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The Tale of How a Toy Frog Helped Make the Leap into High Tech. Part 2. Development and Perspectives
Getting Started in Control Engineering Russia No. 4’17
The cherished dream of all developers of additive machines has always been metal. If not directly, then indirectly, one way or another, everything comes down to metal. And this is understandable.
It is the metal part that is the “real” product, and not just a model, layout or “prototype” in varying degrees of approximation to the final product. Everyone wants a cherished end product with maximum added value. Machines that make metal parts are the pinnacle of engineering. The most advanced knowledge in metallurgy, laser technology, optics, electronics, control systems, measuring devices, mechanics, vacuum technology, etc. is concentrated here.
One of the first additive manufacturing technologies that made it possible to obtain a metal part immediately, without technological transitions, is selective laser sintering (English Selective Laser Sintering, SLS), sometimes called Direct Metal Laser Sintering (English Direct Metal Laser Sintering, DMLS). The formation of the finished product occurs by sintering any powdered material, which is subjected to melting under the influence of a laser beam. A uniform layer of initial powder is sprayed onto the printing platform, and with the help of laser radiation, it turns into a sintered, solid material.
Then the movable base goes down to the thickness of one layer, and the operation is repeated again: applying the powder, sintering, lowering the base (Fig. 1). The melting process itself takes place in an environment without oxygen access, which avoids the oxidation of the resulting product. Over time, you end up with a hard, fused object buried in unused powder that can be easily scraped off. At first glance, this process resembles the technology of powder metallurgy, but it does not require complex equipment and therefore is a particularly advantageous solution for small batches of parts and products of complex shape. More complete information on this technology, or rather the entire set of "metal" technologies, is given in the NAMI publication [1] - we, as in the first part of this publication, will restrict ourselves to a review of what has already been achieved and what is possible.
Fig. 1. General functional principle of laser sintering technology
In fact, the powder is not melted - it is sintered, i.
e. it is melted only on the surface to connect the layers. However, its complete melting is also possible, leading to the creation of more durable objects. This method is known as selective laser melting (eng. Selective Laser Melting, SLM), which will be discussed below.
Major patents expired in SLS in 2014, reducing hardware costs and allowing further improvements to the SLS process. Now the prices for industrial printers, on which molds for casting high-quality plastic parts are made using the SLS technology, start from ?100 thousand (hereinafter, the prices are given in accordance with [2]).
A problem with SLS technology is that more than 60% of the unused powder is usually wasted as it deteriorates after thermal shock. This impact occurs when fresh powder hits a freshly sintered area or is near the sintering zone. To reduce this loss, small objects can be printed in the hollow parts of larger objects. While this may take longer due to the need to efficiently sort and organize the component parts, the cost per print cycle can be reduced to a more reasonable level.
Printer manufacturer MarkForged has come up with another solution to this problem. It not only allows for efficient disposal of contaminated and spoiled powder, but also potentially maximizes part volume by combining the benefits of SLS and FDM printing. The object creation nozzle distributes the metal powder layer by layer, encased in a plastic binder. During the formation of the part, the intermediate structure is sintered. MarkForged's equipment allows the use of metals such as 6061 aluminum or Ti-6Al-4V titanium, making the company's technology suitable for joints that are subsequently welded onto tubes to create frame structures. MarkForged Metal X printer available for ?93,000 and is the most inexpensive laser sintering process equipment on the market.
Fig. 2. 3D printed titanium seat belt buckle is more expensive than the stamped version, but saves a lot of weight
In terms of materials, in 2014, EOS announced the creation of new metal materials for 3D printing, in particular EOS Titanium Ti64ELI titanium alloy .
The abbreviation ELI stands for "ultra fine grain". This light alloy has high mechanical properties, is corrosion resistant, has a low specific gravity and is biocompatible. An example of a part printed from EOS Titanium Ti64ELI is shown in fig. 2.
EOS Titanium Ti64ELI can be machined, EDM, welded, microblasted, polished and coated. And, importantly, the unclaimed powder of this material can be reused.
The mechanical properties of another printing method, SLM, are very close to those of the powder base material. This means that they can match the strength of cast or milled parts. The advantage of SLM technology is that it allows almost any shape to be printed, while cast parts usually require trade-offs due to metal casting features and machining limitations. But there is also a disadvantage: it is not possible to produce hollow closed parts with SLS/SLM technology, because then an opening must be provided to remove the remaining powder.
Due to the respective properties of the base material as raw material and melt, the well-known aircraft manufacturer Airbus has decided to produce fasteners using SLM technology, which connect the cockpits to the main structure of the Airbus A350 XWB aircraft.
The original fasteners were designed to withstand loads of 3400 kg with an actual load of 1700 kg. Parts made using SLM technology turned out to be 50% lighter, and during the test they broke only at a stress of 13,500 kg. Airbus does not disclose the level of costs that could be higher with SLM technology, but higher payloads or lower fuel consumption usually offset investments in lightweight aerospace structures.
In January 2017, Renault Trucks surprised its customers with an SLS version of the Renault Trucks DTI5 Euro 6 four-cylinder engine (fig. 3), which resulted in 120 kg, or 25%, lighter than its conventionally built engine. predecessor [3]. While both versions of the engine looked the same from the outside, their details, such as the rocker (rocker), clearly demonstrated how much the restrictions imposed by machining or casting processes can be discarded using SLS technology.
Fig. 3. Version of Renault Trucks DTI5 Euro 6 four-cylinder engine made with SLS technology.
Engine parts are printed in red. The picture on the right shows the old and new (printed) valve rocker
Another growing use for 3D printing is tool making. For example, FDM technology allows you to quickly create tools that require resistance to heavy loads. For example, Oak Ridge National Laboratory developed a cutting and drilling tool for the production of Boeing's 777X jet aircraft. Measuring over 5m long and 1.7m wide, this instrument has been listed in the Guinness Book of Records as the largest and strongest 3D piece. It takes just 30 hours to print, which compares favorably with conventional milling and finishing that took several months.
As for the technology of 3D printing of metal products, printers manufactured by InssTek Inc. successfully repair even military aircraft [4], in particular F-15K fighters, which are the main component of the South Korean air force. For this, DMT technology and the flagship Grand Teton 3D printer with a 5 kW ytterbium fiber laser are used (Fig.
4). The printer is capable of processing 2000×1000×1000 mm parts in 5/6 axes and repairs the turbine shell made of titanium alloy and the air seal made of cobalt alloy. The difficulty here lies not only in imprinting a new layer of metal, but also in achieving the same quality as the original metal.
Fig. 4. 3D printer "Grand Teton" (a) and control of the part restored on it (b)
The evaluation of the quality, reliability, safety and compliance with the specified technical characteristics of parts repaired using this technology was carried out by the Korean Aerotechnology Research Institute (Korean Aero Technology Research Institute) and General Electric and InssTek. As a result, the manufacturer received a certificate and permission to use such parts without any prohibitions or restrictions.
SLS and SLM technologies are also becoming increasingly popular in the medical field. For example, the manufacturer of orthopedic implants, Osteo Anchor, has already received awards and patents in connection with the development of a new surface texture for bone implants.
3D printing allowed them to create a serrated surface for cementless fixation of endoprostheses in arthroplasty, which better grips and better interacts with the bone. Implants are made as a single unit from the basic design, but custom variations can be easily made to give them greater biological similarity before printing.
3D printing technology in the field of medicine related to living cells also promises truly incredible opportunities. In Israel, Nano Dimension, which is famous in the world of 3D printing for its pioneering technology for making complex electronic circuit boards, has entered into an agreement with biotech firm Accellta, which creates stem cell culture technologies. The purpose of the agreement is to conduct laboratory tests of a 3D bioprinter.
At the same time, bioengineers from the Wake Forest Institute for Regenerative Medicine (USA) have developed an unusual 3D printing technology that allows you to create full-fledged copies of individual bones, muscles and cartilage from stem cells.
Until now, scientists have been able to print only very thin layers of living tissue (up to 200 microns) - otherwise the tissue began to die, since nutrients and oxygen cannot penetrate to such a depth without the presence of blood vessels. But in this case, they used a special polymer that allows them to lay the cells in layers and at the same time maintain a small gap between them. After printing, bioengineers place the organoid in a mouse, where it gradually “overgrows” with blood vessels, and the polymer decomposes, giving way to them. As a result, a full-fledged organ with the desired shape and all the necessary types of tissue appears at the site of the workpiece [5]. In addition, 3D models are already widely used for planning operations: a doctor can examine a complete three-dimensional copy of a patient's organ [6] (Fig. 5).
Fig. 5. Happy and healthy five-year-old Mia Gonzales shows a 3D replica of her heart, printed on a 3D printer from Stratasys, which accurately showed doctors a heart defect At first, the use of 3D printing in this area seemed impractical, since the layer-by-layer printing of an optical material led to a loss of its optical characteristics.
The problem was solved by LUXeXcel, which drew attention to large-format inkjet printers and their adaptation for printing optical materials [7]. For each optical design, a project is created using CAD and printed out by a printer. Thanks to this approach, the range of equipment and tools that could be required for its implementation (casting machines, diamond cutting and polishing machines, equipment for grinding ingredients) is reduced. In addition, it does not require additional purchase of any tool kits with the need for their constant modification or replenishment.
The print quality problem has been solved by the use of inkjet printers and very fluid materials, resulting in high precision optics with smooth surfaces. At the same time, the design of the optics can be of arbitrary shape, with combinations of different textures and optical elements, and its adjustment to specific requirements makes it possible to go beyond the elliptical (oval) or concentric formation of the beam from the emitter.
Fig. 6. Carclo free-form 3D printed optics
The optics are formed by a jet of a transparent, ultraviolet-curing polymer that is sprayed in droplets at a resolution of 1440 dpi or more. The material used is polymethyl methacrylate or polycarbonate. Drops harden under the influence of radiation from an ultraviolet lamp placed on a piezoelectric print head. The surface is smooth due to the introduced delay between the jet exit and the application of the UV light - this allows an optical quality surface without any grinding and polishing requirements. Today it is already possible to print microstructures or Fresnel lenses, focus on spot lighting, perform light scattering, and finally add color or print prismatic structures (Fig. 6).
What's next? Industrial technology continues to evolve. For example, Made In Space has developed and successfully tested a 3D printer capable of printing in a low-gravity vacuum environment. According to company representatives, now 3D printing will be possible not only on board the ISS (International Space Station), but also in outer space.
The new high-tech 3D printer, known as The Zero-Gravity, will be the first step in space-based industrial manufacturing: it can use approximately 30 different materials to create finished 3D shapes. The presence of a 3D printer is an effective solution that will significantly improve the conditions of stay on the ISS. Now astronauts will be able to print the necessary tools, parts and other items on their own.
Another space achievement will be the launch of a lunar rover, a lunar rover developed by the Google Lunar XPrize contributors from Germany, which is preparing to launch two lunar rovers and visit the lunar module landing site of the Apollo 17 mission [8]. Four-fifths of the lunar rover and some elements of the landing platform, created by the private space company PTScientists (Eng. Part-Time Scientists - "part-time scientists"), are made by 3D printing, including aluminum-magnesium-silicon alloy using Audi technology ( Fig. 7). Not long to wait for this mission, Falcon 9 rocketalready pre-ordered, and its launch is expected within two to three years.
Fig. 7. Lunar rover wheel made of 3D-printed aluminium-magnesium-silicon alloy, held in the hands of PTScientists founder Robert Boehme
materials that change the shape of an object in response to changes in light, heat, water, air pressure, and other factors. To do this, 3D printing is combined with shape memory materials. The MIT Self-Assembly Lab is already working with 4D-printed self-assembly molds made of programmable carbon composites [10]. And at the Livermore National Laboratory. E. Lawrence (Eng. Lawrence Livermore National Laboratory, LLNL) has developed a new technology that allows you to create complex figures on the principle of origami. Researchers already have 3D printed structures that can fold, unfold, or expand and contract in size as a result of electricity or heat.
You need to understand that 3D printing does not work on its own - in addition to a printer, you will need related software and certain skills. But it opens up great opportunities that are unattainable using traditional technologies, and most importantly, it reduces the time from the inception of an idea to the completion of a project.
If you did everything right, then the part, depending on the complexity, will be in your hands in a couple of hours or days. With a ready-made prototype, it is much easier to make and justify decisions. The field of 3D printing is currently dominated by SLS/SLM technology, which offers the designer almost complete freedom, allowing the final product to be lighter in weight and have better strength characteristics than conventional technologies. It is also now possible to print completely dissimilar materials. Multi-color printing has already become common.
Due to the fact that 3D printing technology has literally burst into various areas of the industry, which can be seen even in this overview publication, one problem has arisen with their use. Its reason lies in the fact that these technologies did not come from industry, as is usually the case. They were born outside of it and only after being mastered by amateurs and university students entered various industries [9]. At first, we can say that this played a positive role, since it did not limit the search for optimal options for the implementation and use of 3D printing, but over time, this turned from an engine into a brake.
Each manufacturer went his own way, which led to a lack of common standards and some anarchy.
To solve the problem of standardization, implying the harmonization and compatibility of 3D printing and processes on a global scale, the American National Standards Institute (English National Standards Institute, ANSI) undertook together with NAMII (English National Additive Manufacturing Innovation Institute - National Institute of Innovation for additive manufacturing, USA) [11]. To speed up the development of standards, last year they created two initiative groups. Solving this problem will contribute to the development of the additive manufacturing industry.
This publication has examined a number of aspects and demonstrated the effectiveness of 3D printing technology. Nevertheless, new technologies always need a balanced approach with an assessment of an acceptable level of investment and total costs. Perhaps, based on the amount of work, it will be more profitable for someone not to organize their own 3D production, but to use the services of specialized companies or, with the accumulation of certain experience, rent the necessary equipment.
The purpose of this article was to show the history of 3D printing technology, its applications and opportunities. We hope it has been achieved.
Literature
- Dovbysh V. M., Zabednov P. V., Zlenko M. A. Additive technologies and metal products. Moscow, NAMI.
- Schlenker M. 3D Printing: From Toy to Tools, Smart Industry // The IoT Business Magazine, Avnet Silica 2017.
- Metal 3D printing: technology of the future for lighter and more compact engines. press releases. 01/11/2017.
- Butler B. InssTek Called to South Korea to Use Grand Teton 3D Printer to Repair Fighter Jets.
- www.livemd.ru/tags/3D_bioprintery/
- 3D Printed Heart Model Helps Change Prognosis for 5-Year-Old Mia.
- Hayes K. Multifunctional optics opens up new frontiers for the use of solid-state light sources (SSL) // Semiconductor lighting engineering. 2015. No. 5.
- How to make money on the Moon and Apollo?
- Rentyuk V.
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