Linear AMS Additive Manufacturing Solutions

Founded in June 2003 in Livonia, Michigan

Start up company with a handful of employees

Early adopter of Metal Additive Manufacturing for specialty molds/tooling

Specialized in prototyping of plastic injection molds

Led the industry as an early adopter of DMLM technology

History: Linear

Today: Linear AMS Employs 130+

More than a decade of design & manufacturing expertise

Growth focused on metal AM solutions

Services Metal Additive Manufacturing:

Value Added Manufacturing Turnkey Solutions – Design, Build, Inspect & Post

Processing AM Consulting

Proven design & production for real applications Engine Parts Production Tooling/Molds Heat Exchangers Structural Parts Medical Instruments Control Manifolds/Actuation

Recent investment by Moog Inc. Global manufacturing company

Moog Overview

Founded in 1951 by Bill Moog

Medium-size, multinational

$2.5B sales in FY’15

Public – NYSE (MOG-A)

100+ locations in 28 countries

Over 11,000 employees

Reputation for high quality and technical excellence

People-oriented environment with emphasis on individual responsibility

Safety Critical High Performance

High Reliability Demanding Environments

WHEN PERFORMANCE REALLY MATTERSTM

Metal Additive Manufacturing

Process of manufacturing components from digital 3D design data

Builds layer upon layer

Uses powerful laser beams to successively bond thin layers of powder metal at exactly the points defined by the CAD design data

Created with high accuracy, detailed resolution, and excellent mechanical properties

What is Metal Additive Manufacturing (AM)?

Enhanced feature set/product attributes:

Lighter weight

Improved performance

Complex shapes

Improved reliability

Reduced part count

Shorter lead times

Reduced costs

Features of Metal AM

Supply chain optimization

Operating costs reduction

Tooling elimination

Spare part inventory reduction

Customization & redesign opportunities

Time-to-market delivery improvements

Sustainabilitiy & energy efficiencies

Rapid turn around times

Highly accurate

Improved reliability

Greater geometric flexibility

Compatibility with other processes

Benefits of Metal AM

Linear Offering

Value-Added Manufacturing Design & Recipe Optimization

Scope of Work

Prototype

Design & concept testing

“One-offs”

Pre-Production

Design & engineering services

Metallurgical expertise

Proprietary application development

Production manufacturing development

Full Production

Large capacity of EOS, SLM and Renishaw DMLM machines

Full scale production and process control

Turnkey Solutions

Decade of proven AM Expertise

Experienced Engineering Team

with Proven Capability

Titanium, Inconel, Aluminum, Cobalt,

Chrome, etc.

Aerospace, Defense (ITAR),

Industrial, Energy, and Medical

Design Production Inspection Post Processing

Prototype through Rate Production

More than 80,000 Parts Produced

Extensive capacity (20+) DMLM

Machines

EOS, SLM and Renishaw DMLM

Machines

Proven processes (ISO9001/AS9100)

Metrology and Material Analysis

Lab

White Light & BorescopeInspection

μ-CT Inspection

Flow Test Equipment

Stress Relief/Heat Treat Ovens

HIP (Hot Isotropic

Pressing)

Ultrasonic Cleaner

In-House Machining & Finishing

AM Consulting Philosophy: “Educate others of the full potential of Additive Manufacturing.”

Training

Hands-on workshops

Abbreviated, in-depth, customized options available

Center of Excellence (COE)

Cell/layout optimization

Machine operations

On-site training

Technical consulting and support

Pods

Secure room with dedicated machine

Protected IP

No up-front investment/maintenance

Additive Manufacturing

Capabilities

SLM280 EOS M270 EOS M280 EOS M290

Fast, Flexible and Cost-Effective

200, 400 and 1,000 watt lasers

Build platform sizes:

280 x 280 x 350mm

228 x 228 x 190mm

228 x 228 x 304mm

250 x 250 x 325mm

Featured DMLM Machines

Operate in protective argon and nitrogen environments

Array of DMLM Machines

EOS, SLM, Renishaw

Single and Multi Laser Systems

Extensive Production Capacity

Renishaw

Aluminum (AlSi10Mg) Light-weight, good thermal and dynamic properties

Titanium (Ti64/Ti64ELI) Low specific weight and biocompatibility

Cobalt Chrome Excellent corrosion and temperature resistance

Inconel 625 & 718 Great tensile, fatigue and rupture strength

Maraging Steel (MS1) Impressive hardness and strength

Stainless Steel:15-5, 17-4, 316L Excellent ductility and high corrosion resistance

Hastalloy-X High strength and oxidation resistance

In Development (e.g. Copper, etc.)

Metal AM Printing Materials

AM Processes MRE40633

Design of AM components EPS42894

Process control for LPBF AM EMS45279

AM powder specification for Ti 64 EPS43680

Thermal processing for AM Ti64 EPS46237

Thermal processing for 15-5PH EPS44249

Surface finish treatments, FOD removal MRE43676

Material properties for AM Ti 64 MRE46017

15-5PH Material Allowable

Data Security & Integrity

Isolated SharePoint

CUSTOMER

Science Around the Process• Material Development• Process Development• Machine Knowledge• Manufacturing

ApplicationsGeometryData

Engineering & Application

Expertise

Key Personnel

Key Personnel

Manufacturing Engineering

Material Engineering/Metallurgical

Inspection

Machine Operators

Quality Assurance

Process Control

Account and Program Management

Design Engineering

Inspection & Post Processing Inspection

Metrology and material analysis lab

White light & Borescope inspection

μ-CT scanning

X-ray inspections

Coordinate Measuring Machine (CMM)

Flow Test Equipment

Post Processing

Stress relief/heat treat ovens

HIP (Hot Isotropic Pressing)

Ultrasonic cleaner

CNC Machining

Makino Sinker and Wide Throat Wire EDM

In-house machining and finishing

Wire EDM MV-S Series

Linear Advantages Strong technical expertise

A decade of Metal AM experience

Broad application pedigree

Materials specialists

Proven production processes and capabilities

More than 80,000 parts built

Mature and repeatable processes

Extensive production capability with EOS, SLM and Renishaw DMLM

Breadth of materials

In-house inspection and post processing

Metrology and material analysis lab

X-ray µ-CT inspection

Stress relief/heat treat ovens

Machining and finishing

Formal quality processes and controls

ISO9001 & AS9100

ISO/TS16949

Additive Manufacturing Examples & Case Studies

• Challenge: To develop functional prototypes for helicopter gas-turbine engine components capable of running in test-bed conditions, e.g. high strength at high temperature

• Solution: Grown on EOSINT M270 with EOS CobaltChrome MP1 Superalloy

• Benefit: Can be built fully dense in 82 hours and be automatically polished. Properties fulfill requirements for running on test-bed.

Fully Functional Engine Parts

Source: EOS of North America; Linear Mold & Engineering, Inc.

Source: P3 digital services

Lightweight Application• Challenge: To create an innovative concave bionic bracket with hollow structures

• Solution: Using Aluminum, weight reduced by 40% to a total weight of 33g

• Benefit: Designed in a bionic way to help save weight, built in one piece and integrated thread, thus less assembly time and parts

Stress test of welded and

sintered bracket

Source: Rennteam Uni Stuttgart

Automotive Application• Challenge: To build a reliable, lightweight axle-pivot with high rigidity, in the shortest possible time.

• Solution: Produced a topology-optimized steering stub axle through the DMLM process.

• Benefit: Perfected form and contouring for a reduced weight by 35% and an increased rigidity by 20%, resulted in significant shortage in development and production time

Source: Within, 3T, EOS

Complex Components• Challenge: Turbulators inside the cooling tubes of the heat exchanger were disrupting the flow of the

cooled fluid

• Solution: Performed a design study and integrated cooling fins on outside surfaces

• Benefit: Compact and scalable design, maximum heat transfer, design structures in thermal management applications (e.g. heat exchangers, sinks, cold plates, etc.) increase compactness and effectiveness

Source: EOS

Improved Performance• Challenge: To maintain a homogeneous distribution inside the combustion chamber. Very fine spray of

fuel is key

• Solution: Designed 76 individual channels, covered solid angle of 150°, 100µm diameter narrowing down to 20µm on the outlet

• Benefit: High flexibility for design of channels, small separation of channels

Conformal Cooling

What is Conformal Cooling?

It is the optimization of cooling or heating channels that follow the shape of the molded part surface for productivity and quality improvements

It is a way of reaching area in a mold that have hot or cold spots to help control the part temp. during molding.

How does Conformal Cooling help make a molder more Lean?

Reducing Scrap

Reducing Cycle Time

Increased Capacity

How are Conformal Cooling inserts built?

Simulation

Design and Optimization

Direct Metal Laser Melting (DMLM)

Post Processing

Conformal Cooling

Reduced cycle times Minimized scrap Widened process window Noted quality improvements Isolated thermal control Increased flexibility in water line designs

Benefits of Conformal Cooling

Linear has adopted Moldex3D software to validate and optimize our designs of plastic parts and molds.

This software allows our tool designers to visualize flow capabilities and thermal properties, as well as embrace process conditions ahead of physical production.

Automotive tooling insert with conventional coolingHottest temperature point, 114ºF.

Same insert with conformal cooling lines created by using the DMLS process. Hottest temperature point, 50ºF.

Moldex3D

AM Enabled Product Solutions

• Challenge: Produce a light weight modular electronic power system (MEPS) suitable for launch vehicles which utilize electronic thrust vector control systems.

• Solution: Replaced lithium-ion batteries with ultra-capacitors and additively manufactured conformal boxes (custom print to order) using light weight materials.

• Benefit: Combined technologies resulted in up to 30% weight savings.

Li-Ion Energy Storage Module

Assembled MEPS Box Printed MEPS Lid Printed MEPS Box

• Challenge: Speed integration and system development for robotics engineers to easily connect high energy density motion control axes

• Solution: Moog produced a highly integrated hydraulic actuator with onboard closed loop position and force control

• Benefit: Quick turnaround, customized, fully integrated Ti-6Al-4V actuator produced in weeks

Robotic Hydraulic Actuator

As printed smart actuator body Assembled smart actuator Smart actuator

installed on robot leg

• Challenge: Moog’s Space & Defense Group electronics assembly & test area required custom electrical connector tooling. The tooling needed to be clean and not generate FOD.

• Solution: Surface treatment per an EPS was used to clean the surface and prevent FOD contamination of production hardware.

• Benefit: The AMC was able to AM two sets of tooling within weeks instead of the quoted months to have the tools machined.

Clean A&T tools

Quick Turn Around Time Tooling

AM tools for AM parts

• Challenge: Locking collars, commonly used on primary flight control actuators during maintenance procedures, require a machining operation to meet parallelism requirements.

• Solution: Custom clamp tooling was printed alongside the production hardware.

• Benefit: The tooling remains in the production process. Tooling and production hardware can be printed simultaneously.

Locking Collar

Locking Collars: AM Tooling

• Challenge: Higher power connectors, for next generation pitch control systems (NGPCS), needed to be redesigned and manufactured quickly to have universal vacuum pickup points so a surface mount machine could install.

• Solution: Printed NGPCS housing and connector locating pallets in ESD plastic and printed nozzle in 316 SS which were fitted to the machine vision adaptor.

• Benefit: Successfully tested vacuum pickup of connectors, eliminating the need for manual placing of connectors.

Electronic Connectors

AM Pickup Nozzle in use

• Challenge: Ti-6Al-4V stand-off bolts for a military aircraft major flight control assembly are a custom machined and processed part. Currently, there is a long lead time and it’s expensive.

• Solution: Modified the design to be manufactured using AM with multiple variants produced at once, surface finish (FOD free), and cut/rolled threads as desired.

• Benefit: Lead time reduced 85% (100 days to 15 days), reduced costs by more than 50%

Stand-off Bolts

Printed Stand off Bolts

• Challenge: Replace Ti-6Al-4V forging and reduce operational steps required to produce a Load Limit Cam Assembly (Roll). As a result, the part had a long lead time.

• Solution: Printed two halves of assembly with integrated rivet tab, surface finish (FOD free), machined, installed bearings and other hardware.

• Benefit: Lead-time reduced by 93%, tested on test stand at operational loads.

Load Limit Cam Assembly (Roll)

Load Limit Cam Assembly components and assembly

• Challenge: Reproduce cover without 3D CAD using AM technology.

• Solution: CT scanned, 3D model generated, plastic mock up made, aluminum alloy part created and compared to 3D model,

• Benefit: Part replicated without need for drawings

Air Speed Servo Roll Ratio Controller Cover

Casting to 3d printed part with CT scan geometry verification

• Challenge: The test shaft, together with a load cell, are used to verify production requirements of an actuator before shipment to the customer. A new test shaft was required.

• Solution: Additively manufactured four torque shafts within one week.

• Benefit: Dimensionally the part was close to the print tolerance specified and the part was considered useable. The AM part withstood the forces induced on it during testing, without failure.

Full 2’ of engagement into coupling spline

AM torque shaft and traditionally machined coupling with internal

spline

Quick Turn Around Time Tooling