Lithographiebasierte Generative Fertigung: Verfahren ... Generative Fertigung: Verfahren,...
Transcript of Lithographiebasierte Generative Fertigung: Verfahren ... Generative Fertigung: Verfahren,...
Lithographiebasierte Generative Fertigung:
Verfahren, Anwendungen und Werkstoffe
J. Stampfl
1Mar. 2016 ERFA AM Leoben
Market Volume
Mar. 2016 ERFA AM Leoben Folie 2
Mill
ion
en
Te
ilep
ro J
ah
r
0
500
1000
1500
2000
2500
3000
3500
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Mio
. USD
Products Services
Worldwide revenues (Million US$).
green: Systeme, blue: Services
Source: Wohlers 2014
Materialverkäufe
Mar. 2016 ERFA AM Leoben Folie 3
Davon: 298Mio$ Photopolymere
160Mio$ Polymere Lasersintern
50Mio$ Metalle Lasersintern
Can we 3D-print it?
Mar. 2016 ERFA AM Leoben Folie 4
Stephansdom 1:400 000
Aerospace Biomedical Industry
nm-scale m-scale
Internet based manufacturing
Mar. 2016 ERFA AM Leoben Folie 5
B2C:
• Thingiverse
• Shapeways
B2B:
• Formerly known as
service provider
(Automotive, Product
Development)
Customized manufacturing
Mar. 2016 ERFA AM Leoben Folie 6
Market: 100.000 aligners per day
Largest use of AMT
Source: Align Technologies
Hearing aid shells
Mar. 2016 ERFA AM Leoben Folie 7
>90% of hearing aid shells are made by AMT
Dilemma of 3D-Printing
Materials
Geometry
Economics
FDMSLS SLAInkjet Printing
-Brittle
photopolymers
Medium surfaces
+Good precision
+Cheap
+Fast
+Polyamide
+Many metals
+Good precision
-Rough surfaces
+Costly systems
-Slow
+ABS
+PLA
-Poor precision
-Rough surfaces
+Very cheap
Medium build
speed
-Brittle
photopolymers
+Good precision
+Good surfaces
+Cheap
+Relatively fast
Mar. 2016 ERFA AM Leoben Folie 8
Additive Manufacturing Technology (AMT)
Mar. 2016 ERFA AM Leoben Slide 9
• Structuring methods:
• Two photon polymerization,
• Digital Light processing
• Benefits of lithography-based AMT:
• High resolution (<100nm)
• Tailoring material properties is easy
• In-vivo-writing
10mm
L-AMT in Wien
Mar. 2016 ERFA AM Leoben Folie 10
TU Wien (Prof. Liska, Prof. Stampfl)• 30 Mitarbeiter AMT Gruppe• >15 Patentfamilien, >70 referierte Journal
Papers, • EU: FP7, H2020, ERC, • National: FFG Leitprojekt, FWF, CD Labor,
Houska Preis• Firmenprojekte Gesamtvolumen >2,25 Mio €:
Lie, CH, D, Il, USA, F
Lithoz GmbH (Keramik)• 90% Exportquote, 25 Mitarbeiter
Cubicure GmbH (Polymere)• 4 Mitarbeiter
Verfahren
Mar. 2016 ERFA AM Leoben Folie 11
DLP
ERFA AM Leoben Folie 12
1
2
3
45
6
1 Light Source (LED 450nm)
2 DMD Chip
3 Optics
4 Coating system
5 Tiltable vat
6 Build platform
Resolution: 40mm
Build-size: 80x45mm²
Build-speed: 10mm/hour
"Lichthärtende Schlicker für die stereolithographische Herstellung von Dentalkeramiken"; US7927538 (B2) 2008
“Device and method for processing light-polymerizable material for the layered assembly of molds”, WO2010045950
“Method and device for generative production of a mould with non-planar layers”, EP2251185 (A1),
“Device and method for processing light-polymerizable material for building up object in layers”, WO2010045951 (A1),
Mar. 2016
L-AMT in Wien
ERFA AM Leoben Folie 13Mar. 2016
Lithoz GmbH
(Weltmarktführer Keramik 3D-Druck)Cubicure GmbH
Förderung Wirtschaftsagentur Wien
Two-photon-polymerization
ERFA AM Leoben 14
Voxel(Width ~ 100 nm)
Sun, H.-B.; Kawata, S.Journal of Lightwave Technology; 21; 624-633; (2003)LaFratta, C. N.; Fourkas, J. T.; Baldacchini, T.; Farrer, R. A. Angewandte Chemie, International Edition; 46; 6238-6258; (2007)
Mar. 2016
Zweiphotonenpolymerisation
Mar. 2016 ERFA AM Leoben 15
TU WienStephansdom
1:400 000
N. Pucher, A. Rosspeintner, V. Satzinger, V. Schmidt, G.
Gescheidt, J. Stampfl and R. Liska, Macromolecules,
42, 6519–6528, (2009).
K. Cicha, Z.Li, K. Stadlmann, A. Ovsianikov, R. Markut-
Kohl, R. Liska, J.Stampfl, J. Appl. Phys. 110, 064911
(2011)
Fast 2PP writing
Mar. 2016 ERFA AM Leoben Folie 16
Resin: Methacrylat
Initiator: R1
Writing speed increase:
From 50mm/s to 5000mm/s
3D CAD Model of race car:
Dimensions of
330x130x100µm3
Precision of ±1µm
Fabrication time 4 minutes
Werkstoffe
Mar. 2016 ERFA AM Leoben Folie 17
Ceramics
Ceramic restorations (crowns, bridges):
• Esthetics
• Mechanical properties
• Process time
AMT for digital dentistry
Christian Dopler Laboratory for
Photopolymers in digital and
restorative dentistry (2012-2019)
Mar. 2016 ERFA AM Leoben Folie 18
Material properties ceramics
[1] Verband der Keramischen Industrie e.V., Brevier Technische Keramik, 2003, p.270
[2] L.L. Hench et al., “Properties of bioactive glasses and glass-ceramics”; pp. 355–363 in Handb. Biomater. Prop. Edited by J. Black and G.
Hastings. Springer US, 1998
[3] R. Felzmann et al, Adv. Engng. Material 2012.
[4] G. Mitteramskogler et al., “Light Curing Strategies for Lithography- Based Additive Manufacturing of Customized Ceramics”, Euromat 2013
[5] R. Gmeiner et al., “Stereolithographic Ceramic Manufacturing of High Strength Bioactive Glass“, accept. & await. publication in Int. J. Appl.
Ceram. Tec., 2014
Material
Al2O3 ZrO2 45S5 Bioglass®
Measured biaxial bending strength
(MPa) 516 [3] 1009 [4] 124 [5]
biaxial bending strength in
literature (MPa) 300-580 [1] 1000 42 [2]
Density (g/cm³) 3,82 5,9 2,7
Relative Density (%) 99,6 99,92 > 99
Solid loading – green parts (vol%) 50 42 47,7
Max. building speed. (mm/h) 9 7 7
Mar. 2016 ERFA AM Leoben Folie 19
Ceramics
Bioglass
Alumina
Zirconia
Mar. 2016 ERFA AM Leoben Folie 20
Polymere
Source: T. Swetly, Capabilities of additive manufacturing technologies (AMT) in the
validation at BMW, Rapid. Tech, Mai 2014
SLA FDM SLA SLS Casting
Ch
arp
y Im
pa
ct S
tre
ng
th [kJ/m
²]
Mar. 2016 ERFA AM Leoben Folie 21
Commercial SLA resins
Mar. 2016 ERFA AM Leoben Folie 22
Commercial SLA resins
Mar. 2016 ERFA AM Leoben Folie 23
Structure-property relations
Properties of photopolymer Increase
crosslink density
Increase
intermolecular
forces
Increase molecular
weight of
monomers
Glass transition temperature Tg ↑ (+) ↑ (+) ↑ (+)
Impact strength (toughness) ↓ (-) ↑ (+) ↑ (+)
Elastic modulus ↑ (+) ↑ (+) ↑ (+)
Polymerization shrinkage ↑ (-) ↔ ↓ (+)
Processability (viscosity) ↔ ↓ (-) ↓ (-)
Reactivity ↑ (+) ↔ ↓ (-)
Better thermo-mechanical properties (Tg, toughness)
Intermolecular bonding (H-binding)
High molecular weight MwDifficulty processing
Mar. 2016 ERFA AM Leoben Folie 24
Monomers & Fillers
spacerN
HO
O
O
O
R
N
H
O
OO
O
R
Polyester UMA
Good thermo-
mechanical properties
low shrinkage
Isobornylacrylate (IBOA):IBOA
Reactive diluent
High Tg
Urethane (meth)acrylate (UMA):
Core-Shell particles (CSPs):
soft core
rigid shell
CSP
Toughening agent
Mar. 2016 ERFA AM Leoben Folie 25
Toughening with CSP
Sample
Nr.
UA
[wt. %]
IBOA
[wt. %]
CSP
[wt. %]
Charpy
[kJ/m²]
Tg tan δ
[°C]
1 88,0 12 - 15,0 69
2 91,0 9 - 39,3 70
3 99,0 1 - 42,1 75
4 86 3 10 57,3 72
Accura X. 37,4 70
Mar. 2016 ERFA AM Leoben Folie 26
Formulation 2M
No redardation
Cheap Synthesis
Mechanical Properties
Unique Advantages
Ductility
Formulation 2M + 20% CTA
Mar. 2016 ERFA AM Leoben Folie 28
The Scientist, 2004
The Economist, 2010
29
Robotization and automation
help to transform emerging
promising technologies into
economically feasible
industries!
Organ Printing
Mar. 2016 ERFA AM Leoben 29
Osteochondral Scaffolds
Mar. 2016 ERFA AM Leoben Folie 30
J-H Shim et al, Biofabrication 8 (2016), 014102
Osteochondral Scaffolds
Mar. 2016 ERFA AM Leoben Folie 31
J-H Shim et al, Biofabrication 8 (2016), 014102
Bovine serum albumin + vinyl ester
Mar. 2016 ERFA AM Leoben Folie 32
J.Torgersen, X.H.Qin, Z.Li, A.Ovsianikov, P.Gruber, R.
Liska and J.Stampfl, Adv. Func.Mat 2013, DOI:
10:1002/adfm.201203880
BSA-SH: Bovine serum albumin macrothiol
GH-VE: Gelatine hydrolisate vinyl ester
Biological materials for 3D-environments
Mar. 2016 ERFA AM Leoben Folie 33
X 25
Y 00
100 mW
X 15
Y 10
330 mW
• X% Bovine serum
albumin
• Y% Gelatine
hydrolisate
• 75% PBS buffer
• 0.5wt% WSPI
• Suitable for in situ
applications
X 16
Y 09
280 mW
500
µm
500 µm
Qin et al., Manuscript in Preparation
Summary
FFG Leitprojekt
• L-AMT führend hinischtlich Präzision und
Auflösung
• Herausforderungen liegen vor allem im
Materialbereich
• Prozesseite hat große Fortschritte gemacht
(Durchsatz, Kosten, Zuverlässigkeit)
• Ziel muss es sein, zu produzieren (Biomed,
Individualisierung, Kleinserien, ..)