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This presentation may contain confidential and/or privileged information. Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
A Peek into the EOS Lab: Micro Laser Sintering
Joachim Goebner, EOS
A Peek into Micro Laser-Sintering
Source: IVAM, EOS
A look into the lab and beyond
Motivation
Technology
Business
Text
Text
Micro Laser-Sintering extends Additive Manufacturing to the Micro World
Sustainability
Time to market
Customization
Functional integration
Complexity for free
Freedom of design
Markets for miniaturized parts are growing
Additive manufacturing serves global manufacturing trends
Micro Laser-Sintering
Source: IVAM, EOS
2002 2006 2008 2009 2014 2016 2013
First working R&D system at University of Applied Sciences Mittweida
3D-Micromac presents “MicroForm”, EOS enters project
MLS technology demonstrator
EOS offers MLS application development
MLS Pre-series systems at EOS & TU Darmstadt
First production facility in place
MLS Series system
Technology: Roadmap Micro Laser-Sintering
Source: HS Mittweida, 3D-Micromac AG, TCC Chemnitz, EOS GmbH
Technology: Current status EOSINT µ60
Effects Facts
Material
Particle size up to 5µm (D90)
Stainless Steel 316L
Molybdenum
Laser
Continuous wave & pulsed
Spot size diameter up to 30µm
Recoating
Layer thickness from 1 to 5 µm
Monitoring of platform & recoater position
Sub µ resolution of the platform
NEW: Bi-directional
NEW: Ceramic blades
Material
Fine detail resolution
Medical devices
High temperature melting applications
e.g. Medical & Automotive
Laser
Best part density and surface roughness
Minimum wall thickness approx. 30µm so far
Recoating
Fine detail resolution
Prepared for manufacturing
Repeatability of layer thickness
Increased productivity
Less wear
Technology: Current status EOSINT µ60
Effects Facts
Process Chamber
Build envelope: Ø 57 mm x 30 mm height
Inert atmosphere ( < 1ppm O2 and H2O)
Gas tight design
Gas cleaning included
NEW: Airlock system with Rapid Transfer Port
Process chamber
Fits micro parts
Enables safe processing of reactive materials
Low running cost
Sustainability
Easy & safe interaction to / from workstation
NEW: Workstation in glove box design
Inert atmosphere
Gas tight design
Gas cleaning included
Airlock system with Rapid Transfer Port
Workstation
Safe pre- and post processing of powder & parts
Low running cost
Sustainability
Easy & safe interaction to / from machine
Technology: Operating reactive powder securely
Source: EOS GmbH
Workstation
EOSINT µ60
Sieving Preparing Cartridges
This area is secure because of the gas tight Machine, Workstation and
Rapid Transfer Port
Powder Platforms
Tools
Powder Platforms
Tools Parts
Part & Tool cleaning
Warehouse
Post processing
QA
Technology: Current status EOSINT µ60
Effects Facts
Software
Workflow structure
Supports different user levels & Remote access
Comprehensive data logging
NEW: 64 bit OS
Software
Easy learning and managing
Fits business; Quick and cheap help
QA, Process control, Traceability
Future oriented, can handle large data
Source: EOS GmbH
Concept Study – Flexure hinges for bendable handling or endoscopy applications
EOS – Electro Optical Systems
Micro Grabber
Challenge
For handling applications, a flexible yet strong arm with a mounted grabber is required
Solution
Flexure hinge designed for optimal mechanical response
Mounted grabber with 300 µm width
Advantages
Functional integration: hinges are integrated in the main body
Miniaturization of grabber mechanics
Flexure hinge arm design Grabber details
Concept Study – Y stent for artery branches
EOS – Electro Optical Systems
Y stent
Challenge
For endovascular aneurysm repairs and for preventing aneurysm (e.g. in fistulae used for dialysis) Y shaped stents are required
Solution
Y stent built with 300 µm wall thickness
Subsequent plasma polishing
Advantages
Anatomic situation of blood vessels can be reproduced in stent design
Post processing eliminates sharp edges
Concept Study – Square holes & lattice structures
EOS – Electro Optical Systems
Square holes & lattice structures
Challenge
Radiation applications from medical devices to space research need structures to guide or shield radiation
Solution
Square holes and even changing cross section are no problem
Wall thickness down to 15 µm imaginable today
Advantages
MLS enables certain solutions for the first time
Lattice structures, a few micron “thick” can be manufactured much cheaper with MLS than with e.g. etching
32µm
90 µm
45 µm
Concept Study – Fluid mixing chamber
EOS – Electro Optical Systems
Fluid mixing chamber
Challenge
Mixing solution required for 3 liquid components; applied mechanical load has to be minimized
Solution
Spiral shaped pipes with 200µm wall thickness and 150µm inner diameter
Advantages
Applied load is minimized, no moving parts required for mixing
mixing ratio can be easily modified by pipe diameter, flow ratio and design of the mixing chamber
Concept Study – Personalised rings
EOS – Electro Optical Systems
Personalised rings
Situation
Increasing costs for precious metals motivate material savings for jewelry without compromising its appearance
Solution
Hollow structures save material
Plasma polishing enhances surface finish
Advantages
Jewelry can be personalized without extra cost
Structures are a unique design feature
Ring & bracelet
Hollow structure as design element
Different ring designs
Business: Application development together with partners is the key to success
Source: EOS GmbH
Manufacturing solutions Application development Manufacturing challenges
Medical devices
Automotive
Molds
MLS Application development since 2009
Jewelry
Watchmakers
Space research
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