ADDITIVE MANUFACTURING is the magazine devoted to industrial applications of 3D printing and digital layering technology. We cover the promise and the challenges of this technology for making functional tooling and end-use production parts.
Issue link: https://am.epubxp.com/i/700770
8 September 13-14, 2016 | @learnadditive | Connecting Additive Manufacturing + Production 3:30 – 4:00 Designing for Direct Metal Laser Sintering and Selective Laser Sintering Greg Thompson | Proto Labs Direct Metal Laser Sintering (DMLS) and Selective Laser Sintering (SLS) are evolving 3D printing processes that are changing the way parts are manufactured. Both can lead to the reduction of components and assembly times, resulting in tremendous cost savings. Additionally, they're both capable of producing complex geometries that would otherwise be very difficult to machine. But it's important to first understand the limitations of these two processes in order to design accordingly. That may mean putting some of the more conventional design rules aside. During this session we will discuss design considerations, such as surface finish, internal features, stresses and shrink, directional dependencies, and support requirements. Knowing how to work around these potential limitations will open up many new design opportunities. 4:00 – 4:30 High-Performance Alloy Parts via Binder Jetting Rick Lucas | The ExOne Company Additive manufacturing by the powder bed binder jetting process offers a cost-effective method for production of complex shapes in high-performance alloys. The process is very similar to ink-jet printing in which the paper is replaced by a layer of metal powder and the ink is replaced by binder droplets. Each binder droplet impinging on the powder layer agglomerates proximate particles into a voxel, or volume element, which becomes a building block of the final 3D part. However, the printed part consists of, at most, 60 volume percent metal powder. Therefore, thermal processes are used to increase the density of the part and achieve desired physical and mechanical properties. For high-performance alloys, this process involves liquid phase sintering, by which the parts are heated to a temperature slightly above the melting point of the alloy. A small amount of liquid then forms along the grain boundaries in each alloy particle, which promotes sliding and rearrangement of the grains to fill in the space between powder particles. This combined printing and thermal process has been developed to form complex shapes in 316L stainless steel, Inconel 625, and Hastelloy 282. Density in excess of 97% is achieved with properties approximating those of the alloys in cast form. Hipping the parts can be used to reach full density and even greater mechanical properties. This presentation will describe the process development, resulting properties, and some applications in energy, thermo-fluid handling and aerospace. 4:30 – 5:00 Hollow Metal AM Inserts and Liquid Spot Cooling for Injection Molding Scott Kraemer | PTI Engineered Plastics We take plastic injection molding to the next level by incorporating metal additive manufacturing and making it cost effective. We started with conformal cooling and have moved on to hollow inserts and a potentially better cooling strategy with liquid carbon dioxide spot cooling. Let me explain how we were able to combine these two new technologies into the potential future of mold making. By changing the mindset of the subtractive machining methods, we can unlock the potential by thicking about solid blocks differently than we have for the last 50 years.