From additive manufacturing to 3D/4D printing. 1, From concepts to achievements

344 Pages·2017·27.238 MB·English

by  André, Jean-Claude

From Additive Manufacturing to 3D/4D Printing 1
To Laurent and Denis, who allowed me
.
to dedicate myself to additive manufacturing
Series Editor
Jean-Charles Pomerol
From Additive Manufacturing

to 3D/4D Printing 1

From Concepts to Achievements

Jean-Claude André
First published 2017 in Great Britain and the United States by ISTE Ltd and John Wiley & Sons, Inc.
Apart from any fair dealing for the purposes of research or private study, or criticism or review, as
permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced,
stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers,
or in the case of reprographic reproduction in accordance with the terms and licenses issued by the
CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the
undermentioned address:
ISTE Ltd John Wiley & Sons, Inc.
27-37 St George’s Road 111 River Street
London SW19 4EU Hoboken, NJ 07030
UK USA
www.iste.co.uk www.wiley.com

© ISTE Ltd 2017
The rights of Jean-Claude André to be identified as the author of this work have been asserted by him in
accordance with the Copyright, Designs and Patents Act 1988.
Library of Congress Control Number: 2017950122

British Library Cataloguing-in-Publication Data
A CIP record for this book is available from the British Library
ISBN 978-1-78630-119-2
Contents
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxix
Part 1. From Spectacular Applications to
the Economic Market of Additive Manufacturing . . . . . . . . . . . . . . . . . 1
Introduction to Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1. Some Significant Examples . . . . . . . . . . . . . . . . . . . . . . . 7
1.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2. Maritime, military, aerial and spatial applications . . . . . . . . . . . . . . . . . 11
1.3. Conception: art and new domestic applicative niches . . . . . . . . . . . . . . . 14
1.3.1. Art and additive manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.2. Archaeology, museum restoration, reproduction . . . . . . . . . . . . . . . 19
1.3.3. Construction sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4. Mechanical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5. Land transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.6. The question of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7. Toys for the young and the “not-so-young” . . . . . . . . . . . . . . . . . . . . 33
1.8. “Traditional” medical applications . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.9. Animation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
vi From Additive Manufacturing to 3D/4D Printing 1
1.10. Scientific applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.10.1. Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.10.2. Chemical and process engineering . . . . . . . . . . . . . . . . . . . . . . 41
1.10.3. Complex structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.10.4. Toward the infinitely small . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.11. Nanometric origami . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.12. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.13. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 2. Integration of Additive Manufacturing
Technologies into Society . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2. Markets and application domains of 3D printing . . . . . . . . . . . . . . . . . 72
2.2.1. Markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2.2. Principal application niches . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.3. Growth dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.4. Studies on the dynamic of growth . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4.1. Convergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4.2. “Attractiveness” of additive manufacturing technologies . . . . . . . . . . 87
2.4.3. Possible positioning of the industry . . . . . . . . . . . . . . . . . . . . . . 132
2.5. Toward a certain stabilization: The dynamics of innovation . . . . . . . . . . . 140
2.6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.7. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Part 2. 3D Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Introduction to Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Chapter 3. Processes, Machines and Materials . . . . . . . . . . . . . . . . . . 181
3.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.2. Stereolithography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.2.1. History of 2D1/2 processes . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.2.2. Other techniques developed since 1984 . . . . . . . . . . . . . . . . . . . . 191
3.2.3. Light–matter interaction and
space-resolved polymerization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.2.4. Consequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.2.5. Families of materials used . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.2.6. Layer implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.2.7. Coupling of polymerized surface generation
and volumetric reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Contents vii
3.3. Process of wire fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.3.1. FDM or FFF materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.3.2. Adhesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.3.3. Synthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.4. Sheet or powder gluing process . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.4.1. Bi-material process (SDL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.4.2. Variant using powders: 3DP Process . . . . . . . . . . . . . . . . . . . . . . 217
3.4.3. Process using a cross-linkable polymer
(SIR, for “Soluble/Insoluble Reaction”). . . . . . . . . . . . . . . . . . . . . . . . 218
3.4.4. Synthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3.5. Powder fusion/sintering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.5.1. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.5.2. Energy sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.5.3. Physicochemical aspects and constraints
linked to the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.5.4. Simultaneous contribution of matter and energy . . . . . . . . . . . . . . . 233
3.5.5. MPA process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.5.6. Synthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3.7. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Acknowledgments
Sincere thanks to 3A, BeAm, 3DCeram, 3D Systems, Fives, Nanoscribe, Poietis,
Prodways, XtreeE, Alex (alias Alexandre Martel, co-founder of 3D Natives.com)
and Laurent Dupont, head of the Lorraine Fab Living Lab® for their effective
cooperation, and particularly for graciously providing certain images.

Prototype part (3DCeram, 2017), reproduction of the Église
de Bonsecours in Nancy (LRGP, 1994) and metallic
part (3A – Applications Additives Avancées, 2017)
Foreword
The evocative expression “3D printing” has been overtaken in everyday speech
by the expression generally preferred by scientists and engineers, “additive
manufacturing”. In both cases, it is a matter of manufacturing objects in successive
layers, and soon every workshop and every school will have a 3D printer and engage
in additive manufacturing. Self-service workshops known as fab-labs already offer
users the possibility to create their own objects. However, the adventure is not over,
as “4D” is coming up over the horizon with materials that evolve over time, not to
mention “bio-printing”, which aims to create organs to be used to repair the living.
Furthermore, the 3D printing of tomorrow, which will be performed without layers,
threatens to make the term “additive manufacturing” obsolete, thereby making it
possible to return to the initial concept of 3D printing. Whatever the case may be,
we are faced with not only a very active and booming world, but also a complex
world that calls on numerous skills in physics, engineering, chemistry of materials
and mechanics with a resolutely multidisciplinary and convergent approach.
To understand the origin of the ideas in additive manufacturing/3D printing,
learn about the current state of what is known and explore the developments to
come, what could be better than to ask one of the inventors of the technology and
one of the first French patent holders in the field, Jean-Claude André, to share his
knowledge with us? This led to the idea of this 3-volume edition that I am pleased to
present; a work that is both erudite and prospective, as its intention is to start at the
genesis of the ideas that led to additive manufacturing to anticipate the impact and
future of still “additive” technologies and, beyond this, to encourage reflection on
the interactions between science and society of today and tomorrow.
xii From Additive Manufacturing to 3D/4D Printing 1
If the first patents date back to 1984, an era where lasers, photo-materials and
computer-aided design had already been mastered, was the idea of additive
manufacturing completely disruptive as would be said today. What was creative was
to put all of this knowledge together to come to something entirely new.
Nevertheless, approval for the concept of additive manufacturing came rather
quickly. It is on this basis that other additive methodologies, currently many of them
with very specific niches, could be developed. These range from prototype and
industrial parts to art, variable spatial scales – from the decameter to the nanometer –,
from the inert to the living, from industrial organizations to very delocalized forms
of manufacturing, etc.
On the basis of these works with varied applicative and societal spectrums, some
of which are in the process of becoming stabilized, others to be invented, the
principles of additive manufacturing can serve as an example, even as a “laboratory”
to better understand how the interactions between research and society can (and
must) develop, whether this is through new scientific concepts and the associated
concepts of creativity, interdisciplinary scientific and technological operations, the
popularization of public research, links with society in terms of the creation of new
markets and jobs, and also forms of responsibility and ethics.
Throughout these three volumes, the author would like to invite you to reflect on
the circuits between the applications that pose new scientific questions and prior
research which opens the door to new applications or new products. The more we
progress in the field of new niches, the more previously unasked scientific questions
are considered, questions whose answers (if they exist) are supported and
encouraged by public authorities and industry, which are gaining awareness of an
immense industrial and/or medical market, as is the case for bio-printing. From
dream to reality, scientists are often in the position to anticipate the length of the
path; however, a dynamic is created. This leads to cultural changes and changes in
practices, particularly concerning the importance of creativity, sharing enthusiasm
for research, openness with others, the multiplying (and sometimes inhibiting) effect
of public actors, on the one hand, and the economic world, on the other, as this work
illustrates wonderfully.
This saga of additive manufacturing, told by one of its inventors, teaches us that
creativity alone does not suffice; it is necessary to have a good dose of perseverance
as well, and it is, of course, necessary to keep moving after the first failures. In
addition, this shows us that sometimes the research structures and the environment
are not entirely receptive to innovation, even when success comes relatively quickly.