Post on 06-Mar-2018
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Additive Manufacturing in Manufacturing: A future oriented technology with high degree of innovation potentials- are we
ready? Challenges and Chances to handle
Prof. D.Sc. M.Sc. Gideon N. LevyAdditive Manufacturing and
Electro Physical & Chemical Processeswww.cdrsp.ipleiria.pt
18th edition of the AEPR forum 24 -27 June 2013 at Ecole Centrale Paris
Motivation
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How to 3D print your brain Jun.23, 2013
Once you have an MRI image of your head, you can then convert it to a 3D model. intirb uses software FreeSurfer to process the MRI brain scans to obtain the grey matter boundary of brain, intirb suggests to use MeshLab to simplify your .STL file
AM is Hot …published 13.02.2013
“3D printing that has the potential to revolutionize the way we make almost everything“ President Obama
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We are approaching our target…
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
4
Agenda II
6. Pre- /Post Processing – Upstream Processes
– Downstream Processes
7. Business Model– Key users: Experimental validation and certification
– Mainstream users: Service Bureaus
– Modern users: E- Shopping (online / on site)
8. Conclusions
What are Nontraditional Manufacturing processes?
5
More than 25 years ago
08.08.1984 17.10.1986
Patent FDM and EBM
30.10.1989 11.05.1994
6
Patents of SLM and 3DP
12.07.1999 03.05.1999
5 Senses
Why do have AM a great potential?
Ab
stra
ct
Real
Per
cep
tio
n ThinkingSpeakingWritingPrintingPaintingCraftingArt, Music
Virtual realitySoftware Film TVSimulation ModellingScience: Rules and equations Physics, Chemistry Mathematics
Everything we have And more….
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AM is an Enabling Multidisciplinary Technology
System / Process
Materials
Applications
Up stream/ Down stream
PolymersMetalsCeramicsCompositeBiologic
Application dedicatedAutomation
Part and powder handlingBatch to continues
……………..
Adaptive controlClosed loopProductivityRepeatability………………
Design for AM3DP design
toolPart finishing
Coating Modifications
…………
IndustryAviationAutomotiveJewelry
Medical devicesScaffolds
Organ printing……..
Sirmione – Lago di Garda, Italy (Was layer by layer nature inspired?)
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Terminology - Process Categories I (2012)
1. Vat Photopolymerization Process Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon
Liquid Photopolymers,
Ceramic or Metal filled photopolymers
2. Material Jetting Process Multiple nozzles Single nozzles
Thermoplastics, Wax or Photopolymers, Metals,
Optical materials, Electronic materials
3. Binder Jetting process a liquid bonding agent is selectively deposited to join powder materials. Polymer, Metal, Ceramic powders
4. Material Extrusion ProcessFDM Polymers, composite
C
C
C
T
T
CChemical
TThermal
TThermal post processing
T
Terminology - Process Categories II (2012)
5. Powder Bed Fusion Process SLS, SLM, EBM
Polymers, metals & ceramics powder
6. Sheet Lamination Process Bonding, hot melt, glue, US welding
Paper, Metal, Polymers
7. Directed Energy Deposition Process focused thermal energy is used to fuse materials by melting as they are being deposited
Metal, polymers, powder, wireT
T
T
C
CChemical
TThermal
TThermal post processing
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Oversell
Commercialisation
“PhD”
DisillusionmentDevelompment& modification
Evaluation
Standardisation
ACCEPTANCE
Evolution
Need
Pioneers
Scientific“push”
Industrial “pull”
Scientific push and industrial pull
Gartner Hype July 2012
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3DP resourcing (and open sources!)
9 3D Printer Kits manufacturer
35 3D Printer Kits Models available
34 3D Printer Fully Assembled Models
/http://www.3ders.org
3Doodler: The World's First 3D Printing Pen
The pen: The 3Doodler pen is 180mm by 24mm. The pen weighs less than 200 grams
Fun Fact: The average 1kg spool of 3mm ABS contains approximately 360-370 feet of plastic. That's approximately 3,960-4,070 feet of 3Doodling, or 3 Empire State Buildings with enough to spare for several more weeks of doodling
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3DP@ Rapid Tech 13.05 2013 Erfurt
CM Equipment sales trend
CM Units/ year
105 160 198335
512 490650
1'032
1'910
2'450
0
500
1'000
1'500
2'000
2'500
3'000
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
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Additive Manufacturing “Machine Tools”
FDM EBM3DP (DoB)
SLASLS
SLM
Metal
The value chain in product creation
CONCEPT MODELING
RAPID PROTOTYPING
Pre-SERIE / BRIDGING
CONFORMAL COOLING / TOOLING
ADDITIVE MANUFACTURINGREVERSE ENGINEERING
The Trend
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US Patents on RP/AM in steady state trend- maturity growth?
Source: www.additive3d.com/home.htm
AM market growth
Systems and Services
Additive Manufactured parts
Materials
14
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
AM Manufacturing and SM (subtractive manufacturing) are comparable tasks with new features
Additive manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. (ASTM standard F 2792 - 09)
Manufacturing is the use of machines, tools and labor to make things for use or sale. The term is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale.
Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".
=
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Manufacturing Implemented Scientific Management (Taylorism)
Scientific management is a theory of management that analyzes and synthesizes workflows, with the objective of improving labor productivity.
Total Quality Management (or TQM) is a management concept coined by W. Edwards Deming. The basis of TQM is to reduce the errors produced during the manufacturing or service process, increase customer satisfaction, streamline supply chain management, aim for modernization of equipment and ensure workers have the highest level of training
Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.
Management philosophy derived mostly from the Toyota Production System (TPS)
Source: www.strategosinc.com/
App
licat
ions
App
licat
ions
App
licat
ions
App
licat
ions
Implement scientific manufacturing management (Tylorism)
The first level of industrial usability was reached Numerous applications of AM are success business
cases Modeling, permanent continuous performance advances
are required
Process, System, Materials
Production integration
Plant integration
Standards TQM Automation Productivity
Upstream processes Downstream processing business process or business
method
App
licat
ions
App
licat
ions
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Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
Part prices (AM vs. Injection) in function of complexity
complexityfor free
complexityfor free
$ / part
AM Design DFF(Design for Functionality)
TraditionalManufacturing
Traditional DFM(Design for manufacturing)
Additive Manufacturing
Source: inspire - irpd Complexity
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Economics behind conceivable future volumes built with AM Technology (SLS).
Number of parts0
4.000-4.500 20.000
Only 20% ofthe material isin the parts
0
Cost [T€]
Motorcycle accessory:Lifetime: 5 years Volume: 10.000
Example Part:
500
Manual finishing required to bring surfaces up to standard for a visible part.
TQM a must for results and confidence in AM
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Fact is that for AM the results “depend” on:
Process / Technology dependent Material dependent Geometry dependent Application dependent System maturity and Equipment maintenance dependent Age and equipment generation dependent Operator skills and experience
AM is reproducible and reliable only under equal well controlled standardized
conditions
Design Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP AM USE
The bottlenecks in AM are the challenges
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The AM Field and Research Opportunities and Efforts
Source Road Map ALM 2009 D. Bourell et al.
Part type have different primary requirements and standards!
Decorative
surface structure
Functional
accuracy
Structural
properties
Medical
biocompatible
The wide ranging applications and requirement is a great challenge for manufacturing. Can a universal systems cover it?
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
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Applications arrays divide and focus consequently on different quality issues and standards
Positioning for plastic part AM manufacturing
Positioning for plastic part manufacturing:AM - Addetive Manufacturing; MI - Micro Injection; IM - Injection Moulding (Source: Levy G.N.iRPD)
Siz
e
IMIM
Complexity
M
S
L
XL
Siz
e
LMAMcuttingcutting
IM
low medium high
Qua
ntity
low
medium
high XXL
XS
LMcutting
MIMIMI
AM
IM
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AM direct metal components production relative to usual options
(Source: Meyer E.B., Levy G.N.)
106
105
104
103
102
101
100
Low Medium High
Geometric Complexity
Cutting
PM - Sintering Die Casting
InvestmentCasting
MIM
Layer Manufacturing
106
105
104
103
102
101
100
106
105
104
103
102
101
100
Low Medium High
Geometric Complexity
Qu
anti
ty
Cutting
PM - Sintering Die Casting
InvestmentCasting
MIM
Addtive Manufacturing
Global Adoption Of The Technology -Application
Patterns For PrototypeTooling
12.2% (12.3%)
Direct Part Production19.2% (14.9%)
Fit And Assembly12.1% (13.3%)
Functional Models18.4% (19.3%)
Visual Aids10.1% (12.0%)
Patterns ForMetal Casting8.9% (8.6%)
Presentation Models7.8% ( 8.1%)
Education/Research7% (5.4%)
Tooling Components2.7% (3.1%) Other
1.8% (2.9%)
Source Wohlers Report 2012
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Art and Interior
FO
C h
ttp://
ww
w.fr
eedo
mof
crea
tion.
com
/
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3DP made Consumer goods will it be successful?
24
Various SLS Ducting, Panels and Covers for F/A-18E/F Manufactured by ODM
Boeing Dreamliner 787
32 SLS manufactured Polyimide air ducts (FR 106)
Functional designEasy to maintain
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No-Tool production plastic - small parts
Series: 520 parts/year
Material: PA12 SLS made glass pearls blasting
Pries: EUR 4‘082.- / 520 part
Delivery: 3 days ( from Data)
AM PA12 case
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Conformal cooling systems and heat exchanger
A great chance is coming up in moulds!
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AMZ Silverstone Racing July 2010 ( with 21 “flying SLM parts)
http://www.amzracing.ch/http://www.formulastudent.com
Segmented impeller
Source :irpd
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Medical device advanced complexity
Medical and biomedical application
Body External
(non-clinical)
Op Theater Instruments
Surgical forceps
Surgical guides
Scalpels
OP support Jigs
Prosthesis Systems
Reconstructive prosthetic
Dental crown bridges application
Body internal Temporary
(clinical)
Scaffolds
Clinical suture
Degradable screws and plates
Drug delivery systems
Body internal Permanent
(clinical)
Hip implant
Knee implant
Inter verbal spacer
Cardiac pacemaker
Retinal implants
Dental implants
Topology of Bio- Device Manufacturing
DegradableNon-degradable Non-degradableNon-degradable
Use in operation theater ?Patient
specificPatient
matched
No
n-d
egra
dab
le
De
gra
dab
le
No
n-d
egra
dab
le
De
gra
dab
le
Use outside operation theater
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Customization – patient matched SLS made cutting template “My Knee”
Supporting SLM made Implants (Stainless or Titan)
SLM
Par
tsS
ourc
e :ir
pd
29
DENTAL (orthodontic, alignments, copings, bridges, implants)
Data AM User
3DP
SLA
SLM
SLS
ALIGN TECHNOLOGY INC.
SLA 40’000 parts per day
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Medical and Life Science a promising future
MCP
Dr. Anthony Atala (USA) : 3D Printing of Body Parts
Institute for Regenerative Medicine in North Carolina
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Technology accomplished allows to build implantable body parts
66
8th July 2011
Logistics and supply chain mangment
Production on Demand
32
AM options in lightweight structures
Lightweight functional steel partAdditive SLS and Composite: no-tool forming
Composites Busch
SLS Micro Parts – also as actuators SMA (shape memory alloy) and ceramics
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The impact of the DirectSpare concept
Obsolete equipment because of unavailability of spare parts becomes useful
Millions of unused spare parts being reduced to scrap...
Ordered spare parts transported around the globe...
Warehouses stacked with spare parts...
Bio inspired AM fabricated systems
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Added Value: Translate process characterization into specific applications
Freedom of Design Lightweight structures (hollow) No-Tool production Assemblies, integrated design Anatomical personalized Ergonometric design Customization individualization Conformal cooling Gradual materials (on the way) Medical scaffolds (on the way) Bio Materials (on the way)
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
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Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
EBM Arcam MultiBeam™
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Up-and-coming Production AM Systems
The 80`s trends in machining is repeating for AM Production oriented design Automation starting point, load unload ease Removable transportable work areas (cylinder, vat etc) Resin regeneration and recycling Production oriented control More process and system control in modern SLS, SLA and SLM
equipment Adaptive control, on-line calibration Closed loop position controls Closed loop laser power controls Closed loop temperature control Reporting Search for efficiency and productivity
[Watch e.g. PRO & EOS System, Prometal S systems, Conceplaser M3]
Continuous Additive Manufacturing
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3DPContinuous Additive Manufacturing
SLM - Machine size categories
Small dedicated <1
Mid range 15-30
Very large > 100
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China 2013 $80 million investment in AM
An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China. Courtesy of Guancha Zhe.
Cell seeded scaffolds
A scaffold in tissue engineering serves as a temporary skeleton to accommodate and stimulate new tissue growth
Allow cell attachment, proliferation and differentiation;
Deliver and retain cells and growth factors;
Enable diffusion of cell nutrients and oxygen;
Enable an appropriate mechanical and biological environment for tissue regeneration in an organised way
Das Bild kann zurzeit nicht angezeigt werden.
AM scaffold manufacturing in tissue engineering
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Bio-M dedicated equipment - Biocell Printing all in one system implementation
http://www.cdr-sp.ipleiria.pt/
Scaffold printing stage Scaffold sterilisation chamber Scaffold bioreactor
PhD Work of Marco Domingos
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
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Feedback control of Selective Laser Melting
P. Mercelis, J.P. Kruth, J. Van VaerenberghDepartment of Mechanical Engineering, University of Leuven, Celestijnenlaan300B, Leuven, Belgium
Agenda I
1. Background
2. Scientific Manufacturing Management
3. Analysis and Synthesis for AM– Economics
– The workflow bottle necks
– TQM Total Quality Management
– TPM Total Productive Maintenance
4. Application Driven
5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
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Direct Indirect
Design ModelsFunctional Models
RP - Prototyping-
Concept modelersPatterns
PartsLong-term use
Thermoforming-Fiber Molding-
ToolingLong-term use
Plastics
PartsLong-term use
Injection molding-Die casting-MIM, CIM
ToolingLong-term use
Metal
Electrical-Medical-
PartsLong-term use
Ceramics
Aviation-
PartsLong-term use
Composite
RM - ManufacturingcomponentsRT - Tooling
inserts
Layer Manufacturing
The structures of biomaterials for AM
Source :irpd
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Interaction manufacturing process material
Traditional processing Non Traditional processing Additive processing
Cast Forming Cuttingmicro
cutting Forming
Electrical
Thermal(e.g.Bea
mEnergy)
chemical (e.g.
Phtopolymer)
AMChemical
AMThermal
AMBiologic
al
Performance
Properties
Bulk (wire, powder liquid)
Preform
Structure
Atom Molecule
ElectronElementary
particle
SLS - Thermoplastics polymers (Red= tried for SLS)
PP
Polymer material choice advances
, iRPD
; EOS
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SLM - materials options
Stainless steel CL 20ES ( 1.4404 ) Hot-work steel CL 50WS ( 1.2709 ) CL 60DG ( 1.2709 ) CL 90RW (1.2083 ) Aluminum CL 30AL ( AlSi12 ) CL 31AL ( AlSi10Mg ) Titanium CL 40TI ( TiAl6V4 ) Nickel-based alloy CL 100NB ( Inconel 718 )
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
Part
Laser Beam
Powder
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
Part
Laser Beam
Powder
Some trends and challenges in AM – Materials research
Filled Materials
Multi material
Local alloying
Digital Materials
Gradual Materials
Designed Anisotropy
Designed local property
Optimized metallurgical structures
Ceramics and composite
Medical and Biomaterials
Nano Materials
Micro parts
Memory shape alloys in AM
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9. Gradable materials (on the way)
CF process allows to customise the tibial component of a total knee implant, that fits the individual anatomy of the patient improving stability of the artificial knee joint
Customise material grading to fit individual patient physiology
Take CT scan of
tibia bone
100% Ti 100% CoCr
GradedCoCr –Ti
materials
Automated designed
tibial baseplate
3DP Digital Materials
100% Material A
100% Material B
75%:25%
50%:50%
25%:75%
Source: SFF 2012, Daniel Dikovsky, Ph.D.
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Agenda II
6. Pre- /Post Processing – Upstream Processes
– Downstream Processes
7. Business Model– Key users: Experimental validation and certification
– Mainstream users: Service Bureaus
– Modern users: E- Shopping (online / on site)
8. Conclusions
Design for AM e.g. Potential in der Aero industries
46
Young Modulus v/s Elongation
SLS Material selection data base I
Tensile Strength v/s Density
SLS Material selection data base IV
47
Design considerations on Laser Cusing andfor the EBM process
Design considerations on Laser Cusing andfor the EBM process
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Topological Optimizations
Topological optimized design results are:• Complex geometries • Conventionally not produce
able• Have to be smoothed
• Highest geometrical freedom• Agile manufacturing• New design concepts
Chances for Layer Manufacturing:
ATKINS Project: a low-carbon footprint manufacturing solution
The £2.7 Million ATKINS Project …
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Post processing options for functional and visual parts enhancements
SLS parts
no surfacetreatment
surface refining
man made
coating
water-tight-repellent
pressure/vac. tight
wear resistance
UV-/ lightprotection
chemical resistance
film finish
flockfinish
laquerefinish
visual/aestheticfunctional
how to do it?Enhancement by finishing
how to do/proof it?
powdercoating
vaporC/PVD
machine made
A. Surface roughnessB. AestheticC. Functional
Best in Class - SLM parts Polishing
50
Engineered surfaces - Engineered Trabecular Structures™
The material can incorporate integrated Trabecular Structures™ and Engineered Surface Porosity™ (ESP).
This enables design for osseointegration and reduces the number of process steps in manufacturing.
Pictures of bone growing into titanium implants with Engineered Surface Porosity, manufactured in the EBM process.
Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg, and ARCAM
SLM HIP Hot Isostatic Pressing
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SLM post heat treatments
Agenda II
6. Pre- /Post Processing – Upstream Processes
– Downstream Processes
7. Business Model– Key users: Experimental validation
and certification
– Mainstream users: Service Bureaus
– Modern users: E- Shopping (online / on site)
– Others?
8. Conclusions
52
Around 30 AM Systems SLA SLS
Harvest Technologies, which was started by David K. Leigh and his father David E. Leigh out of their barn, celebrated the opening of its 40,000 square foot facility
The company that was created, Rapid Quality Manufacturing (RQM), has as its entire focus and business model the creation of higher-volume production parts using DMLS and other additive fabrication technologies. Greg Morris, CEO, Morris Technologies, Inc.
17 M270 und 1 M280 SLM Anlagen
Headquarters: Cincinnati Ohio, United StatesRevenue: $3 MillionEmployees: 75
53
Shapeways is a spin‐out of the lifestyle incubator of Royal Philips Electronics
Agenda II
6. Pre- /Post Processing – Upstream Processes
– Downstream Processes
7. Business Model– Key users: Experimental validation and certification
– Mainstream users: Service Bureaus
– Modern users: E- Shopping (online / on site)
8. Conclusions
54
We are on the right track
Conclusions
The sustainability will be a mayor issue for all of us
The implementation of Scientific Management (Taylorism) is a must
Hybrid systems are in due
Productivity, Automation and quality enhancements are a permanent issue
New application driven manufacturing tasks coupled with product innovations are just around the corner.
Interdisciplinary and complexity are increasing
Additive Manufacturing Processes are a great challenge and chance in manufacturing
5 years to go!
The scientific AM community has to be involved
55
Personalized
Construction of a CUBESAT using AdditiveManufacturing
Additive manufacturing
The sky is the limit !
56
Conclusions by Albert Einstein
The formulation of a problem is often more essential than its solution, which may be merely a matter of mathematical or experimental skill.
The process of scientific discovery is, in effect, a continual flight from wonder.
All meaningful and lasting change starts first in your imagination and then works its way out. Imagination is more important than knowledge.
Albert Einstein