INNOVMAT-2011-Smolenice-Arcam

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INNOVMAT – Smolenice, SK2011-12-13 1

Production Technology forAdditive Manufacturing

Electron Beam Melted (EBM®) Ti-based medical implants

or

How implant manufacturers use Additive Manufacturingto reduce production costs and increase profits





• Swedish innovation from the beginning of the 1990’s

• Arcam AB incorporated 1997

• Listed on Nordic Growth Market• Main owner (25%) Industrifonden (Industrial capital trust)

• Turnover 10.1 M€ (2010)

• First EBM system delivered in 2003

• About 70 systems installed worldwide

• 50 people, in Sweden, the U.S., Italy and China

• Sales partners in Europe and Asia

Arcam







Electron Beam Melting (EBM®)

• A high energy beam (up to 3.000 W)is generated in the electron beam gun

•

The beam melts each layer of metalpowder to the desired geometry

• The high beam power gives high buildrate (up to 80 cm3 /h) and productivity

•

Extremely fast beam translationwith no moving parts

• Vacuum process eliminates impuritiesand yields excellent material properties

•High process temperature (700 ºC fortitanium) gives low residual stress–> no need for heat treatment

• Low operating costs





• Overview

• Applications

•Medical Implants

• Aerospace

• Arcam Products

• Materials

Medical Implants





• Freedom in design

•

Excellent material properties• Cost-efficient production

•And, for implant manufacturing

EBM - Core Benefits





• Design your trademark trabecular structure in CAD

• Optimize for osseointegration

• Pore geometry (no limitation)

• Pore size (down to ~400 µm)

• Porosity (up to ~85%)

• Competitive manufacturing costs

• EBM production cost, typical: < 2 € / cm3 trabecular structure

Trabecular Structures™









• Single-step production of solid and porous sections,with structural continuity between them

• All-porous implants possible (augments, wedges, …)

• No secondary high temperature process to apply theporous structure that could cause grain growth

•High process temperature gives low residual stress,and no need for heat treatment after the build

Production Benefits





Cost Savings with EBM

• The additional cost for applying a porous coating on anacetabular cup can be anything from 30 to 60 € per cup

• With EBM you produce the cups with an integrated porousstructure, which eliminates this cost

•

When producing acetabular cups from bar, 60-70%of the stock material is typically machined away

• With EBM you only use the material needed to producethe cups. The remaining powder is recycled and reused





EBM Production Cost, typicalAdditive Manufacturing of Ti6Al4V acetabular cups with integrated trabecular structures

Cup Weight Build Batches per Cups per Production

size cup, build time / batch week batch cost / cup

(g) (h) (€)

44 71 10 14 16 40

46 79 10 14 16 42

48 87 10 14 13 49

50 95 10 14 12 54

52 104 10 14 12 56

54 113 11 14 10 65

56 123 11 13 10 69

58 133 11 13 9 76

60 143 11 13 9 78

62 154 12 12 9 83

64 165 12 12 9 86

66 176 12 12 7 103

Includes costs for EBM system, material, Support & Maintenance agreement and operator









• Overview

• Applications

•Medical Implants

• Aerospace

• Arcam Products

• Materials

Aerospace





Turbine Blades

Material: γ-TiAl

Size: 8 x 12 x 325 mm

Weight: 0,5 kg

Build time: 7 hours / blade

For stages 6 and 7 in the low pressure turbinein General Electric’s GEnx aero engine, wherethe TiAl (~4 g/cm3) replaces blades made inheavier (>8 g/cm3) nickel-based superalloys





Contact

Arcam AB

Krokslätts Fabriker 27A

SE-431 37 Mölndal, SwedenPhone: +46 31 710 32 00

Web site: http://www.arcam.com

E-mail: [email protected]

Thank you for your attention!

Arcam - Manufacturing Revolutionized

Documents

INNOVMAT-2011-Smolenice-Arcam