3D Systems
Application Engineering Intern
During the summer of 2023 after completing my junior year, I returned to 3D Systems for my second internship there, working as an Application Engineering Intern. During my first internship at 3DS in their Rock HIll, SC location, I worked on creating augmented reality training procedures for field engineers. During my second internship, I moved to the Denver, CO location where I switched to laser powder bed fusion (metal 3D printing). My main project which I ran and managed on my own was to reduce the post processing time of cobalt chrome femoral knee implants by working on the support structures. As side projects, I also designed aerospace coupons that were printed in titanium and inconel to test out further support structures to aid in the developing of these materials. During spare time in between projects, I helped post process titanium spinal cages and cannulated screws for implants.
Final Presentation to CEO and Executives
Femoral Knee Implant Support Project
Softwares used: 3DXpert, Solidworks, Geomagic DesignX
Equiptment used: DMP Flex 500, Keyence 3D Scanner, FaroArm 3D Scanner, Nabertherm
Support Paremeters
These were the support parameters I was working with on 3DXpert to adjust the support structure you see on the right.
File Preperation
When I am happy with the support parameters, I would then compile all of my iterations and arrange them on the digital platform. I then slice the objects and prepare it for uploading to the printer.
DE-support
In order to measure how difficult the supports are to remove, I would manually remove them with an air hammer and give them a rating 1-10 before further analysis.
DE-support 2
You can see the difference in the removal of supports based on different support parameters.
Heat Treatment
In order to relieve a lot of the built in stress due to the extreme heat in metal 3D printing, I heat treated a plate of parts to decrease the deviation further. The equipment used was a Nabertherm.
3D Scan
After I give the supports a rating, I would then 3D scan the implant. Since the part was printed in cobalt chrome, the surface is very metalic and shiny. To ensure I got a scan I would spray it with a 3D scan spray to create a temporary matte finish. The 3D scanner I used was the Keyence VL-700 Series.
Analysis
The final stage in this process was to import the 3D scan as well as the initial design file, and align them so they are perfectly on top of each other. I used Geomagic DesignX to combine the point cloud from the scan and align the parts. Using the deformation tool, I was able to calculate the deviation of the printed model to detect any deformation the printing/supports may have caused. Using this data, I created tables and charts on Minitab to generate the optimal support structure which would create minimal post processing time as well as a succesful print.
Aerospace Coupon Project
Softwares used: 3DXpert, Solidworks
Equiptment used: DMP Flex 500, wall grinder, air hammer
Design
These are the coupons I designed on Solidworks. My intent was purposely design a tricky part to 3D print in metal to test out support structures to help develop the materials. These parts were printed out in titanium and inconel.
My first few prints turned out better than I imagined. However, because of titaniums material properties, the supports were very difficult to remove. The issue was that if I made the touch points to the supports more thin to aid in de-supporting the part, they would eventually be so thin that it would break off during printing.
DE-support
You can see here that some of the touch points remained on the part and the wall supports were too thick.
Post Processing
Here are the final products after some post processing and polishing.
