Michelle terfansky

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The Next Industrial Revolution: Additive Layer Manufacturing and its Transition into Nanomanufacturing

Part 2

Boris Fritz Adjunct Professor Loyola Marymount University Additive Manufacturing Consultant Retired Engineer 5 - Northrop Grumman Aerospace Founder, Past-Chair: NanoManufacturing Tech Group Vice-Chair, Innovation Watch Committee

March 12, 2015

Engineering Systems Class

Print A House, Or An Entire Neighborhood

•  A University of Southern California professor has devised a layered fabrica8on method he calls Contour Cra:ing that he believes could be used to print en8re buildings.

The Multi Prototyping Lab •  h=p://www.rapidprototypingmachine.com/ •  The Mul8 Prototyping Lab is capable of Dual

Addi8ve 3D Prin8ng (ABS and PLA), high-­‐ precision milling, extrusion deposi8on, drop-­‐ on-­‐demand metal (including nanoscale) prin8ng, plus much more. It is capable of producing fully func8onal prototype parts.

•  The Mul8 Prototyping Lab is able to produce prototypes completely in one machine. Not having to move the prototype from one machine to another provides many benefits including lower up-­‐front cost, faster prototyping, higher accuracy, lower prototype produc8on costs, plus much more.

•  MPL wins RAPID 2013 Innova8ve Award.

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Materials Update

•  Voxeljet800 from Augsburg, Germany is the first AM machine to build continuously along one axis with the build plane at a 30 degree angle.

•  They use PMMA – Polymethyl Methacrylate •  Voxel8 from Somerville, MA has officially unveiled their

multi-material electronics printer. The Voxel8 Developer’s Kit is a low-cost 3D printer capable of 3D printing in two materials: PLA and conductive silver ink, with the PLA stored in the base of the printer and the ink located directly in the printhead itself. https://www.voxel8.co

Voxel8

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•  The company will be displaying, alongside their amazing printer, a quadcopter produced almost entirely in one piece from their machine. The PLA and connective circuits of the quadcopter were 3D printed in one go, with the electronics, battery, and motors inserted throughout the printing process.

•  Not only does this hint at the possibility of, one day, 3D printing complete electronic items in one process, but, more immediately, the design of electronic devices becomes free from the two-dimensional plane of a PCB board. Instead of allowing electronic parts to dictate design, Oliver explains that designs will now dictate the placement of electronic parts. As users model new objects, they can weave their electronics into the design itself, allowing circuits to traverse curves and climb walls. Engineers will no longer need to find a location to situate their circuit boards, but can place them wherever they see fit.

Voxel8

https://www.voxel8.co

First 3-­‐D Printed Records Sound Awful—And Amazing

The needle drops and a series of high, repetitive whines come from the

album. Then a crackling sound, and a muffled

guitar riff. Finally, Kurt Cobain’s voice —

audible, but distant and hollow, like he is singing in a tunnel with a scarf

over his mouth. It’s about the worst

version of “Smells Like Teen Spirit” you could find. But it is awesome

all the same for its totally unique medium.

This particular LP is part of the batch of the first

records ever to be created on a 3-D printer.

ChefJet 3D Printer for Sugary Treats

•  Liz and Kyle von Hasseln had modified a 3D printer to churn out custom sugary treats.

•  3D Systems has aquired them to sell 3D printers for crea8ng custom culinary crea8ons.

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ORD Solutions Announces New Food Printing 3D Paste Printer •  h=p://ordsolu8ons.com •  ORD Solu8ons, the Canadian manufacturer, of the wildly successful 5 material/color RoVa3D printer that launched on Kickstarter in July, is shaping up to be a pre=y innova8ve bunch. The company has taken their flexible RoVa3D design and applied it to 3D printed food. They have a paste prin8ng version of their original printer, allowing users to extrude viscous materials, like food silicone & other so: materials. You can swap out the plas8c pouring extruder for a paste extruding syringe. The fully assembled printer is selling for $899 (Canadian Dollars).

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3D Printing of Food for Space Missions

•  Last year’s course included a project on this topic which was co-­‐authored as a paper by the student Michelle Terfansky along with Prof Thangavelu, Prof Khosnevis and myself. It was published as an AIAA Paper early this year and we even had a write up in Wired Magazine.

•  Please see Prof Thangavelu for a copy of the paper.

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Mathematical Art Project •  h=p://bugman123.com/Math/index.html •  This rose is actually a plot of a single,

con4nuous, parametric math equa4on. I got this idea while trying to create a visualiza4on of a spiraling spin-­‐la>ce relaxa4on for a physics experiment involving a Nuclear Magne4c Resonance (NMR) spectrometer.

•  Here is some Mathema4ca code: •  (* run8me: 16 seconds *) •  Rose[x_, theta_] := Module[{phi = (Pi/2)Exp[-­‐

theta/(8 Pi)], X = 1 -­‐ (1/2)((5/4)(1 -­‐ Mod[3.6 theta, 2 Pi]/Pi)^2 -­‐ 1/4)^2}, y = 1.95653 x^2 (1.27689 x -­‐ 1)^2 Sin[phi]; r = X(x Sin[phi] + y Cos[phi]); {r Sin[theta], r Cos[theta], X(x Cos[phi] -­‐ y Sin[phi]), EdgeForm[]}];

•  ParametricPlot3D[Rose[x, theta], {x, 0, 1}, {theta, -­‐2 Pi, 15 Pi}, PlotPoints -­‐> {25, 576}, LightSources -­‐> {{{0, 0, 1}, RGBColor[1, 0, 0]}}, Compiled -­‐> False] 10

The world’s Lirst 3D-­‐printed guitar, October 12, 2012

Desktop 3D Printers & 3D Systems, Stratasys, Bukobot 3D Printer Wiki & Airwolf 3D

Based on the RepRap tradi8on of self-­‐replica8on and open source so:ware, Bukobot can print most of the parts necessary to build a second printer and the so:ware is free to use and modify by all. Bukobot also relies on some of the best aspects of previous RepRap models, while making some improvements along the way, making it is easy to build, easy to use, extremely sturdy, and extremely affordable. Most importantly, Bukobot is designed to expand to fit your needs so that, as you upgrade your model to include more printheads and a larger prin8ng playorm, you can easily incorporate new parts and expand the printer’s structure. This leaves it open to hacks and tricks provided by Bukobot users from the Buko community.

AirWolf 3D is a new company that has a=empted to fix problems that the previous desktop printers had.

World's Lirst printed plane The pres8gious 'New Scien8st' magazine has

featured 'the world's first printed plane' in its 29 July 2011 issue.

A collabora8ve venture between The University of Southampton and 3T, the plane went from drawing board to flight in seven days -­‐ two days for design and five days to produce the component parts using plas8c addi8ve manufacturing. The UAV (Unmanned Aerial Vehicle) has a wing span of 1.5m and was made of four parts (two wings, a body and a nose cone) along with an internal component tray -­‐ all 'printed' using 3T's AM technology. The first flight of the UAV was captured on video by the New Scien8st.

h=p://www.3trpd.co.uk/news/new-­‐scien8st-­‐uav.htm

SULSA is the world's first 'printed' aircraft. (Credit: Project SULSA UAV)

Heading to Costco? Pick Up a 3D Printer from ROBO 3D

•  Everyone’s favorite warehouse club, Costco, will be selling desktop 3D printers star8ng September 19th. The machine that the US’s second and the world’s seventh largest retailer has decided to introduce to their 3 million customers is the ROBO1 3D printer from San Diego-­‐based ROBO 3D.

•  The ROBO1 3D printer is selling with two 1 kg spools of filament at a price of $729.99.

•  h=p://www.robo3dprinter.com 14

SpaceX launches cargo ship with 3-­‐D printer to International Space Station

•  Sept 21, 2014 Dragon should reach the space sta8on Tuesday. It's the fi:h sta8on shipment for the California-­‐based SpaceX, one of two new commercial winners in the race to start launching Americans again from home soil.

•  The space sta8on-­‐bound 3-­‐D printer was developed by Made in Space, another California company. It's sturdier than Earthly models to withstand the stresses of launch, and meets NASA's strict safety standards. The space agency envisions astronauts one day cranking out spare parts as needed. For now, it's a technology demonstrator, with a bigger and be=er model to follow next year.

•  Made in Space – founded in 2010, they have 25 employees and have flown 400 microgravity parabolas with 30,000 hrs of tes8ng.

•  I have arranged to have them as keynote speakers at the RAPID conference in May

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Made in Space Latest News After running for about three months aboard the ISS, the first 3D printer in space has finally sent a bit of itself back to Earth for testing. At 7:44 pm EST yesterday, SpaceX’s Dragon cargo spacecraft landed in the Pacific Ocean, about 259 miles southwest of Long Beach, California. Among the 3,700 pounds of NASA cargo on board, the spacecraft carried 3D printed samples produced on the Made In Space Zero G Printer, currently installed on the International Space Station. In addition to a number of samples, hardware, and data from biology and biotechnology experiments conducted on the ISS, objects fabbed on the Zero G Printer will be returned for study. The printer was first installed on the Space Station last November, where it made the history books as the first 3D printer in space, subsequently performing the first 3D prints in space, including a wrench e-mailed from Earth to the ISS and printed in ABS. Now that they’ve been returned to Earth, they will be compared to their Earth-printed equivalents, the same CAD files manufactured as control objects in the NASA study.

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Made in Space Latest News

Costello continues, “Experiments like 3-D printing in space demonstrate important capabilities that allow NASA and humanity to proceed farther on the journey to Mars.” As braniacs on Earth apply rigorous study to the 3D printed parts to determine the sorts of effects that microgravity may have had on the printing process, the Made In Space printer will continue chugging away. Comparing the materials from space with the materials grown on earth, will give us a better understanding of any significant differences.

Design for RP&M versus traditional design

•  Engineers Must Learn to Design for RP Applications. This Requires a Shift in Approaching the Manufacturing Process. Additive Manufacturing Allows for Parts to Be Made That Would Previously Be Considered Assemblies.

•  Example: Ecs-duct, Part of an Aircraft’s Ventilation System. Presently Made As Kevlar Lay-ups on Mandrels As 5 Separate Pieces, With the Center Vane Embedded in the Plies. The 5 Pieces Have to Be Bonded and Insulated As an Assembly. Many Labor Hours & Several Weeks to Manufacture. Nylon Part Made in 2 Days As One Single Piece on SLS System.

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No More Tooling

• Eventually AM will mean the end of Tooling.

• When the final product can be grown directly with all its inherent features, you don’t need tooling anymore.

• This means not only the cost savings involved with making the tooling but maintaining it over the life of the aircraft. That’s a lot of money!

Factory of the Future

Nanotechnology: The Race for a 2.6 Trillion Dollar Market

We can now buy over 800 products that incorporate nanotechnology, and that number will undoubtedly grow by the time this presentation is given. The U.S. government's National Science Foundation estimates that within a decade, the total market impacts of nanotechnology will reach a trillion dollars. This market includes nanostructured materials ($340 billion), semiconductors and integrated circuits ($300 billion), pharmaceuticals ($180 billion), nanostructured catalysts ($100 billion) and nanotechnology-enabled aerospace products ($70 billion). But NSF did not even consider the cosmetics, agriculture, textiles, non-aerospace defense, and non-pharma medical. So their projections may be much too low--by a factor of two and a half (according to Lux Research).

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Nanotechnology Development 500 BC – Colloidal gold/silver 1959 Feynman – “There's Plenty of Room at the Bottom” 1981 Drexler – popularized the term “nanotechnology” 1989 Eigler – built first atom-by-atom constructed structure

Cup of Lycurgus

How big is Nano?

•  Nanotechnology Deals With Materials & Systems That Have At Least One Dimension Of About 1 To 100 Nanometers (Nm). A Nanometer Is 1 Billionth Of A Meter.

•  Ten Shoulder To Shoulder Hydrogen Atoms Span 1 Nanometer (10 Angstroms), 1000 nm = 1 micron, 1000 microns = 1 mm.

•  A DNA Molecule Is About 2.5 nm Wide

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Nanomanufacturing

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Why Do Materials Get Stronger the Smaller They Get?

•  In 1920 A. A. Griffith Wants To Know Why The Actual Strength Of Solids Is Between 1/50 To 1/100 Of The Calculated Theore8cal Strength.

•  Strength Of Actual Glass Fibers Was Only About 25,000 Psi, While Theore8cal Strength Was 2,000,000 Psi – What Gives?

•  Experiments With Glass Rods, Hea8ng And Drawing Thinner And Thinner Glass Fibers. At 1/10,000” (0.0001) The Limit In His Day, The Strength Grew To 1,600,000 Psi. Later Work Of Thinner Fibers Actually Exceeded The Theore8cal Strength.

Cleared for Public Release, Control No. 06-026 dtd. 3/28/06

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Why Do Materials Get Stronger the Smaller They Get?

•  Rather Than The Chemical Bond Strength (Theore8cal Strength) Normal Size Materials Are Actually Controlled By Stress Concentra8ons On The Surface Area Of A Material. One Tiny Scratch Or Crack Is All It Takes.

•  Important Fact About Stress Concentra8ons: A Tiny Hole Weakens A Material Just As Much As A Great Big One! Surface Stress Is Where All The Problems Come From. Most Of These Cracks Are Smaller Than An Op8cal Microscope Can See (Half A Micron). If The Surface Is Made Smooth & Kept Smooth Large Parts Can Be Just As Strong – Which Is Hard To Do. But Nature Has Done It With Abalone Shells Without Needing To Be Smooth At All! Abalone shells withstand hammer blows, yet are made of chalk and calcium carbonate!

•  At Nano-­‐scale The Materials Are At Their Theore8cal Strength-­‐their bond strength. There Is No Room For Cracks between individual atoms!

Cleared for Public Release, Control No. 06-026 dtd. 3/28/06

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Molecular Beam Epitaxy (MBE) • Atomic Spray Painting On Surfaces (CVD) • Builds Materials One Atomic Layer At A Time • Grows Lasers That Read Compact Discs (A

Solid State Semi-conductor Laser) •  Invented in 1968 at Bell Labs • MBE Can Grow Nearly Perfect Crystals One

Atomic Layer At A Time

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Molecular Beam Epitaxy (MBE)

• Over 70% Of The World’s Supply Of Compact Disc Lasers Are Made By MBE

• MBE Is Now Capable Of Creating A Square Centimeter Of Semiconducting Laser – An Enormous Expanse Of Over 1 Quadrillion Atoms – With As Few As 3 Atoms Out Of Place!

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The Varian Gen II Molecular Beam Epitaxy system at UT-Austin

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Self-Replication: Exponential Mfg

•  Nanomanufacturing And Our Rapid Prototyping & Manufacturing Process Have Something In Common: Additive Layer Manufacturing

•  One Ultimate Goal: Self-replication: •  Background – Descartes (1596-1650), •  Theory Of Self-reproducing Automata By John Von Neumann

(1903-1957) •  Simple Example Of Self-replication In Nature: Fire!

•  From RP's Reprap Project To The Fablab At Mit Self Replication Is Finally Taken Seriously For Near Term Results. These Are The Full Scale Initial Attempts At Self-replication

•  Greatest Payoff For Self-replication Is At The Nanomanufacturing Level

•  Software Control Of Matter: Http:// Ideasfactory.Wordpress.Com/

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Kinematic Self-Replicating Machines by Robert A. Freitas

Jr., Ralph C. Merkle •  Most Complete Book On Exponential Manufacturing •  SIMD (Single Instruction Multiple Data) Architecture

•  One Single Data Store Records Instructions •  The Data Store Transmits Information To Trillions Of Molecular

Sized Assemblers Simultaneously •  This Way Each Assembler Does Not Have To Store Entire Program

For Creating Desired Product •  Includes Key Safety Concern: The Self Replicating Process Can

Be Easily Shut Down •  While A Hard Copy Of This Book Can Be Purchased For $142.50,

A Downloadable Version Is Available For Free At Http:// Www.Molecularassembler.Com/KSRM.Htm

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A New Manufacturing Revolution •  Self-replication Was A Dream For Centuries •  It Is Beginning To Happen Now With Limitations But With Rapid

Progress •  It Is Vital To Begin Educating Our Industry That This Is A Viable

Technology That Needs To Be Implemented

Mechanosynthesis and CAD

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