Challenges of material development for Selective Laser Sintering Coachulting Forum 31.1.2018
Agenda About ADVANC3D Materials GmbH Status Quo of SLS Plastic Material Requirements of customers Cornerstones for material development Productportfolio of SLS Powder
About us Founded by François Minec in 2015 putting together know how of several companies Focus on plastic raw materials for additive manufacturing (SLS/FDM) Deliver a superior material to be used on wide range of 3d printing machines.
Material Selection-Status Quo Current material consumption in SLS: 91% 5% 2% 2% PA12 PA11 TPU Others Mainly used products are based on PA12, then PA12 and sometimes PA12 If you prefer you can also get PA12. Users let some space for PA11, TPU and less than 2% some others (TPE, PP, PS ) This does not correspond to the general plastic market in which PP is one of the most common products and PA only a niche ADVANC3d Materials internal data Basically only one manufacturer.
Advantages & Disadvantages of PA 12 Why PA12??? One of the largest processing windows in the market;. Spherical particle shape; Printer compatibility, it was the 1st SLS material -> printers were developed around it; Works well with different additives. Drawbacks Only 50% recycling rate; Limited temperature resistance; Not representative of materials used in most applications; Limited mechanical properties (e.g. in comparison with PA11); Expensive; No differentiation of service between companies.
Material Requirements Market requirements Competitive price Wide range of applications Printer compatibility Availability After processing Targeting all and developing an innovative material is a huge challenge : it means a unique solution What are the technical challenges to create it?
Material Requirements Technical requirements Theory Practice Thermoplastic powder Polymer nature (PA/TPU/PP ) Surface Thermal stability Specific granulometry Flowability Large processing window Powder recyclability
Particle size and Granulometry Each layer build has between 80 and 120 µm depending on the settings chosen. The particles size needs to be smaller than the layer thickness. The granulometric distribution of the powder should be controlled to have a narrow shape. Smooth surface is possible with smaller particle size and the most spherical shape. But: too small particles can be counterproductive. Full control of granulometry and selectivity of size is mandatory for the flow. PSD (Particle Size Distribution) Scan
Particle Shape Depending on its nature a polymer powder will be manufacture by chemistry processes (spherical) or by grinding. The particle shape is crucial for the powder flow.
Processing window and thermal stability PA12 was the first material to be developed for SLS applications. The machines were optimised around it and it s thermal behaviour. T crystallization = 147,4⁰C and T melting 189,1 ⁰C The space between Tc and Tm is called processing window. The larger the processing window is the better is to SLS materials. DSC Scan (Differential Scan Calorimetry)
Processing window of standard polymers PLA PLA Temperature range fits to SLS But: no clear cristallisation temperature PET PET High melting temperature which is not covered by standard printers no clear cristallisation temperature Adaption of the polymere needed to get a material which could work
Powder development, an iterative and long term process 4. Lab scale SLS Pilot scale powder manufacturing Recyclability study 3. grinding, powder modification and testing 5. YES/ NO Real scale testing on SLS machines 2. Material preparation 1. Material theoretical check YES/ NO
Technical assistance as a source of Knowhow
Practical experience to learn more about material and specific behavior Temperature C Material Process Formiga P100 P110 P 380 P 385 P 390 P395 Removal Process Removal Process Removal Process Removal Process Removal Process Removal Process Removal PA12 175 154 174 154-155 174 130 175-176 145 175-176 145 176 133-135 172-173 135 PA12 CF 168-174 153-155 168-174 153-155 168-174 133-135 168-174 133-135 168-174 133-135 168-174 133-135 171,5 133 PA12 HT 175 154 174 154-155 174 132 175-176 145 175-176 145 176 133-135 176 133-135 PA12 LW 175 154 174 155 174 130-135 175-176 145 175-176 145 176 133-135 172-173 135 PA12 GB30 175 154 174 155 174 130-135 175-176 145 175-176 145 176 133-135 172-173 135 PA12 ESD 168-174 153-155 168-174 153-155 168-174 133-135 168-174 133-135 168-174 133-135 168-174 133-135 171,5 133 PA12 Black 168-174 153-155 168-174 153-155 168-174 133-135 168-174 133-135 168-174 133-135 168-174 133-135 171,5 133 PA11 Nat 185-189 150-165 185-189 150-165 185-189 150-165 185 165 185-189 150-165 185-189 150-165 185-189 150-165 PA11 CF 188 150 188-198 150-155 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 PA11 ESD 188 150 188-198 150-155 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 PA11 White 185-189 150-165 185-189 150-165 185-189 150-165 185 165 185-189 150-165 185-189 150-165 186 157-160 PA11 Black 187 156 187-189 155-160 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 185-189 150-165 PA11 GB 185-189 150-165 185-189 150-165 185-189 150-165 185 165 185-189 150-165 185-189 150-165 185-189 150-165 TPU 90 120-130 115 120-130 115 120-135 110 120-135 110 120-135 110 130 110 120-135 110 TPU 90 Black 120-130 115 120-130 115 120-135 110 120-135 110 120-135 110 130 110 120-135 110 PP 132-137 100-110 132-137 100-110 132-137 110-120 132-137 110-120 132-137 110-120 132-137 110-120 132-137 110-120 EOS P396
Wide range of SLS Powder PA11: biobased material with medical and food application PA12: available in natur and black Variations of PA12/PA11: PA12 HT: resistant to high temperatures, nylon based with aluminium PA12/PA11 CF: conductive, nylon based reinforced with carbon fibres PA12/PA11 ESD: dissipative, nylon based reinforced with carbon fibres PA12/PA11 GB 30: reinforced nylon with glas beads PA12 LW: nylon based with hollow glas beads to reduce weight PA12/PA11 FR: UL 94 / V-0 @3.2 mm PP Flex: 50% Elongation TPU: Flexibel, 90 Shore A, no smoke Polysterene (Axalta) PLA (under development)
Thank you for your attention QUESTIONS? ANKE JOHANNES B U S I N E S S M A N A G E R A N K E. JOHANNES@ADVANC3DMATERIALS.COM + 49 152 900 968 49 A D V A N C 3 D M A T E R I A L S G M B H I N F O @ A D V A N C 3 D M A T E R I A L S. C O M