1. What is it? Why is it such a “hot” area? How is UL involved?
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. 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. 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. Material Jetting
An additive manufacturing process in which droplets of build material are selectively deposited
Wax or Photopolymers
Multiple nozzles
Single nozzles …

5. Binder Jetting
An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials.
Zcorp
Voxeljet
ProMetal/ExOne …

6. 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. 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. 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. 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. 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. Web 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

12. 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. 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. 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. 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. 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. 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 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. UL Research continued Industry-funded projects Dental projects
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. 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. U of L’s Vision for our Additive Manufacturing Institute
U of L Additive Manufacturing Institute
(Engineering, Medical/Dental, Business, Logistics, etc.)
Bio/Medical Thrusts
(Implants, Tissue Engineering, Dental Restorations Medical Devices)
Rapid Prototyping Center
(product development for industry)
Advanced Materials & Processes Thrusts
(research/development/modeling of machines & materials)

22. 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

23. Questions?