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Additive Manufacturing
a game changer in industry
October 2016
Philippe Reinders Folmer
General Manager Benelux
Slide 211/3/2016
introduction
Additive Manufacturing, a game changer in industry
3D printing is being called the 3rd industrial revolution, is that so? And if
so, what do you see of it in daily life?
A lot is being written about 3D printing, but mostly about desktop
printers to make plastic objects. Prices are dropping to interesting
levels, software is getting easier to use and every month a FabLab is
being opened somewhere in the country.
But if we look closer at 3D printing, and separate ‘home applied’ from
industrial applications, then we will see an interesting development
going on in the background of this 3D-hype: the industrial application of
3D metalprinting – Additive Manufacturing.
Also called 3D printing, is a process of making a 3-dimensional solid object of
vitual any shapefrom a digital model.
CAD file file preparation (orientation, supports, slicing) machine file
A laser melts fine metal powder particles together in a specific patern
Powderbed is lowered by 20 to 100 micron and new powder deposited
A new patern melts upon the previous layer, forming a 3-dimensional part
What is Additive Manufacturing?
Rapid Manufacturing
Laser Sintering
✔✗
Additive Manufacturing
Laser Melting
The process uses gas atomised metallic powders like:
Stainless Steel 316L & 17-4 PH
Cobalt Chrome and dental CoCr
Titanium Al64V *
Titanium Al6Nb7 and Commercially Pure *
Inconel 718 & 625
Aluminium AlSi12 *
Tool steel (H13)
Hastalloy X
No pre-treatments or binders are used
* Reactive materials require ultra low oxygen levels
What metals can be processed?
• Atomisation – a molten metal
stream is disintegrated into fine
particles after colliding with a
high velocity stream of
atomising medium like water, air
or inert gas.
• Mechanical – during milling
forces act on the material to
reduce the particles.
• Chemical – by reduction of
metallic oxides, thermal
decomposition or by means of
electrolytic deposition.
Slide 511/3/2016Source "Powder Metallurgy Science" Second Edition, R.M. German, MPIF.
Metal powder production methods
Each method results in powders with
different characteristics and appearance:
• Oxide reduction
irregular shape, large surface area and
substantial internal porosity
• Electrolytic
high purity with dentritic morphology
• Mechanical
Irregular shape and potential
contamination
• Water atomising
irregular shape, but no internal porosity
• Gas atomising
spherical shape and no internal porosity
Slide 611/3/2016
A Chemical; Sponge Iron-Reduced Ore
B Electrolytic: Copper
C Mechanical: Milled Aluminium Powder
Containing Disperoids (17)
D Water Atomization : Iron
E Gas Atomization: Nickel-Base Hardfacing Alloy.
Source "Atomization - The Production Of Metal
Powders" A. Lawley, MPIF.
Particle characteristics
Slide 711/3/2016
Ti6Al4V
Small bespoke series components
dental crowns & bridges, implants etc
Complex geometries & structures
Thermal management, medical implants, transition to composite structures
Hidden internal features
conformal cooling, valve bodies etc.
Nobel materials & alloys
materials difficult to machine & hazardous to process via other methods
Short series or one off components for test & development
Suitable applications – where does it works best?
• Started in 1973
• 16 product divisions in 2013
• Industrial Metrology
(Probing, Calibration, Styli, fixturing,
Gauging)
• Position Encoders
(optical, magnetic and laser)
• Additive Manufacturing
(Lasermelting machines, vacuum casting systems)
• Healthcare
(Raman spectroscopy, Neurosurgical robots and software, Dental
scanners and software)
Renishaw 40 years - more than metrology
Slide 1011/3/2016
Renishaw’s approach = production process
Use of vacuum chamber & pure Argongas
• Material integrity
• Ultra low oxygen level (<0,01%)
• Short start-up time (12 minutes from start)
• Low gas consumption (average 30 to 50 ltr/hr)
Glove access & external hopper
• Operator safety
• Material integrity
• Re-use and refill during process
Off-line file preparation
• File integrity & traceability
• Machine exchangeability
• Operator safety
• Design driven Manufacturing or Manufacturing driven Design..?
– Limitations by current production methods
• Benefits for ‘Designing out of the box’:
– Reducing the number of components
– Optimising design
– Increasing functionality
– Reducing weight
– Optimising flow
– Increasing reliability
• AM is an additional metalworking method in combination with current
production methods like milling, turning, polishing
Additive Manufacturing opens the box
Slide 1111/3/2016
Material:
• 1.2344 tool steel
Dimensions:
• 170 x 46 x 18 [mm]
Layer thickness:
• 50 µm
Build time:
• 48 hours
Post treatment:
• Manual polishing
Conformal Cooling
Channels
Finished Moulded handles
– courtesy Gardenia
AM examples – Tooling
Considerable reduction
of cycle time
• Ideal design of size,
form and function of
cooling channels
• Quality improvement of
injection moulding
AM examples – Tooling
Slide 1411/3/2016
Identify & position
key features
Create a structurally
optimised design
Consider
part/process
orientation demands
Design for process – pump housing redesign
Original DFP3 pump front plate part
• Weight Removal• Part consolidation• Reduction in manufacture and
assembly time
Aim
Design for process – assembly front plate
Improved flow path smoothness through CFD simulation of fuel flow velocity
a) original flow pathsb) redesigned flow paths
DelphiDesign for process – assembly front plate
• Pressure test = 2mm wall section • Built on Renishaw AM250 in Ti6Al4V• 54% reduction in volume• 21% reduction in overall packaging area• 5 non-value added assembly operations eliminated
DelphiDesign for process – assembly front plate
Solid Aluminium machined part – 870g mass
This part is a cantilever arm used to hold a display which is attached to a first class seat. The arm can be swivelled out from its closed position in a recess in the side of the seat to its open position in front of the viewer. The weight of the display itself is not a significant loading on the arm, but the arm must survive an abuse load of a person on board leaning or falling on the monitor
Design for process – CO2 reduction
Optimised topologies for offset loading:a) 667N (150lb) and b) 1334N (300lb)
The mass of the 667N loading was 324g which was a reduction of 63% on the original.
The mass of the 1334N loading was 501g which was a reduction of 42% on the original
3 of the various iterations
Design for process – CO2 reduction
Cross members
Cross section through the part using a finer mesh and Ti material. Note the presence of reinforcing cross members to compensate for the reduced stiffness due to thinner walls
Mass 324g = 63% saving
Design for process – CO2 reduction
Topologically
optimised
0.37 kg
Machine from
solid billet
0.80 kg
Complex
lattice
0.31 kgImages courtesy of Loughborough University
Design for process – CO2 reduction
Data courtesy of Econolyst
0
100
Use
Materials Manufacture Distribution
Optimised
Use
CO2
(kg)
Materials Manufacture Distribution
Environmental impact of manufacturing process
LatticeSolid
Data courtesy of Econolyst
50,000
Use
Materials Manufacture Distribution
CO2
(kg)
Use
Use100
Solid = 44 tonnes
Lattice = 16 tonnes
Optimised = 20 tonnes
Materials Manufacture Distribution
Example based on 90M km (Long haul) application
Environmental impact over product lifecycle
Phases we have to go through
Mind shift: Manufacturing driven design Design driven manufacturing
Initial focus on design optimising
But that only makes a workpiece ‘printable’
Next challenges:
– re-design with post-processing and up-scaling in mind
– Focus on process control rather than 3D production only
Current examples in dental application:
– Implant based dental structures = 3D printing + CNC-milling
– Repeatability: Build-to-Master, Build-to-Build, Machine-to-Machine
Slide 2411/3/2016
AM – let the game changing begin...
Slide 2511/3/2016
Design considerations for production
Manage the re-design process
• Layerthickness & detail versus speed
• Orientation & functionality versus nesting & quantity
• Add fixturing items for post-processing
Manage the process
• Maintain file integrity
• Safety (separate powder handling from production)
• Production control (‘build to master’ and ‘build to build’)
Slide 2611/3/2016
Technology considerations for production
Powderbed
• Small intricate designs, internal and conformal features
• Typical fine mechanical, high tech parts
Hybrid machine tools
• Larger industrial parts, no internal features
• Less waste, less machine time (more AM time)
Sand printing
• Direct printing of moulds in sand
• larger products, castings
• Time saving on design and re-design
Slide 2711/3/2016
Powderbed technology and parallel production
Empire mountain bike
Original carbon fibre frame
was 2400 gr.
Titanium frame only 2000
gram, and much stronger
Based on an article in 3D Printing Industry by Alban Leandri (June 2, ‘15)
Improved development cycles• Prototype and validate conceptual design faster
• Tooling production can be skipped to go straight to finished parts
• Test multiple configurations, reduce product-launch risk and time to market
Complex-design Parts• Traditional design considers the possibilities and limitations of milling, turning,
casting, forging and welding
• AM creates space to innovate and explore new designs
Consolidation of design• Consolidate multiple parts into fewer components, reduce assembly time and
costs, and increase reliability and simplify design modifications
Weight reduction• Key driver for Aerospace industry: lighter weight = lower fuel consumption
• Topological optimisation and lattice structures carve out unnecessary material
How Can the Aerospace Industry Benefit from AM?
Slide 2811/3/2016
• GE uses AM to create fan blade edges with complex shapes to
optimize airflow. Difficult and time-consuming to machine. By 2016,
GE plans to make these large production runs with AM.
• The buy-to-fly ratio of Lockheed Martin’s Bleed Air Leak Detector
(BALD) brackets was reduced from 33:1 to about 1:1 by using
electron beam melting (EBM). Even though the titanium alloy used
in the AM process costs more than the wrought one traditionally
processed, the cost of each bracket was cut down by 50% without
compromising mechanical properties
• Single part fuel nozzles used in GE’s LEAP engine are made with
AM. These were formerly composed of 20 different parts, and are
now five times more durable than those produced with
conventional methods.
It’s happening already in the Aerospace industry
Slide 2911/3/2016
Slide 3011/3/2016
Thank you