Lect 2. Lean Manufacturing - 3d Printing.pptx

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1. ADVANCED MANUFACTURING SYSTEMS (ME-431) Lecture – 3 Lean Manufacturing, 3D Printing Course Instructor: Dr. Ammar ul Hassan Email Id: [email protected] Department of Mechanical Engineering, University of Engineering & Technology, Taxila

2. I NTRODUCTION Lean Manufacturing is a production process/ methodology based on an ideology of maximizing productivity while simultaneously minimizing waste within a manufacturing operation. The lean principle sees waste is anything that doesn’t add value that the customers are willing to pay for. Lean production is a systematic manufacturing method used for eliminating waste within the manufacturing system.

3. I NTRODUCTION One of the key technology trends in the manufacturing sector at the moment is 3d printing, or additive manufacturing. It has been recognized as a potential industry game changer due to its innovative nature but also because of its lean characteristics. 3d printing has the capacity to reduce waste, save time and thus save money and in a sector, which is constantly being challenged in those areas, it’s no wonder it’s garnering a lot of attention.

4. I NTRODUCTION 3D printing  or  additive manufacturing  is the  construction  of a  three-dimensional object  from a  CAD  model or a digital  3D model .  It can be done in a variety of processes in which material is deposited, joined or solidified under  computer control , with material being added together (such as plastics, liquids or powder grains being fused), typically layer by layer.

5. I NTRODUCTION 3D printing or additive manufacturing , creates physical objects from a geometrical representation by successive addition of materials. 3D printing technology can print an object layer by layer deposition of material directly from a computer aided design (CAD) model.

6. I NTRODUCTION

7. 3D Printing/ Rapid Prototyping & Rapid Manufacturing Companies have used 3D printers in their design process to create prototypes since the late seventies. Using 3D printers for these purposes is called  rapid prototyping .

8. History :

9. History :

10. General principle:

11. How it works:

12. Materials Traditionally, 3D printing focused on   polymers (PLA, PP, ABS)   for printing, due to the ease of manufacturing and handling polymeric materials. However, the method has rapidly evolved to not only print various polymers but also   metals, ceramics and composites ,  making 3D printing a versatile option for manufacturing. Layer-by-layer fabrication of three-dimensional physical models is a modern concept that "stems from the ever-growing CAD industry, more specifically the solid modeling side of CAD.

13. Multi-material 3D printing A drawback of many existing 3D printing technologies is that they only allow one material to be printed at a time, limiting many potential applications which require the integration of different materials in the same object. Multi-material 3D printing solves this problem (using different extruders) by allowing objects of complex and heterogeneous arrangements of materials to be manufactured using a single printer.

14. Processes and Printers The main differences between processes are in the way layers are deposited to create parts and in the materials that are used. Each method has its own advantages and drawbacks, which is why some companies offer a choice of powder and polymer for the material used to build the object.   The main considerations in choosing a machine are generally speed, costs of the 3D printer, of the printed prototype, choice and cost of the materials, and color capabilities.  Printers that work directly with metals are generally expensive . However less expensive printers can be used to make a mold, which is then used to make metal parts.

15. 3D Printer Parameters 3D printer parameters are settings that control how a 3D printer creates an object. These parameters include:  Nozzle size : The size of the nozzle that extrudes the filament  Filament size : The size of the plastic wire that is fed into the printer  Melting temperature : The temperature at which the filament is melted  Bed temperature : The temperature of the heated bed that the print is placed on  Print speed : How fast the print head moves while extruding filament  Layer height : The thickness of each layer of the print  Infill density : The ratio of solid material to the total volume of the print  Infill pattern : The pattern of the internal structure of the print  Support structures : Additional structures that support overhangs or complex geometries  Cooling and fan settings : Settings that can improve print quality and reduce issues  Retraction : Settings that rewind filament at the end of a print move  The right combination of parameters can help ensure that the print is high quality and meets the desired specifications

16. Types of 3D Printers Nozzle Based Laser Based

17. 1 . Nozzle based deposition system Nozzle - based deposition systems or Material extrusion: consist on the mixing of polymers and other solid elements prior to 3D printing . The mixture is passed through a nozzle that definitely originates, layer by layer, the three-dimensional product. And fused deposition modeling: The melted material is deposited layer-by-layer and fused together because the layers are in the molten state as the build platform moves downwards until the finished product is obtained.

18. 2. LASER BASED WRITING SYSTEM

19. LASER BASED WRITING SYSTEM Selective Laser Sintering (SLS) expresses one of the latest and advanced technologies for manufacturing printlets . The essential components of a SLS system are a spreading platform, powder bed, and a laser system (laser and a scanner). After the powder is evenly spread over the building platform, the laser draws specific scanning patterns on the powder surface, which are predesigned depending on the characteristics of the finished product. The powder is sintered by softening or melting of the thermoplastic polymer. Subsequently, the powder bed moves down by a height of one-layer thickness while the reservoir bed moves up to deposit a new powder layer onto the previously sintered layer followed by laser sintering. The process of powder layering and sintering are repeated till desired printlets are formed.

20. 3. Stereolithography Stereolithography is a 3D Printing process which uses a computer-controlled moving laser beam, pre-programmed using CAM/CAD software. Stereolithography is a form of 3D printing technology used for creating models, prototypes, patterns, and production parts in a layer by layer fashion using photochemical processes by which light causes chemical monomers and oligomers to cross-link together to form polymers. The 3-D printer's laser "paints" one of the layers, exposing the liquid plastic in the tank and hardening it. The platform drops down into the tank a fraction of a millimeter and the laser paints the next layer. This process repeats, layer by layer, until your model is complete.

21. 3. Stereolithography

22. 3D Printing materials

23. Polyamide Alumide CARBON FIBER POWDERS NITINOL (Ni- Ti ) GRAPHITE & GRAPHENE

24. Plastic Filament: Plastic is the most common material used in 3d printing because of its low cost and its easy to use, its also the easiest to melt and can solidify at low temperature. Two common 3D printable plastics are ABS and PLA.

25. Acrylonitrile Butadiene Styrene (ABS) ABS is rigid plastic produced from petroleum. It require higher extruder temperature. A heated printing surface is recommended to prevent wrapping of the 3D printed material. While printing ABS there is usually smell of hot plastic.

26. PLA Polyactic acid or polylactide (PLA) Polylactic acid or polylactide  (PLA) is a polyester derived from renewable biomass, typically from fermented plant starch, such as corn, cassava, sugarcane or sugar beet pulp

27. Flexible Plastic:

28. Nylon (Polyamide):

29. Glow in Dark Plastic:

30. Wood Filament:

31. Copper Filament: Copper Filament is printed with a desktop 3D printer. It is similar to printing with actual copper but much easier. The weight of the material is three time heavier than regular PLA filament. Copper filament will print on both heated and non heated build platform. The material has no wrapping issue

32. Powder:

33. Full color sandstone:

34. Flexible and Strong Plastic:

35. Porcelain Ceramic:

36. Metallic plastic:

37. Resin:

38. Metals:

39. Brass, Bronze, Platinum, Gold and silver

40. Steel:

41. Aluminum:

42. Challenges in 3d printing technology The technology is still under the developing stage. Hence it undergoes several challenges such as optimization process, improving performance of device for versatile use, selections of appropriate substance, etc. To improve the performance of 3D printed products and to expand the application range in novel drug delivery systems. To achieve quality 3D Products, many important parameters need to be optimized like printing rate, interval time between two printing layer, distance between the nozzles and the powder layer , etc .

43. Concept Modeling:

44. Functional Prototyping:

45. End Use Parts:

46. Finishing:

47. Advantages Advantages Rapid production of prototypes. Low cost of production. No storage cost. Quick availability of structures. Manufacturing speed.

48. Disadvantages Disadvantages Unchecked production of dangerous items Limitation of size Limitation of raw material Cost of printers

49. Applications:

50. Applications:

51. Applications:

52. Applications:

53. Applications:

54. Applications:

55. Applications:

56. 3D PRINTING PRODUCTS

57. Thanks