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Time
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09:45 - 10:15
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Aerospace & Defence 1
Functional Additive of Soft Materials for Future Defense Applications
Dr. Christopher Crouse, Research Team Lead, Polymer and Responsive Materials & Processing, Air Force Research Laboratory, Materials and Manufacturing Directorate
Christopher Tabor, Research Scientist, Air Force Research Laboratory
This presentation will provide a brief overview of the Polymer and Responsive Materials & Process Research Team in addition to the functional additive manufacturing technologies for soft materials that being developed across the Air Force Research Laboratory. Specific examples include photo-curable hydrogels for soft-robotics, materials for flexible and stretchable electronics, printing on conformal surfaces, and autonomous direct ink-write technologies will be addressed in detail. Finally, a forecast of materials challenges for the AM community with respect to defense applications will be presented.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Functional AM
2. Photo-curable materials
3. Flexible/stretchable electronics
4. Novel AM techniques
5. Materials Challenges
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10:15 - 10:45
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Aerospace & Defence 1
Moderate your Enthusiasm – Implementing AM Successfully
Jon Meyer, CEO , APWORKS GmbH
Additive Manufacturing (AM) has gone through a hype cycle, which has created confusion and misinformation about its true benefits. Jon Meyer, an industry expert with a wealth of experience in implementing AM technology successfully, will set the record straight. Drawing on his extensive background in this field, Jon will share valuable insights into the key factors that determine when and how AM can add value, as well as when it doesn't. Attendees will come away with a better understanding of the potential benefits of AM and some practical tips on how to leverage this technology to improve their own products.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. What are the main business benefits of AM technologies
2. Why do companies struggle to adopt AM successfully
3. What are the most common misconceptions about AM
4. What does a good application of AM look like
5. Strategies for successfully implementing AM
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10:45 - 11:15
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11:15 - 11:45
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Novel AM Computation
Using AI to build self-aware 3D printers
Dr Douglas Brion, Founder & CEO , Matta
Additive manufacturing is being applied across industries, but the technology is still limited by its vulnerability to diverse errors. Expert operators are required to manually detect and correct errors and tune process variables for new parts and materials. This talk will discuss the application of recent advances in large AI models and deep learning to tackle these problems. Like humans, these AI models learn about the physics and processes behind “how a part is made”, opening the door to autonomous error detection and correction, improved part quality, and 3D printers that can learn to use new materials completely by themselves.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Generalisable AI models can reliably detect and range of errors and their causes.
2. If trained correctly, AI networks can enable closed-loop feedback for error correction.
3. Physics and explainable AI can be used to try and understand neural network predictions.
4. Generating large data sets correctly (and autonomously) is half the problem!
5. AI techniques can be applied across geometries, materials, printers, and setups.
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11:45 - 12:15
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Novel AM Computation
Creating the Physical Future of Humankind through Computational - or - From code to Aerospike
Josefine Lissner, Founder and CEO , Leap 71
Computational Engineering is a new field where engineers move away from manual CAD drawings and start coding. They encode their knowledge on how to build components and entire machines into algorithms that can then automatically produce shapes and geometric variations. This speeds up product design cycles, leaves engineers room to focus on innovation rather than trivial, repetitive things. Computational designs are not only faster but can be orders of magnitude more complex as well – depending on the selected manufacturing process. The talk will give an overview over this new way of doing things and shows industrial applications from some of LEAP 71’s public projects.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Engineering today needs changing – it is too slow
2. The success of the computer industry is based on a software paradigm
3. We are applying computer code and algorithms to solve complex engineering challenges
4. We have exciting results (3D-printed objects, large code base) to show
5. Going forwards we see this approach scale through an open-source movement
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12:15 - 13:45
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13:45 - 14:15
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New Processes and Functional Materials
Design for Metal Jet Printing
Denis Cormier, Professor, Rochester Institute of Technology
Metal Jet Printing (MJP) is an emerging metal additive process with distinct differences from conventional metal AM processes. This talk will cover what those differences are, and how they affect part design and what can be produced. As an example, the absence of a powder bed means that closed-cell lattice structures that are impossible to produce with powder bed fusion processes can be metal jet printed. Other DFAM topics such as minimum unsupported surface angles, lattice beam diameters, and design for printed electronics will be covered.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. The basic steps of metal jet printing
2. How closed-cell lattices can be printed
3. Minimum unsupported surface angles
4. Material capabilities and limitations
5. How lattices encapsulated within solid skins may be produced
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14:15 - 14:45
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New Processes and Functional Materials
Advances in multi-material microstereolithography
Shoji Maruo, Professor, Yokohama National University
Multi-material microstereolithography can provide highly functional 3D microdevices, which are expected to be applied in many fields such as medicine, photonics, micromachines, and sensors. However, there are still technical issues such as material waste and long fabrication time. Recently, we have developed a multi-material two-photon lithography technique using droplets that minimizes material waste. It was demonstrated that micro-optical components could be fabricated using this technique. We have also developed new photocurable materials such as silica slurry and conductive polymer. The combination of multi-material 3D printing and new functional materials is useful for the fabrication of highly functional microdevices.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Multi-material 3D printing
2. Micro stereolithography
3. Two-photon lithography
4. Glass 3D printing
5. Conductive polymer
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14:45 - 15:15
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15:15 - 15:45
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15:45 - 16:15
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Next Generation AM - Volumetric Additive Manufacturing
Factors determining the spatial resolution, accuracy and repeatability of computed axial lithography
Hayden Taylor, Associate Professor of Mechanical Engineering, University of California, Berkeley
Computed axial lithography (CAL) is a volumetric additive manufacturing process for photopolymers that defines 3D geometries through tomographic reconstruction of a light dose in a vat of material. Current research seeks to expand the range of macromolecules processable with CAL, demonstrate initial applications, and, crucially, probe the minimum feature sizes and maximum component sizes that are practically achievable. This talk will offer a framework for assessing the geometric capabilities of CAL, addressing both physical and computational considerations. I will describe the position- and orientation-dependent spatial modulation transfer function that is inherent in CAL. I will also discuss computational approaches to optimizing light dose delivery for complex and heterogeneous geometries.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Spatial resolution in CAL depends on position and geometric orientation in the printing volume
2. The computational phase of CAL may be accelerated by using a voxel-free representation of the desired geometry
3. Where dimensional accuracy is paramount, it may be advantageous to focus on optimizing light doses at the surface of the desired object instead of on a regular spatial grid
4. Diffusion of oxygen and other species can play an important role in determining spatial resolution and accuracy in objects printed with CAL
5. Optimization of the delivered light dose distribution needs to consider the effect of subsequent post-processing on the final geometry of the component
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16:15 - 16:45
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Next Generation AM - Volumetric Additive Manufacturing
Materials Progress and Process Modeling in Volumetric Additive Manufacturing
Maxim Shusteff, Group Leader, Materials Engineering and Biomanufacturing , Lawrence Livermore National Laboratory
The volumetric additive manufacturing (VAM) paradigm in photopolymer 3D printing refers to creating a 3D object all at once, without layering. This approach has now proliferated into a variety of 3D printing methods, and a breadth of possible materials with which to employ them. Here we will examine the defining characteristics of VAM printing, and explore the recent advancements in developing VAM-compatible materials for biological applications, and for challenging engineering requirements. We will also examine the benefits of modeling the photopolymerization process in the volumetric modality and insights that emerge for understanding layered 3D printing processes.
5 THINGS YOU WILL LEARN DURING THIS SESSION:
1. Volumetric AM is defined by two essential characteristics: simultaneity of producing the 3D structure, and pre-assembly of feedstock material.
2. VAM printing of hydrogel biomaterials for tissue engineering requires advancements like overprinting, multiple materials, and precise photon dose control.
3. Advanced engineering materials such as glass and silicones printed via VAM are gaining in complexity and shape control
4. Combined finite-element modelling of volumetric light dose absorption with diffusive molecular transport creates useful predictions of AM photo-resin behavior
5. Reduced-order modelling based on this learning will be critical for continued progress
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16:45 - 17:45
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Networking Drinks & Tour of the Labs
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19:30 - 22:00
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