft (in contracting)
– Layer-by-layer process monitoring of metal powder bed
fusion for process model and part quality validation
• NIST (in contracting)
– Modeling of Inconel alloys in metal powder bed
processes.
• NSF project
– Applying DDCP-FEM to friction surfacing additive
manufacturing
21. Additive Manufacturing
U of L’s Vision for our Additive
Manufacturing Institute
U of L Additive
Manufacturing Institute
(Engineering,
Medical/Dental, Business,
Logistics, etc.)
Rapid
Prototyping
Center
(product
development
for industry)
Advanced Materials
& Processes Thrusts
(research/development
/modeling of machines
& materials)
Bio/Medical
Thrusts
(Implants, Tissue
Engineering, Dental
Restorations
Medical Devices)
22. Additive Manufacturing
Conclusion
• Additive Manufacturing is poised to transform the
production of “physical goods” in much the same
way that the internet transformed the production
of “informational goods.”
• UL is leading the way in additive manufacturing
research and implementation
– We are “a” world leader in AM
– Targeted investment and recruiting could make us
“the” world leader in AM
