Additive Manufacturing: New Opportunities for Prototyping
Transcript of Additive Manufacturing: New Opportunities for Prototyping
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Additive Manufacturing: New Opportunities for Prototyping
Mohsen Mohammadi, PhD, PEngAssociate Professor and Director
Marine Additive Manufacturing Centre of Excellence
University of New Brunswick
Fredericton, NBApril 28, 2021
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The Evolution of Manufacturing
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The Evolution of Manufacturing
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Next Manufacturing Revolution: Industrie 4.0
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What is Metal Additive Manufacturing?
Additive Manufacturing Manufacturing Manufacturing AdditiveHere And there
Additive Manufacturing (AM): A process of joining metals to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies (ASTM F2792 − 12a).
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Additive vs Subtractive Manufacturing
The fabrication fabrication fabrication fabrication fabrication fabrication fabrication
Additive Manufacturing (AM): A process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies (ASTM F2792 − 12a).
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Subtractive Manufacturing
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Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Direct Metal Laser Sintering• Selective Laser Melting• Electron Beam Machining
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Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Direct Metal Laser Sintering• Selective Laser Melting• Electron Beam Machining
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Hybrid Manufacturing
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Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering
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Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering
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Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering
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Additive Manufacturing: SchematicMore complex shapes with less used materials, which is the case for marine components can be produced using AM
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Additive Manufacturing ProcessMore complex shapes with less used materials, which is the case for marine aerospace components can be produced using AM
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Metal Additive Manufacturing (AM)More complex shapes with less used materials, which is the case for marine components can be produced using AM
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Metal Additive Manufacturing (AM)
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Wire Arc Additive Manufacturing (WAAM)
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CAD to Part in 3D Printing
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AM: Capabilities and Opportunities
• Rapid Manufacturing • Design Freedom • Mass Customization • Added Functionality • Less Tooling• Process Improvements• Environmental Drivers
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AM: Complexity is FreeMore complex shapes with less used materials, which is the case for aerospace components can be produced using AM
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AM: Single Step Manufacturing
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AM: Optimizing Design Structure
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AM: Optimizing Design Structure
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Some Facts about Metal AMBy 2020, GE Aviation will be manufacturing well in excess of 100,000 partsvia additive manufacturing for the Leap and other jet engines.
85,000 fuel nozzles from GE for the Leap Engine
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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Some Facts about Metal AMAirbus had 1,000 parts 3D printed to meet deadline
3D printed brackets designed by Airbus to save weight
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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Some Facts about Metal AM
Boeing have had 20,000 3D printed parts for 10 different military andcommercial airplanes (30 parts for 787 Dreamliner).
World’s lightest material from Boeing
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Some Facts about Metal AMAuto Industry will be the biggest industrial sector adopting AM for R&D till 2020
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Metal AM in Marine ApplicationsTruMarine used additive manufacturing to repair boat engine turbochargers
Metal 3D printed boat propeller
Engine TurbochargerAM can offer corrosion resistant parts suitable for marine applications
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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AM: Revolution for Spare Parts in Marine
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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What is going on with Metal AM in these days?
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What is going on with Metal AM now?
NORSK Titanium (Norway), Boeing 7XX landing Gear
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What is going on with Metal AM now?
Siemens (2017)
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What is going on with Metal AM now?
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What is going on with Metal AM now?
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Commercialization Success StoriesDamaged beveling wheel from a legacy machine in the shipbuilding sector
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Commercialization Success StoriesDamaged beveling wheel froma legacy machine in the shipbuilding sector
Material Characterization: • Hardness test• Chemical composition3D Scanning:• Reverse engineering• CAD File• STL File• 3D Printing Process
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Commercialization Success Stories
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Commercialization Success Stories
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Commercialization Success Stories
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Commercialization ActivitiesClosed face Impeller for military grade pump (Canadian Navy)
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Future Projects:OUTLOOK
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Commercialization Activities
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https://www.businesseventscanada.ca/economic-sectors/advanced-manufacturing
Advanced Manufacturing in Canada
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https://www.businesseventscanada.ca/economic-sectors/advanced-manufacturing
Advanced Manufacturing in Canada
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Canada’s (CSC), along with the UK and Australia, will share the same combat vessel platform. MAMCE has already established partnerships with research centres aligned with these programs, such as AMRC and the University of Manchester in the UK.
National Shipbuilding Strategy
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[Ref. https://lop.parl.ca/content/lop/ResearchPublications/2015-35-e.pdf]
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The Centre is an excellent investment for suppliers looking to offset Canada’s Industrial and Technological Benefits (ITB) requirements.
This program is run by the University of New Brunswick (UNB) and will be eligible for the IRB/ IT multiplier. Partnership in the Centre will also give access to cutting edge research on metals important to marine applications. Supporting the Centre will ensure that the workforce is in place for the future of marine manufacturing in Canada
Industrial and Technological Benefits
9:1Potential Offset Benefit
Future Fighter Jet Program
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Nuclear Additive Manufacturing• 4th Generation Nuclear Reactors
• Supercritical-Water-Cooled Reactor
• Repair and MaintenanceSteel
Stainless Steel Corrax®Stainless Steel 316 L
NickelNickel Super Alloys, IN625
Zirconium
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AM in Isolated Locations
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Acknowledgements
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Thank You!