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Additive Manufacturing of High-Performance Ceramics

 

April 30, 2018  |  8:30 a.m. – 4:30 p.m. |  Marriott Cleveland Airport, Cleveland, Ohio

 

 

 

Book a room at Marriott Cleveland Airport hotel, click the red button below.

 

 

 

 

Distance to IX Center: 7 miles

Rate $134.00/night + tax

ACerS Headquarters Hotel

Host to the Ceramics Expo Welcome Reception, Monday, April 30th, including one (1) complimentary drink

Complimentary Shuttle to/from IX Center

Complimentary in-room Wi-Fi

Complimentary self-parking (usually $8/car/night)

 


 

Are you exploring what is going on with additive manufacturing techniques? Whether you are an engineer or scientist working in a national lab, on a factory floor, or on a college campus, then this is a great opportunity to learn what is going on in the industry, as well as the forecast of what is to come in a one-day short course taught by leaders in additive manufacturing. The course will cover technology overviews, as well as a look at the different aspects of manufacturing applications and markets.

 

Course description and learning outcomes  

Ceramic additive manufacturing has the potential to radically change the market. The available manufacturing systems for ceramic have reached an advanced stage already and present a real alternative and a sensible addition to conventional manufacturing methods. This tendency of development has awakened great interest in industry and research, but also great uncertainty. It is therefore necessary to offer a deep insight into the subject to uncover the potential of the technology. This one-day course addresses the diverse technologies that are included in ceramic additive manufacturing with primary focus on methods that have reached commercial production – 3D printing/binder jetting, extrusion technologies, and lithography-based processing.  

 

Click here for full schedule

 

Students will learn and gain a basic understanding of

– the operating principles and process function of the various methods

– the design, size, and property capabilities and limitations of the different methods

– the importance of ceramic processing science throughout each of the AM processes

– the technical and market challenges, limitations, opportunities, and forward view of ceramic AM in industry

 

Course outline and instructor biographies
 

 

Presentation:  Introduction and Overview of Additive Manufacturing

 

The term “additive manufacturing” covers a wide range of technologies, each suited to a range of applications, materials, part sizes and forms.  The scope of additive technologies and particularly those relevant to ceramics will be addressed.

 

Instructor:

Shawn M. Allan, Vice President, Lithoz America LLC

Allan currently serves as Vice President of Lithoz America LLC, which is based in Troy, New York, and is the U.S. subsidiary of Lithoz GmbH from Vienna, Austria. Allan earned his bachelor’s degree in materials science and engineering from Alfred University in 2002, and completed his master’s degree at Georgia Tech in 2005. He has been active in materials consulting and research at Allan Materials, Ceralink Inc, and Sandia National Labs. He is co-inventor of two patents, and has coauthored over 30 publications & conference presentations, resulting from a wide array of collaborative commercially-applied materials processing R&D, including ceramic process development.


 

Presentation:  Key Drivers for AM Ceramics

 

This contribution focuses on the key drivers for a successful implementation of AM and it highlights how to find the “real” AM applications. Showcases will demonstrate the potential of AM by highlighting improved designs that are enabled by AM and correlating new applications.

 

Instructor

Dr. Johannes Homa, CEO and co-founder, Lithoz GmbH

Johannes received his master’s degree in industrial engineering at Vienna University of Technology in 2005, and finished his Ph.D there in 2008. He has been teaching since 2009 at different universities, and is the co-inventor of three patents. Homa is the co-founder and CEO of Lithoz GmbH. Lithoz GmbH is based in Vienna, Austria and is the world leader in additive manufacturing of high-performance ceramic components.


 

Presentation:  Lithography-based Ceramic Manufacturing (LCM-Technology)

Lithography-based ceramic manufacturing (LCM) is a slurry-based process that relies on the selective curing of a photosensitive ceramic suspension. LCM enables the production of precise ceramic parts with the same material properties as conventionally formed ceramics.

 

Instructor:  Dr. Johannes Homa (biography above)


Presentation:  Binder Jetting Additive Manufacturing of Ceramic Materials.

This session will review the current state of the art in terms of Binder Jetting machine capabilities as it relates to ceramic powder printing, as well as discuss applications of binder jetting additive manufacturing for ceramic materials.

 

Instructor:

Jesse Blacker, Product Development Manager & Principal Investigator, ExOne

Blacker is the Product Development Manager & Principal Investigator at ExOne,  has a B.S. Degree in Mechanical Engineering from the University of Cincinnati,  and has served as a Senior Program Manager and Technical Principal Investigator for numerous advanced materials research and development programs for both Government and commercial customers, including numerous SBIR programs. Blacker is leading ExOne’s new material development efforts in the area of ceramics, carbon, and refractory metals, and currently serves as the Principal Investigator on a three-year, $1.5M contract with the U.S. Missile Defense Agency entitled “Three-Dimensional Printing of Silicon Carbide for Optical Structures.”

 


 

Presentation:  Applications and Experiences as a Manufacturer

This session will discuss the integration of additive manufacturing with conventional ceramic manufacturing, and will explore business considerations, competing technologies, potential applications, among other topics.

 

Instructor

Thomas Henriksen, President, Ceramco, Inc

Henriksen is a recognized expert in ceramic injection molding, and leads Ceramco in setting its strategic and operational goals to include adding ceramic 3D printing to its range of offerings. He has also recently investigated and developed techniques to micro-mold production quantities of intricate small ceramic shapes. He earned a B.S. in Materials Engineering from Drexel University and is past President of the Association of American Ceramic Component Manufacturers (AACCM)

 


 

Presentation:  Mass production with Additive Manufacturing: Pros and Cons

Through continued focus on innovative technologies, Johnson Matthey (JM) has developed the capability to 3D print ceramics using a binder jet technique. This presentation details JM’s 10-year development journey from the initial R&D scoping exercises, through prototyping, to full scale production in JM’s newly commissioned facility. During this process a number of barriers have been encountered which have had to be overcome. The presentation will also detail case studies of how binder-jet technology can be used to enhance product performance. From lightweighting parts used in the aerospace industry, to the optimization of fluid flow via in the design of complex catalyst supports and the use of customized components used in medical applications; this technology has a lot to offer.

 

 

Instructor

Samantha Thomas, Research Group Leader, Johnson Matthey

Thomas is Research Group Leader for Johnson Matthey’s Ceramic 3D printing team. She received her Ph.D from Cambridge University in Materials Science, focused on piezoelectric ceramics. She has worked for Mflex, a printed electronics company as a development chemist and then for Xaar, a printhead manufacturing company. In her current role, she combines her experience in ceramics and inkjet to manage the team developing 3D printing of ceramics. Recently, Thomas has been invited to become a board member for the AM UK Strategy team.

 


 

Presentation:  Additive Manufacturing of Ceramic Components by Ceramic On-Demand Extrusion (CODE)

An extrusion-based additive manufacturing process, Ceramic On-Demand Extrusion (CODE), known for producing ceramic components with near theoretical density will be introduced. In this process, an aqueous ceramic paste with high solids loading and low binder content is extruded on demand at a controlled flowrate through a positioning nozzle to fabricate a 3D part layer-by-layer. After each layer is completed, it is surrounded by oil filled to a level just below the top surface of the deposited layer, and then infrared heat radiation is used to uniformly dry the layer. Sample alumina parts produced using the CODE process demonstrate its ability to fabricate monolithic ceramic parts of complex geometry. Mechanical properties of these parts (after sintering) will be compared to those produced by several existing ceramic additive manufacturing processes.

 

  Instructor

Ming C. Leu, Keith and Pat Bailey Distinguished Professor and Director, Intelligent Systems Center, Department of Mechanical and Aerospace Engineering at Missouri University of Science and Technology

 

Leu founded Missouri S&T’s Center for Aerospace Manufacturing Technologies in 2004 and served as its director until May 2016. Prior to joining Missouri S&T, he was program director at the National Science Foundation, 1996-1999, the State Chair Professor in manufacturing productivity at the New Jersey Institute of Technology, 1987-1996, and a faculty member at Cornell University.

 

Leu obtained his Ph.D. degree in 1981 from the University of California at Berkeley in mechanical engineering. His research interests include additive manufacturing, virtual prototyping, CAD/CAM, robotics, machine dynamics and control, and cyber-physical systems. He has published over 410 papers in in professional journals and conference proceedings. Also, he has written one e-book and 10 book chapters, and has been granted four U.S. patents.

 

Leu has received numerous awards, including the University of Missouri President’s Leadership Award (2017), ASME Blackall Machine Tool and Gage Award (2014), ISFA Hideo Hanafusa Outstanding Investigator Award (2008), MCASTA Outstanding Scholar Award (2006), and the Missouri S&T AMAE Faculty Excellence Award (2001 & 2004), just to name a few. He was elected to CIRP Fellow in 2008 and to ASME Fellow in 1993, and is a member of the Sigma Xi, Tau Beta Pi, and Phi Kappa Phi honor societies.

 

Presentation: Perspectives on Additive Manufacturing of Ceramics via Robocasting

 

A revolution or cool useless parts?  A perspective of 3-D printing of ceramic materials will be presented in general and more specifically for a technique known as robocasting.

 

Robocasting is a specific subset of extrusion-based AM techniques utilizing concentrated fine-particulate pastes carried in a volatile solvent medium.  Removal of the solvent transforms the paste into a solid-like state thereby “curing” the particulate assemblage and facilitating the creation of components.  Relationships between inter-particle forces and rheology which facilitates robocasting will be introduced.

 

Robocasting is particularly suitable for commercial-scale manufacturing of porous lattice structures for filtration of molten metals, catalyst supports, and load-bearing hydroxyapatite bone scaffolds.  The character and performance of these structures will be reviewed.

 

Considerations for designing parts most amenable to robocasting will be discussed as well as the advantages, disadvantages, limitations, and future challenges of robocasting.

 

 

Instructor

Joseph Cesarano III, PhD, President, Robocasting Enterprises, LLC

Dr. Cesarano received a BS Suma Cum Laude in Ceramic Engineering from Alfred University in 1983 and an MS in Ceramic Engineering and PhD in Materials Science from the University of Washington in 1985 and 1989 respectively.  He has been a Visiting Scientist at Oak Ridge National Labs and the Swedish Ceramic Institute.  From 1989 – 2007 he was a scientist with Sandia National Laboratories and served as an adjunct professor in the Department of Chemical and Nuclear Engineering at the University of New Mexico and in the Department of Materials Science and Engineering at New Mexico Tech.

 

At Sandia he specialized in colloidal science and manipulation of fine particles for the development of material manufacturing technologies and process improvement.  He is an inventor of robocasting technology for 3-D printing of ceramics, has nine patents, and is an author on more than 30 technical papers.  His publications on polyelectrolyte stabilization of ceramic particles are used in Materials Science curriculums world-wide and have been cited over 1,000 times.

 

Dr. Cesarano is currently the President of Robocasting Enterprises LLC and serves on the Board of Trustees for Alfred University.

 

Registration

 

 

 

On or before March 29, 2018

After March 29, 2018
Member $575 $725
Nonmember $675 $825
Student $425 $525
 

 

If you have questions about registration, please contact Customer Service at 866-721-3322 (option 6) or 1-240-646-7054.

 
Cancellation policy

ACerS reserves the right to cancel a course up to 4 weeks before the scheduled presentation date. Please contact ACerS customer service at 1-866-721-3322 or 1-240-646-7054 to confirm that the course is happening before purchasing your airline tickets. ACerS is not responsible for the purchase of non-refundable airline tickets or the cancellation/change fees associated with canceling a flight.


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