Three Dimensional Printing

Emanuel Sachs
Professor of Mechanical Engineering
sachs@mit.edu

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1. REPORT DATE (DD-MM-YYYY)

30-05-2001
4. TITLE AND SUBTITLE
Three Dimensional Printing
Unclassified
6. AUTHOR(S)
Sachs, Emanuel ;

2. REPORT TYPE
Workshop Presentations

3. DATES COVERED (FROM - TO)

30-05-2001 to 01-06-2001
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
8. PERFORMING ORGANIZATION REPORT
NUMBER

7. PERFORMING ORGANIZATION NAME AND ADDRESS

MIT
xxxxx, MAxxxxx
9. SPONSORING/MONITORING AGENCY NAME AND ADDRESS
10. SPONSOR/MONITOR'S ACRONYM(S)
Office of Naval Research International Field Office
11. SPONSOR/MONITOR'S REPORT
Office of Naval Research
NUMBER(S)
Washington, DCxxxxx
12. DISTRIBUTION/AVAILABILITY STATEMENT
APUBLIC RELEASE
,
13. SUPPLEMENTARY NOTES
See Also ADM001348, Thermal Materials Workshop 2001, held in Cambridge, UK on May 30-June 1, 2001. Additional papers can be
downloaded from: http://www-mech.eng.cam.ac.uk/onr/
14. ABSTRACT
3D Printing is an SFF Process which creates parts in layers. Each layer is formed by spreading powder and selectively joining the powder by
ink-jet printing of a binder material.
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF:
17. LIMITATION
18.
19. NAME OF RESPONSIBLE PERSON
OF ABSTRACT
NUMBER Fenster, Lynn
Public Release
OF PAGES lfenster@dtic.mil
38
a. REPORT
b. ABSTRACT c. THIS PAGE
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International Area Code
Unclassified
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703767-9007
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427-9007
Standard Form 298 (Rev. 8-98)
Prescribed by ANSI Std Z39.18

3DP Team
TM

FACULTY

RESEARCH STAFF

Emanuel Sachs

James Serdy

Michael Cima

Chris Stratton

Samuel Allen

Benjamin Polito

Nick Patrikalakis
Linda Griffith

Post-Docs and
Visitors
Hiroyasu Tsuchiya
Yasushi Enokido

GRADUATE STUDENTS
David Ables
Ren Apitz
Diana Buttz
David Guo
Richard Holman
Sang-bum Hong
Hongye Liu
Adam Lorenz
Mark Oliveira
Chilukuri Ram
Stephen Smyth
Scott Uhland
Markus Werner
Calvin Yuen

The 3D Printing Process

wmm
u

mmm.
li

Drop Piston

Print Layer

Spread Powder

Any material as a
powder
Scaleable with
multiple nozzles

Repeat Cycle

Local Composition
Control
Ld
Wfc
W/,
Intermediate Stage

W%.

Ld

Last Layer Printed

Finished Part

3D Printing is an SFF Process which creates parts in layers.

Each layer is formed by spreading powder and selectively
joining the powder by ink-jet printing of a binder material.

MITs 8-jet Printhead

Allows for wide range of materials,

precise droplet location and scalability.

Printing a layer

Removing the Green Part from the Powder Bed

Office Modeler;
Z Corp., Burlington, MA

Low cost machine.

Office environment (water binder, starch powder or plaster based)
High reliability.
FAST

Ceramic Molds for Metal Castings;

Soligen, Inc. Northridge, CA

3D Print Ceramic mold

Colloidal silica binder into alumina powder

Fastest route to a casting.

Soligen Operates Parts Now which accepts files
and returns castings.

* It

Filters;
Specific Surfaces, Franklin, MA

Focus: ceramic filters for power

plants - high filter area, durable,
cleanable.
Successful tests in bag houses
(2000 hours). Tests on full scale
pilot plant next. EPRI funded.

Medical Applications;
Therics, Inc. Princeton, NJ

Drug delivery devices.

Scaffolds for tissue engineering.
Direct printing of tissue and
organs.
Direct printing of metallic
prostheses.

Direct Printing of Metal Tooling;

ExtrudeHone Corp., Irwin, PA

Directly print metal tooling.

Polymer binder into metal powder.

Tooling by Direct Printing

Colloidal latex binder
Stainless steel or
tool steel powder

Debind by
thermal decomposition &
pre-sinter to 63% dense

Remove
unprinted
powder

Infiltrate to
full density
with copper
alloy

Green part
58% metal
10% polymer
32% open porosity

Finish

Tool
Insert

Finished Tool and Molded Part

Conformal Cooling in an Industrial Application

Tool made by 3D Printing

with serpentine cooling
channel

Condition #1
Condition #2

Improvement over Production Tool

Cycle time
Part Distortion
15%(limited by sprue)
9%
0%(limited by sprue)

37%

Conformal Cooling; Data from Design of Expts

Typically

20% reduction in cycle time

15% reduction in shrinkage

Schmidt et al, Conformal Cooling vs Conventional Cooling: An Injection

Molding Case Study with p-20 and 3DP tooling, MRS 4/00

Partnership in Technology

EXIRUDEHONE

Blow Mold Cavities

MoldFusion First Design

Two conformal and opposing flow circuits

MoldFusion Second Design

Two conformal linear flow circuits

Turbulence chevron features

Temperature (C)

Demonstration of Performance:Conformal Cooling

70
60
50
40
30
20
10
0
0

60

120

180

240

Time (sec)

Conformal Cooling Condition

Tem p rature
e
[degC]

25

plastic

20
15
10

coolant

si mul ati on d ata

experi men al
t atd a

Mold ( k, r, c)

5
0

30

60

90

T me
i [se c]

L <
k

One cooling
cell

Cycle Time
rc

Adjacent
cooling cell

Conformal Cooling Channel

Design Methodology
cooling
zone 1
Map to
entire
mold
conformal cooling
Design for sufficient cooling
Design for temperature drop
Design for cooling uniformity
Design for pressure drop
Design for mold strength &
deflection
Design for

part
before design

after design
Map to
entire
mold

cooling
zone 2

Surface Textures for Heat Transfer Augmentation

Heat Transfer Coefficient

2

h (W/m -K)
25,000
20,000
15,000

Chevron

10,000
As-printed

5,000

EDM

0
0

4,000 8,000 12,000 16,000 20,000

Reynolds Number

No ribs

Pressure Drop (DP)

DP (psi)
10

Chevron

5
No ribs

0
0

4,000

8,000

12,000

16,000

Reynolds Number

Rapid Thermal Cycle Tooling

Mold
Temperature

Constant Temperature

Tg

Inject
Part
Eject Part

Time

Cycled Temperature

3D Printed Tool for Rapid Thermal Cycling

The tool has cooling/heating channels in the top plate and stands on 2000 posts
(which allow for thermal expansion/contraction)

Homogeneous Metal Parts by Infiltration

~1 min

Porous skeleton of
nickel or other high
temperature material

~1 hour

Infiltration using same

material containing a
melting point depressant
(MPD)

Diffusion of MPD into

skeleton creates a solid
homogeneous part

Liquid
Infiltrant
Nickel
Skeleton

Homogeneous
Final Part

~1 kg infiltrated part (Ni4Si)

Infiltration Distance
Skeleton made of ~ 50150 mm powder (both cases)

Capillary limit

1 2g
h=

rg r
>0.5 m typical for 100 mm
powder

Premature freezing of
infiltrant can choke
liquid flow

Ni infiltrated
with Ni-10Si

Steel infiltrated
with Cu

Solidification Time Sequence

Wire bundle infiltrated and
quenched at various times
Ni wire w/ Ni10Si infiltrant
Infiltrated at 1200C

10 seconds

100 seconds

Initial 50mm wire

5 minutes

Solidification Time Sequence

Wire bundle infiltrated and
quenched at various times
Ni wire w/ Ni10Si infiltrant
Infiltrated at 1200C

10 seconds

100 seconds

Initial 50mm wire

5 minutes

Mechanical Properties
Tensile Tests of Ni-4Si Specimens
Stress (MPa)

500
400
300

Infiltrated Skeleton
Cast Ingot
Inf before heat treat
Inf before heat treat

200
100
0
0

10

15

20

25

30

Strain (%)

Infiltrated skeleton held 12 hrs at 1200C

for homogenization
Cast ingot of same composition
Hopefully Cr or other elements will
provide more strengthening
Infiltrated

Cast ingot

Other Material Systems

AlSi
Low solubility (no freeze-off)
Similar to cast microstructure
Pure Al infiltrated w/ Al12Si at 625C achieved
93.5% density

NiCrSi
solid solution strengthening
keep constant Ni:Cr ratio during diffusional
solidification

Si

1250C

Steel?

Ni

Ni:Cr ratio
constant

0.2
0.4
0.6
0.8
MOLE_FRACTION CR

1.0 Cr

3D Printing: Dry vs. Wet Layer Spreading

Dry

Spherical as small as 10 m
Acycular as small as 20 m

Wet

Anything that
can be slurry
processed

Parts with Fine Metal Powder

Architecture 1: Stationary Bed, Raster Print

Printhead Inspection

Gantry
Fast Axis

Slow
Axis

Z Corp.

Powder Bed

Feed Piston
Powder Spreading Roller

ExtrudeHone Corp.

Small Parts; Distinguishing Features

Powder beds are small , light (<1 kg) and often cohesive.

Perimeter is short
Vector Print the perimeter.

Y axis

Move powder bed

Y axis (Slow axis)

X axis (Fast axis)

Raster printing

X axis

Vector printing

Architecture 2: Moving Bed, Vector Print

2a. Layer Inspection
(Done in transit)
3. Layer
Drying

2. Layer
Forming

4. Binder
Printing
1. Substrate
Load &
Unload
5. Binder Drying

All stations in use all

the time.
Automation ready.
Improved surface
finish.

Barrium Titanate Parts made by 3DP with Slurry

Local Composition Control; Like Color ink-jet Printing,

but with Materials

Titanium Carbide
slurry printed in Moly
powder; 83% dense

Information Flow
CAD
CAD Model
Model
Mesh
Mesh Generator
Generator

(a) LCC object design

Dimension:
- 110mm X 68mm X 30mm in
FA SA, VA, respectively

Tetrahedral
Tetrahedral Model
Model
LCC
LCC Modeler
Modeler
Material
Material Slice
Slice

Geometric
Geometric Slice
Slice

Halftone
Halftone Process
Process
Halftoned
Halftoned Slice
Slice
Encoder
Encoder
Instruction
Instruction File
File
3D
3D Printing
Printing
(d) printed layer

Summary:
3DP for Thermal Management

Cooling/heating channels - high complexity

Surface textures
Macro cellular structures
Locally controlled porosity
Locally controlled thermal conductivity