2022 Programme

Time Information
09:30 - 09:45
09:45 - 10:15

Healthcare applications

Additive Technology in Clear Aligner Manufacturing
Chunhua Li, VP of Materials, Product Research and Development, Align Technology, Inc

The additive manufacturing technology enables fabrication of series of fully customized clear aligners for every patient. In this presentation, clear aligner digital platform and how to fully leverage additive technology at scale will be reviewed. The goal and challenge of direct 3D printed clear aligner will be discussed.
10:20 - 10:50

Healthcare applications

Making Healthcare Better with Additive Manufacturing
Tommy Hearne, Staff engineer, Stryker

Additive Manufacturing promises a myriad of potential benefits for design, manufacturing, and supply chains. This presentation will describe how the benefits of Additive Manufacturing have been realised at industrial scale, through the design and manufacture of medical devices with real world patient impact – focusing on customer needs, the performance of Additive products and exploring enabling technologies for the future.
10:50 - 11:20
Coffee and Exhibition

11:20 - 11:50

Complex structures

The future of 3D printed aircraft components
Sean Butterworth, Principal Materials Scientist, BAE Systems

Additive manufacturing promises to improve complex system manufacturing and fabrication by decreasing the number of parts and manufacturing operations, while also decreasing wastage. Great strides have been taken from a materials standpoint for component printing, however materials with greater functionality are less mature.

Within BAE Systems - Air, we currently have an active additive manufacturing business producing flight test approved parts, but are also looking to the future of what could be achieved with multifunctional materials and additive manufacturing processes. Embedded sensors, antennas, graded electrical properties for lenses and meta-materials are all active streams of research and development. This presentation sets out some of the work we are currently undertaking and directions we hope to see additive manufacturing processes and materials move into in the future, to allow functional and smart component fabrication.
11:55 - 12:25

Complex structures

Cellular Fluidics: Tuning Multiphase Interfaces in 3D Using Architected Porous Media
Nikola Dudukovic, Staff Scientist and Principal Investigator, Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory

Many processes in both nature and industry occur at the microscale and involve complex multiphase interfaces. Most microporous media, both natural and man-made, tend to be stochastic and therefore difficult to predict or control reliably. On the other hand, conventional microfluidic devices are often limited to enclosed channels and planar geometries, which hinders their usefulness in multiphase reaction or transport processes involving gas phases.

We present a novel platform based on capillary fluid flow in ordered three-dimensional open-cell lattices [1]. Using deterministic cell and lattice design, combined with additive manufacturing methods that provide access to length scales < 100 um, we can fabricate complex 3D structures with tuned porosity and advanced functionalities.

This approach enables selective placement and direction of liquid flow or gas flow into predetermined continuous paths through the structure, as well as optimizing for the occurrence of gas-liquid, liquid-liquid, or gas-liquid-solid interfaces. We demonstrate the application of cellular fluidics for processes such as transpiration cooling, CO2 capture, selective patterning, and biological cell culture.
12:25 - 13:30

13:30 - 14:00

Next Generation Additive Manufacturing 1

Multi Material 3D Printing in Dentistry
Tom Callewaert-Doré, Lead technologist 3D printing, Canon Production Printing

Canon Production Printing is committed to enabling sustainable digital productive printing solutions and services through continuous innovation.

In this presentation I will discuss our view and efforts on Multimaterial 3D dental printing for fabrication of functional end use products , such as crowns and bridges in a general overview.

We will also cover the advantages of AM in terms of affordability, sustainability and quality as well as the technological challenges in workflow and product development.
14:05 - 14:35

Next Generation Additive Manufacturing 1

Probing the response of cells on architectured surfaces
Professor Ricky Wildman, Professor of Multiphase Flow and Mechanics, Faculty of Engineering, University of Nottingham

I will show how we can use high resolution 3D printing techniques, such as projection micro stereolithography and two photon polymerisation, to probe the biological response of cells on architectured surfaces, potentially leading to the development of new implants that can promote healing and regeneration of tissue.
14:40 - 15:10

Next Generation Additive Manufacturing 1

3D and 4D Laser Printing: Recent Progress
Martin Wegener, Professor, Institute of Applied Physics, Karlsruhe Institute of Technology

We review our recent progress on 3D and 4D laser printing on the micrometer and nanometer scale. This includes light-responsive metamaterial architectures based on liquid-crystal elastomers, the local director of which we align in situ by means of quasi-static electric fields during the 3D multi-photon printing process. Furthermore, we introduce in-situ diagnostics by means of optical-coherence tomography (joint work with ZEISS).

Finally, we report on our efforts on using two-step absorption instead of two-photon absorption. Focus-scanning 3D printing based on one-color two-step absorption allows for democratizing 3D nanoprinting (joint work with Nanoscribe). Projection-based light-sheet 3D printing using two-color two-step absorption supports printing rates approaching 107 voxels/s at voxel volumes below 1 µm3.
15:10 - 15:40
Coffee and Exhibition

15:40 - 16:10

Metallic Implementation 1

The key enabling research & development programmes currently in progress to support Additive Manufacture across the Nuclear business (title tbc)
Dave Poole, Manufacturing engineering manager, Additive Manufacturing, Rolls-Royce plc

This presentation will cover how the dedicated Additive Manufacturing team within Rolls-Royce Submarines has developed and implemented Laser Powder Bed Fusion for high integrity, safety critical nuclear applications.

The presentation will also describe the key enabling research & development programmes currently in progress to support the growing number of exciting applications being targeted for Additive Manufacture across the Nuclear business.
16:15 - 16:45

Metallic Implementation 1

NASA’s Development of a Probabilistic Damage Tolerance Approach for Advanced Additive Manufacturing Technologies
Richard Russell, Technical Fellow for Materials, NASA

The implementation of additive manufacturing techniques to produce critical spaceflight systems is well underway.  These technologies will be a key contributor to developing both launch vehicles and spacecraft that will play a crucial role in delivering the first woman and the next man to the surface of the moon by 2025.  In 2021 NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” design to create certification and qualification strategies for mature technologies for both metallic and non-metallic materials. 

The fracture control methodologies that NASA uses for the qualification of critical spaceflight hardware is heavily reliant on a full understanding of the design, analysis, testing, inspection and tracking of hardware.  New advances in additive manufacturing technologies have quickly created unique challenges that are not captured in the current NASA-STD-6030 framework.  Examples include the use of multiple lasers, adaptive technologies and components that cannot be inspection using quantitative nondestructive evaluation.  To adapt, NASA has begun to produce explore the adaptation of Probabilistic Damage Tolerance Approaches (PDTA).  This approach includes the development of computational modeling, understanding the “effect of defects” and the implementation of in-situ monitoring and inspection techniques.
16:45 - 18:00
Drinks reception

17:00 - 18:30
UoN Department of Mechanical, Materials and Manufacturing Engineering Lab visit

A chance to tour the University of Nottingham's world-class Additive Manufacturing facility. 

PLEASE NOTE: This is available on a first-come, first-served basis and will be made available on day one of the conference.
Time Information
08:20 - 09:00
Informal update on standards and breakfast networking, ASTM
Dr Martin White, Head of Additive Manufacturing Programmes - Europe, ASTM

09:15 - 09:25
09:30 - 10:00

Next Generation Additive Manufacturing 2

Additive Manufacturing in Electrical Machines: Opportunities and Challenges
Dr. Nick Simpson, Senior Lecturer in Electrical and Electronic Engineering, University of Bristol

The electrification of transport, in pursuit of Carbon Net Zero, is driving demand for a step change in the power-density of electrical machines.

A viable route is to exploit the geometric freedom of metal additive manufacturing to realise next-generation electrical windings enabling targeted electromagnetic loss mitigation, integrated thermal management, and high-temperature insulation coatings.

This talk will present some of the latest advances in the field of Additive Manufacturing in Electrical Machines and discuss some of the ongoing challenges.
10:05 - 10:35

Next Generation Additive Manufacturing 2

3D printing and polymerisation-induced phase seperation
Pavel Levkin, Head of the Biofunctional Materials Systems research group, Karlsruhe Institute of Technology

3D printing offers enormous flexibility in fabrication of polymer objects with complex geometries. However, it is not suitable for fabricating large polymer structures with geometrical features at the sub-micrometer scale. Porous structure at the sub-micrometer scale can render macroscopic objects with unique properties, including similarities with biological interfaces, permeability, superhydrophobicity and extremely large surface area, imperative inter alia for adsorption, separation, sensing or biomedical applications.

In my presentation, I will demonstrate a method combining advantages of 3D printing and polymerization-induced phase separation, which enables formation of 3D polymer structures with controllable inherent porosity at the sub-micrometer scale. 3D polymer structures of highly complex geometries and spatially controlled pore sizes from 10 nm to 1000 µm can be fabricated using this method. Produced hierarchical polymers combining nanoporosity with micrometer-sized pores demonstrate improved adsorption performance due to better pore accessibility and favore cell adhesion and growth for 3D cell culture.

The developed method extends the scope of applications of 3D printing to hierarchical inherently porous 3D objects as well as superhydrophobic 3D objects, making them available for a wide variety of applications.
10:35 - 11:05
Coffee and Exhibition

11:05 - 11:35

3D Electronic materials

Title TBC
Sean Chang, Process integration specialist, Kilby Labs, Texas Instruments

Session description coming soon
11:40 - 12:10

3D Electronic materials

Making additive manufacturing economically meaningful
Professor Eric MacDonald, Professor of Aerospace and Mechanical Engineering and Murchison Chair in Engineering, University of Texas at El Paso

3D printing has been historically relegated to fabricating conceptual models and prototypes; however, increasingly, research is now focusing on fabricating functional end-use products. As patents for 3D printing expire, new low-cost desktop systems are being adopted more widely and this trend is leading to a diversity of new products, processes and available materials. However, currently the technology is generally confined to fabricating single material static structures.

For additively manufactured products to be economically meaningful, additional functionalities are required to be incorporated in terms of electronic, electromechanical, electromagnetic, thermodynamic, chemical and optical content.  By interrupting the 3D printing and employing complementary manufacturing processes, additional functional content can be included in mass-customized structures. This presentation will review work in multi-process 3D printing for creating structures with consumer-anatomy-specific wearable electronics, electromechanical actuation, electromagnetics, propulsion, embedded sensors in soft tooling and including metal and ceramic structures.

Other projects to be presented include stereovision process monitoring of powder bed fusion, 3D printed smart molds for sand casting, complex ceramic lattices for electromagnetic lenses, elastomeric lattices for the athletic gear, computation geometry and complexity theory for 3D printing, thermography stereovision for directed energy deposition.
12:15 - 12:45

3D Electronic materials

Additive manufacturing enabling high current transport printed circuit boards for electric vehicle applications
Marco Gavagnin, Technology Forecasting Team Leader, R&D, AT&S AG

Electrification in automotive industry is one of the driving trends for innovation in electronics interconnect solutions. Electric vehicles require printed circuit boards (PCBs) capable of high current transport through thick copper structures, usually obtained via subtractive methods. ln this study, the additive manufacturing of copper onto printed circuit boards is proposed as alternative sustainable solution achieving thick structures starting from thin metal layers.
12:45 - 13:45

13:45 - 14:15

Global Trends

Trends in the field of additive manufacturing
Professor Paulo Bartolo, Professor of Advanced Manufacturing, Nanyang Technological University

This presentation will provide an overview of key research activities being conducted at the Singapore Centre for 3D Printing focusing on the development of novel multi-material and multi-modal systems for a range of industrial sectors. New materials and key aspects related to process digitisation will be also discussed.
14:20 - 14:50

Global Trends

Functional Additive Manufacturing: 3D Printing of permanent magnetic materials
Dr Nesma Aboulkhair, Additive Manufacturing Lead, Technology Innovation Institute, UAE, Technology Innovation Institute, UAE

Additive manufacturing (AM) of functional materials is receiving growing attention at a significantly fast pace. The use of metal AM processes with magnetic materials to fabricate devices rather than components has recently seen a lot of advancements. NdFeB as a permanent magnetic material combined with the plethora of advantages that AM has to offer promises new prospects in various applications. However, it poses a lot of challenges due to its brittleness when processed by laser powder bed fusion (L-PBF).

In this work, we present an overview of the cracking phenomenon that occurs during production of these magnets and propose feasible means of mitigation. The microstructural features, their formation mechanisms and phase transformations during the characteristic layer-by-layer processing in L-PBF, were investigated. The structural integrity of the printed magnets was also evaluated. Although the crack reduction was enabled, residual cracking remained that compromised the mechanical performance of the magnets.

Therefore, we demonstrate that infiltration was successful to improve the structural integrity of the manufactured magnets. The magnetic properties were measured and correlated to the process parameters and the metallurgy of the manufactured parts. Lastly, a demonstration for using the printed magnets in a motor is presented.
14:50 - 15:20
Coffee and Exhibition

15:20 - 15:50

Metallic Implementation 2

Directed Energy Deposition - applications in space and aerospace
Dr. Carl Hauser, Section manager and technology consultant, Laser Additive Manufacturing, TWI Ltd

Directed Energy Deposition (DED) technology is experiencing increasing interest and strong growth, particularly for large format applications in the space and aerospace sector. To help understand robustness of scalability, TWI took lead in the Open Architecture Additive Manufacturing (OAAM) project to develop and demonstrate DED equipment capabilities to support the manufacture of large metallic components, all for the benefit of UK Aerospace.

This presentation will summarise the project, then introduce two case studies using laser and blown powder DED; (1) a gas turbine engine casing; and (2) rocket nozzle. Attention will focus on path planning, post machining, near net shape capabilities, the relevance of thermal induced distortion and the effect of different build orientations on material properties.
15:55 - 16:25

Metallic Implementation 2

Decoupling resolution and throughput: How to achieve faster build rates through Large Area LPBF
James DeMuth, CEO and Co-founder, Seurat Technologies

Metal AM has not yet gained significant market share in high-volume manufacturing because of the current limitation to the speed of the process, which strongly affects the production price per piece that can be achieved. The speed at which parts can be built is limited to how fast material can be melted and solidified into the underlying part.  

But high speed without high resolution is not a powerful equation. With existing metal AM processes, the two are often at odds. Decoupling them means production scale with precision. 

This presentation will include the following:

  • How to achieve faster build rates by evolving from a serial printing process to a parallel process
  • Why increasing build speed with high resolution unlocks new applications for AM
  • New frontier opportunities
16:25 - 16:30
Chairman's round up and close of conference