1. Why the use of 3D Printing Improves the Engineering Field

2. How the 3D Printing Process Works Create the 3D part model Load the model into the printer and let the additive manufacturing process take over – 3D printers build parts layer by layer until the part is complete (as opposed to being pressed, casted, etc) Apply finish to the part if needed – Printed parts may need to undergo finishing steps in order to create a smooth part

3. Types of 3D printing and usable materials 3-D Printing Technologies TechnologyDescriptionApplicable MaterialsKey Players Stereolithography Selectively cures a uniform layer of material with a UV laser Photopolymers3D Systems Digital light processing Cures an inkjet-deposited material layer in a support material with a UV light PhotopolymersTexas Instruments, Envisiontec Polyjet Cures an inkjet deposited layer with multiple materials using a UV light Photopolymers Objet (Stratasys) Selective layer sintering Selectively fuses material powder using a laser Thermoplastics, metals EOS, Morris Technologies (GE Aviation), Optomec Electron beam melting Selectively fuses material powder using an electron beam MetalsArcam Selective heat sintering Selectively fuses material powder using a thermal head ThermoplasticsBlueprinter Fused filament fabrication Extrudes a material filament through a heated nozzle Thermoplastics, food, wood and ceramic composites with a thermoplastic binder Stratasys, Makerbot, Printrbot Powder bed inkjet printing Selectively inkjet prints a liquid binder to fix material powder into a solid Thermoplastics, food, wood and ceramic composites with a thermoplastic binder Zcorp (3D Systems), ExOne Laminated object manufacturing Trims sheets of material and joins with adhesive Paper, polymer films, metal sheets Mcor, TNO, Solido, Kira Source: Lux Research ©2013

4. Fields of Use Key 3-D sectors Aerospace Materials: Titanium, high-performance thermoplastics, stainless steel, CFRP, GFRP, nickel alloys, cobalt-chrome Use: Engine components, brackets, connectors Medical Materials: High-performance thermoplastics, titanium, stainless steel Use: Implants, prosthetics Automotive Materials: Steel, stainless steel, magnesium, thermoplastics Use: Interior components, aesthetic components, body panels Electronics Materials: Thermoplastics, functional materials Use: Embedded electronics, smart objects, sensors, conductive traces Consumer use Materials: Thermoplastics, paper Use: Art, architectural models, replacement parts Source: Lux Research ©2013

5. Advantages of 3D Printing Fast creation – 3D printed parts have short lead times and can be made on short notice No need for drawings – No need for drawings during prototyping or manufacturing process – Saves time for those making, checking, and approving drawings Not limited by shape and intricacy of part – Manufacturing methods such as casting will be limited in part intricacy due to pouring mechanics – Allows for custom parts to be made with ease Less waste – The additive manufacturing approach keeps waste to a minimum

6. 3 Major Engineering Processes Prototyping Manufacturing Post-Manufacture

7. Prototyping The prototyping process is used to create one or more parts to test in order to produce an improved final product 3D printing aids in this process by… – Creating multiple parts in a short amount of time – Cutting the costs of manufacturing processes, tooling, and machining – Allowing quick changes to be made along the way

8. Prototyping Continued Shapeways = 3D printed Protomold = Molded part Small Bracket = 1 cm 3 Large Jig = 50 cm 3 As you can see, 3D printing has a cost advantage when making a smaller number of parts 3sourceful

9. Ford Example of Prototyping Advantages “Using 3-D printing, Ford saves an average of one month of production time to create a casting for a prototype cylinder head for its EcoBoost family of engines, designed for better fuel efficiency. This complex part includes numerous ports, ducts, passages and valves to manage fuel and air flow.”

10. Manufacturing 3D printers have seen little use in large scale manufacturing due to material costs, but 3D printers are still a viable option because… Cuts cost of tooling and machining (which can be very expensive depending on the process) Tweaking the product is as easy as tweaking the 3D model Can decrease the lead time for customers

11. GE Aviation and Manufacturing GE is building a light aircraft engine – Shaving off 15% of fuel usage ($1 million/year) 3D printers will be used to manufacture parts – “Instead of depositing materials, it uses a laser to turn metal powder into solid shapes, layer by layer. The method simplifies the manufacturing of precisely shaped fuel nozzles that help the engine run at high temperatures without producing nitrogen oxides.”

12. Post-Manufacturing (part of the 3D printing future) No matter the material, a finished product will not last forever. Replacement parts can be hard to come by and expensive. 3D printers allow the manufacturer or customer to replace a broken part with ease and in without having to wait weeks for procurement and shipment – Military example: Build a new part oversees instead of waiting for a new one to arrive. The part file is all that’s needed.

13. Conclusion 3D printers can create parts from thermoplastics, metals, and polymers 3D printers are currently used in many fields and are growing in popularity – Due to its advantages over other manufacturing processes in prototyping, manufacturing, and post-manufacturing

14. Sources Hayes, T. (2013, July). The future of 3-d printing. Retrieved from http://www.osaopn.org/home/articles/volume_24/july_august_2013/features/the_fut ure_of_3-d_printing/ Bullis, K. (2013, May 14). A More Efficient Jet Engine Is Made from Lighter Parts, Some 3-D Printed. Retrieved from http://www.technologyreview.com/news/514656/a-more- efficient-jet-engine-is-made-from-lighter-parts-some-3-d-printed/ Sujay (2013, February 20). Cost = f(size, quantity, technology) + a whole lot more. Retrieved from http://blog.3sourceful.com/post/43619184865/ cost-f-size-quantity- technology-a-whole-lot-more Ford Motor Company’s EcoBoost V-6 cylinder head with DI. (2009). Retrieved August 2, 2013, from: http://www.thecarconnection.com /news/1020747_fords-ecoboost- almost-ready-for-liftoff [Untitled Photograph of Composite fan blade test]. Retrieved August 2, 2013, from: http://www.technologyreview.com/news/514656/a-more-efficient-jet-engine-is-made- from-lighter-parts-some-3-d-printed/ [Untitled Photograph of 3D printing process]. Retrieved August 2, 2013, from: http://shop.felixprinters.com/learn The New Z Printer 850 by 3D Systems. Retrieved August 1, 2013, from: http://i.materialise.com/blog/entry/the-month-of-april-in-3d-printing [Untitled photograph of 3D printed gears]. Retrieved August 1, 2013, from: http://www.3dprintingera.com/how-to-3d-print-gears/

15. Reflective Note My audience here would be those who work with me and are in my field. I felt that they should understand why it is that 3D printing is a manufacturing process that should be used in engineering. This type of document would be presented to my group or sent around to those it pertains to.