Additive Manufacturing of High-Performance Ceramics
October 12, 2017 | 8:30 a.m. – 4:30 p.m.
Location: Omni William Penn Hotel, Pittsburgh, Pa., in conjunction with Materials Science & Technology 2017 (MS&T17).
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.
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
Session 1: General overview
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 in this presentation.
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 additive manufacturing ceramics
This presentation will focus on the key drivers for a successful implementation of additive manufacturing (AM), and also 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.
Dr. Johannes Homa, CEO and co-founder, Lithoz GmbH
Dr. 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. He earned his master’s degree in industrial engineering at Vienna University of Technology in 2005, and completed his Ph.D there in 2008. He has been teaching since 2009 at different universities, and is the co-inventor of three patents.
Presentation: Applications and experiences as a manufacturer
Thomas Henriksen, Ceramco, Inc.
After earning a bachelor’s degree in Materials Engineering from Drexel University, Henriksen began his career in process engineering, eventually became Ceramco’s plant manager, and today serves as president of Ceramco. A recognized expert in ceramic injection molding, Henriksen leads Ceramco in setting its strategic and operational goals, and has also led the company to add ceramic 3D printing to its range of offerings, giving him hands-on knowledge about the benefits and deficits of the technology. He has also recently investigated and developed techniques to micro-mold production quantities of intricate small ceramic shapes. He is past President of the Association of American Ceramic Component Manufacturers (AACCM)
Session 2: Technology overview
Presentation: Binder jetting additive manufacturing of ceramic materials
This presentation will review the current state-of-the-art binder jetting machine capabilities as it relates to ceramic powder printing, as well as discuss applications of binder jetting additive manufacturing for ceramic materials.
Jesse Blacker, Product Development Manager & Principal Investigator, ExOne
Blacker currently serves as product development manager and principal investigator at ExOne. He earned a bachelor’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 Small Business Innovation Research programs.
Blacker leads ExOne’s new material development efforts in the area of ceramics, carbon, and refractory metals. He is also currently the principal investigator on a three-year, $1.5 million contract with the U.S. Missile Defense Agency entitled “Three-Dimensional Printing of Silicon Carbide for Optical Structures.” Prior to joining ExOne, Mr. Blacker was employed by Touchstone Research Laboratory as a senior program manager where he led over three million dollars’ worth of material development programs in the areas of carbon foams and advanced aluminum alloys
Presentation: Additive manufacturing of ceramic components by ceramic on-demand extrusion (CODE)
This presentation will introduce an extrusion-based additive manufacturing process for producing ceramic components with near theoretical density called ceramic on-demand extrusion (CODE). 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.
Dr. 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.
Dr. 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 a 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.
Professor Leu obtained his Ph.D. degree in 1981 from the University of California at Berkeley, his M.S. degree in 1977 from the Pennsylvania State University, and his B.S. degree in 1972 from the National Taiwan University, all in mechanical engineering. Dr. Leu’s 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 refereed publications 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.
Presentation: Lithography-based ceramic manufacturing (LCM-technology)
This presentation will cover Lithography-based ceramic manufacturing (LCM), 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.
Dr. Johannes Homa, CEO and co-founder, Lithoz GmbH
Bio listed above
Session 3: Technology overview II and panel discussion
Speaker: Dr. William Carty, Alfred University
Panel discussion — Additive manufacturing: barriers and opportunities for the ceramic industry
|Course Registration Fee|
If you have questions about registration, please contact Customer Service at 866-721-3322 (option 6) or 1-240-646-7054.
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.