STRATEGIEN FÜR DIE DRITTE INDUSTRIELLE REVOLUTION · Crystal structure γ- monoklin α-triklin...
Transcript of STRATEGIEN FÜR DIE DRITTE INDUSTRIELLE REVOLUTION · Crystal structure γ- monoklin α-triklin...
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© inspire AG, irpd
Manfred Schmid, inspire AG, irpd, CH-9014 St. Gallen
Berlin, 4. März 2015
STRATEGIEN FÜR DIE DRITTE INDUSTRIELLE REVOLUTION
© inspire AG, irpd
� Introduction
Institute inspire-irpd, SLS principle, plastics pyramid
� SLS-Powders – ‘state of the art’
basic properties, different powders, market & current
assortment, limitations
� SLS-Powders – ‘research & recent developments’
combination of properties, ‘exotic’ polymers and commodities
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University of
Applied Science
Industry
SME‘s
basic application technology product
R&D driven R&D development development
Competence centre for the Swiss Industry regarding production technique and tooling.
Founded on an initiative of ETH-Zürich and machine building industry. Approved as ETH-research annex institute (non-profit foundation).
knowledge and technology transfer process
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Selective Laser Sintering (SLS) - principle
powder
supply
Part
cylinder
sintered
part
Convection
IR heater LASER
Beam
roller / blade for powder distribution
powder
supply
IR heater IR heater� layer thickness: 100 µm
� temperature: 170°C
� CO2-laser: λ = 10.6 µm
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Selective Laser Sintering (SLS): process steps to control
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market
share:
~1%
~5%
~94%
HP –Plastics
Use (°C): 160-260price: > 15 $/kg
Engineering Plastics
Use (°C): < 140price: 5 to 10 $/kg
Standard Plastics
Use (°C): < 90price: < 2 $/kg
amorphous partially crystalline
price
& p
erf
orm
ance
Plastics pyramid: properties, quantity, price
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PA, PET, POM
market
share:
~1%
~5%
~94%
PE, PP, PS, PMMA
HP –Plastics
Use (°C): 160-260price: > 15 $/kg
Engineering Plastics
Use (°C): < 140price: 5 to 10 $/kg
Standard Plastics
Use (°C): < 90price: < 2 $/kg
amorphous partially crystalline
price
& p
erf
orm
ance
Plastics pyramid: properties, quantity, price
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Plastics pyramid: reality for SLS
HP –Plastics : PEK
Engineering
Plastics
Standard
Plastics
: PA12, PA 11
: PP, TPE, PS
price: > 500 $/kg
price: 60 - 100$/kg
price: 60 - 200 $/kg
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Commercial Materials:
PA12 unfilled: 3D-Systems, EOS, Arkema, ALM, Exceltec
differs in particle distribution and recyclability
PA12 filled: 3D-Systems, EOS, ALM, Exceltec, Windform
mainly: aluminum, glass beads, carbon & mineral
PA11 unfilled: 3D-Systems, EOS, Arkema, ALM, Windform
difficult to process but excellent EaB
‘Exotic polymers’: PEEK, PP, PS, TPU, PEPA(X)
Market share:
90-95%
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Arkema (F)Orgasol® Invent Smooth
3D Systems (USA)Duraform® PA
EOS (D)PA2200/2001
Market situation: the commercial PA 12 materials
Evonik (Vestosint®) Arkema (Orgasol®)
PA 2200
µm
DuraForm® PA
µm
Orgasol® Invent Smooth
µm
100 µm 100 µm 100 µm
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Market situation: the commercial PA 12 and PA 11 materials
WindFormDirect sales
ExcelTec (F)Direct sales
ALM (EOS)Direct sales
Arkema (F)Direct sales PA12/11
Evonik Arkema[A]
[B]
[C]
Orgasol® IS
3D Systems (USA)Direct sales
EOS (D)Direct sales
PA 12: Duraform® PA, PA 2200
PA 12 GB filled
PA 12 Al filled
Rilsan® Invent
PA 12 CF filled PA 11 GB filled
[A] neat material[B] confectioner[C] available mixtures
PA 12 MF filled„dry blends“!
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74 J/m ☺32 J/mImpact strength (Izod)
47% ☺14%Elongation at break
37 MPa43 MPaTensile strength
ca. 1'500 MPaca. 1'500 MPaE-modul (MPa)
limited�goodRecyclability
small (<10°C) �large (>20°C)SLS Process window
188 - 195°C178 - 187°CMelting point
α-triklinγ- monoklinCrystal structure
PA11PA12PA12 / PA11 for SLS in
comparison
SLS - Standardpolymere
� suitable sintering temperatures (large window)
� low melt viscosity (for medium mol weight (Mw))
� Intrinsically good mechanical properties (H-bonds)
SLS-Powders – ‘state of the art’
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0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0 10 20 30 40 50 60 70
Young's M
odulus XY [MPa]
Elonga on at break XY [%]
PA12
PA12 Glass Beads
PA12 Carbon fibers
PA12 Aluminum
PA 11
PA 11 filled
PA
12 -
CF
PA11PA12
PA12 GB/MF
PA12 Al
Properties of the commercial PA 12 and PA 11 materials
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0
10
20
30
40
50
60
70
80
Ten
sil
e s
tren
gth
[M
Pa]
XY-direction Z-direction
PA12 types PA11 types reinforced types
still 10-30%
loss of
mechanical
properties in
Z-direction
Anisotropy of properties
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5 main topics:
> Thermal behavior
- sintering window
> Particle
- spherical- smooth surface
> Powder
- distrib. (20-80 µm)
> Rheology
- low zero viscosity
> Optical properties
- absorption 10.6 µm
combination of properties
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thermal situation in building chamber
SLS-Material: thermal situation during build
thermodynamic: super-cooled liquid; meta-stable phase (solid/liquid at the same time)
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Sources: LSS, GmbH/B. Caulfield et al. (2007)
6 controlled zones
2 controlled zones ∆tmax
=10ºC
∆tmax =4ºC 97% area
Temperature distribution build platform surface
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Ts
Lateral growth and
curling trade
off with part
bed
temperature
Lateral growth
Curling
∆T Part bed:
5°C !
164°
C
168°
C
� Thermal control of SLS processing is a key factor for success
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O O C
O
n
Material very expensive and not recyclable!
source EOS
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First TPU for SLS
from Lehmann & Voss
- tricky to process;
- great detail resolution;
- high flexible material;
SLS-Materials: Polyurethan
outstanding
Elongation at break
EaB > 350%
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SLS-Materials: Polyamide 6
Material for increased thermal
and mechanical treatment;
Powder must be in a controlled
drying condition;
Large properties difference
between parts in dry/conditioned
status
Norm Einheit Werte d.a.m. Cond.
Allgemeine Materialkennwerte:
Dichte der lasergesinterten Bauteile ISO 1183 g/cm3 1,13
Wasserabsorption bei Sättigung (23°C RH50)/Artikel ISO 62 % 3,3
Wasserabsorption bei Sättigung (23°C
RH50)/Pulver
ISO 62 % 4,1
Schüttdichte ISO 60 g/cm3 0,6
Partikelgröße (D10) ISO 13320-1 µm 32
Partikelgröße (D50) ISO 13320-1 µm 66
Partikelgröße (D90) ISO 13320-1 µm 122
Mechanische Kennwerte:
Zugmodul (23°C) ISO 527 Type 1A MPa 3360 1270
Reißfestigkeit(23°C) ISO 527 Type 1A MPa 77 40
Bruchdehnung (23°C) ISO 527 Type 1A % 3,4 20
Biegemodul ISO 178 MPa 2500 980
Charpy Kerbschlagzähigkeit (23°C) ISO 179/1fU kJ/m² 2 4,7
Thermische Kennwerte:
Erster Schmelzpunkt (2°C/min) ISO 11357-3 °C 210
Wärmeformbeständigkeit (0,45 MPa) ISO 75/Af °C 191
Wärmeformbeständigkeit (1,8 MPa) ISO 75/Bf °C 77
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SLS-Materials: iCoPP
authorized by:iCoPP polypropylene (PP) for Selective Laser Sintering!
� outstanding impact and chemical resistance� sterilisable (medical)� sealability with other PP-parts
� Special powders designed for cosmetic industry: > 150 €/kg!