AMC 2018 Sessions Highlight Innovation in AM Technologies

Did you know? Registration is now open for the Additive Manufacturing Conference (AMC 2018), scheduled for September 11–12, 2018. This year’s conference is returning to North America’s largest manufacturing event, the International Manufacturing Technology Show (IMTS), at McCormick Place in Chicago, Illinois.

Details regarding conference speakers and sessions are available now as well. Check out these abstracts so you can begin planning your AMC 2018 agenda: 

Should Your Manufacturing Technology Be Ambidextrous?

Dr. Jason B. Jones, President, Hybrid Manufacturing Technologies

The commercial advent of hybrid CNC machines incorporating directed energy deposition (DED) only five years ago has enabled a new level of processing flexibility and attracted the co-location of additional capabilities—all essentially extending the multi-tasking capability of machine tools. This presentation examines and shares lessons learned from the very first commercially available, open-architecture hybrid CNC systems implemented until now. Beyond the headlines and the hype, the newfound ambidexterity for seamlessly switching from adding material to removing it has found various applications all centered around one common theme: the ability to simplify. Importantly, a classification framework is proposed herein for understanding the many variants of hybrid processing, including those commercialized to date, which also reveals near-future implementations.

Accelerator-Based, Large-Format Computed Tomography for Additive Manufacturing

Jesse Garant, president, Jesse Garant Metrology Center

Industrial computed tomography (CT) is an innovative x-ray technology ideal for internal inspection of complex, 3D-printed parts. As a non-destructive testing (NDT) method that provides non-contact inspection, CT is primed to meet the challenges of additive manufacturing. This presentation will discuss high-energy CT using a linear accelerator, which has yielded significant reductions in inspection time for larger parts and cleaner imaging of internal components. This translates to savings in cost and time as well as improved quality management and part development for industries like aerospace and automotive. This presentation will also cover the types of analyses available with high-energy CT scanning.

Parameter Development for Aerospace Applications

Matt Tusz, director/co-founder, Magnitude Innovations Inc.

Just like no pair of shoes is ideally made for any given foot, metal processing parameters are designed for fulfilling multiple material requirements independent of geometries. In critical aerospace applications, process limitations are sometimes discovered much too late for significant delays and cost overruns to be avoided. Based on this demand and Magnitude’s experience, we present a methodology and success story of an application that demanded significant parameter redesign and optimization to meet final application needs. Through this example of an aerospace titanium hydraulic manifold, we address the challenges faced with printing large geometries that are victim to extreme residual stresses, subsurface porosity and high-fatigue requirements and demonstrate how this approach can be transferred to other specific applications.

Can AM with Titanium Beat Carbon Fiber on Lightweight Parts on a Like-for-Like Basis?

Dimitris Katsanis, founder/CEO, Metron Advanced Equipment Ltd.

Carbon fiber (CF) is a fantastic structural material. It is light and strong, and it can be molded into smooth aerodynamic and organic shapes. Being anisotropic, the main strength of the material is coming from aligning the fibers against the primary load path on the component. Titanium, on the other hand, is isotropic, is almost three times the density of carbon fiber but is not really any stronger. With the advent of additive manufacturing, aerodynamic and organic shapes can now be manufactured using titanium alloys. At the beginning of this project, it was not expected that the titanium replacement would be lighter than the CF component. So, we set out to make it as light as possible and at the same time pass the same maximum load and fatigue strength tests. Complex internal structures designed to take the load, the Ti material varied in thickness from about 1.5 millimeters down to a minimum of 0.4 millimeter. After several loops of FEA, the internal geometry of the part was fixed. Very short supports were placed in some areas and either totally omitted in others, or different structures were used as supports. The component was then segmented so it could fit into the build chamber of an ARCAM Q10. When the parts were cleaned and joined together, the weight was about 10 percent less than the CF part and passed strength tests.

Designing for HP’s Multi Jet Fusion: 3D Printing Production and Prototype Parts

Jon Eric Van Roekel, Process Engineering Manager, 3D Printing, Protolabs

John Briden, Sr. R&D engineering manager, HP Inc.

Multi Jet Fusion (MJF) 3D printing is more than just a rapid prototyping service. MJF is a new 3D printing technology that also allows designers to manufacture cost-effective production parts and reduce part components while receiving the parts fast enough to accelerate the development cycle. In order to utilize this technology to its full potential, one must understand the design considerations of MJF. This presentation will explain exactly how the process works, including feature and powder removal, and explore the process limitations of MJF. It will also go in-depth on how to optimize part geometry to capitalize on the benefits of the new technology for both production and prototype parts. The presentation will also highlight how HP’s Immersive Systems group partnered with Protolabs to incorporate MJF end-use parts into its next-gen production model of an immersive technology device coming to market this year. HP and Protolabs will co-present this session, discussing the key development and manufacturing challenges they were able to address by using the MJF process not only for prototyping but also the production phases.  

Advancements in AM Facility Safety Standards

Speaker TBA, UL

The introduction of additive manufacturing (AM) technologies has the potential to transform modern industrial production, but it also brings new considerations for manufacturers and their employees. These considerations include potential safety risks and various hazards associated with the material, equipment and facility where parts are manufactured using powder-based AM techniques. Further, AM capabilities can be particularly complex when introduced in existing production facilities with established safety management practices. This presentation will discuss the AM industry’s first standard for AM Facility Safety Management; UL 3400. Covering topics such as hazard classification, design requirements, applicable standards, process safety information, SOPs, emergency planning and response, and process hazard analysis, UL 3400 addresses the potential hazards and risk mitigation measures required for safe functioning of the facility. This presentation will also cover how to navigate the requirements of your local municipality and the alignment to ASTM, NFPA, OSHA, International Building Codes (IBC) and other relevant standards.

CIMP-3D is a World-Class Facility for Developing and Implementing AM Technology for Critical Metallic Components

Dr. Timothy Simpson, co-director, Penn State CIMP-3D

CIMP-3D serves as the DARPA Open Manufacturing Program’s Manufacturing Demonstration Facility for Additive Manufacturing (AM) and seeks to:

1.  Advance enabling technologies required to successfully implement AM technology for critical metallic components and structures
2. Provide technical assistance to industry through selection, demonstration and validation of AM technology as an “honest broker”
3. Promote the potential of AM technology through training, education and dissemination of information

Unlocking Generative Design Potential with Live Parts

Andy Roberts, inventor Live Parts, Desktop Metal

Join the creator of Live Parts for a deep dive into the cellular growth principles driving Live Parts and a demonstration of its capabilities. Live Parts, the latest development from within Desktop Metal’s research and innovation group, DM Labs, is an experimental, generative design tool that applies morphogenetic principles and advanced simulation to shape strong, lightweight parts in minutes. Powered by a GPU-accelerated multi-physics engine, Live Parts auto-generates designs in real-time. This enables users to quickly realize the full potential of additive manufacturing—including material and cost efficiency and design flexibility. The tool produces functional parts with complex, efficient geometries that are ideally suited for 3D printing. For users, Live Parts requires no prior knowledge of design for additive manufacturing techniques or guidelines. 

Putting Large-Scale Additive to Work in Composites

Austin Schmidt, president, Additive Engineering Solutions

As the technology ecosystem for large-scale additive matures, we are beginning to see tooling applications get proven-out in a variety of industries. The ability to output commodity pellet material, in multi-meter dimensions, with outputs of tens to hundreds of pounds an hour allows for economical use of the technology in numerous applications within the composites industry. In the first part of this talk, we will discuss the expanding ecosystem around large-scale additive. First, we will cover what equipment is needed to get into large-scale additive (printer, five-axis machining center, inspection equipment, etc.). Second, we will look at different commodity thermoplastic materials (ABS, PC, PET-G, PPS, Ultem, Noryl) and their respective applications. Finally, we will review what coatings are available to aid in the manufacturing of production-ready tools. As a case study, we will look at how large-scale additive was used to go from design, to printing, to machining, to pulling a successful carbon-fiber part in 72 hours.