AM magazine 29th issue

The AM Magazine will introduce and update the latest developments in layer manufacturing and Rapid Product Development technologies.The focus of the magzine is to serve the Design and Manufacturing professionals, Research and Development organisations andEducational Institutions who are particularly seeking to adopt layermanufacturing and rapid product development technologies.

Endorsed by

SUBSCRIPTIONSAnnual SubscriptionsRs. 3,000/-The AM Magazine is published bi-monthly by RAPITECH Solutions Inc.* All payments are to be made by DD drawn in favor of “ RAPITECH Solutions Inc.,Bangalore”

Publisher

Chief Editors

RAPITECH Solutions Inc. INDIA

Professor Deon de Beer

Dr. Wan Abdul Rahman

Professor Khalid Abdel Ghany

Vaal University of Technology, South Africa

Standard and Industrial Research Institute of Malaysia (SIRIM), Malaysia

Director of CAD/CAE and Rapid Prototyping and Manufacturing Lab.Central Metallurgical Research and Development Institute (CMRDI), Cairo, Egypt

ADVERTISING/OPERATIONS

Jyothish KumarRAPITECH Solutions [email protected] Mob: +91 9901033712

EDITORIAL ADVISORY BOARD

Professor P.Bartolo

Assitant Professor Bahram Asiabanpour, Ph.D

Professor Alain Bernard

Associate Professor Chua Chee Kai

Dr Gurunathan Saravana Kumar

Professor David W. Rosen

Professor Bopaya Bidanda

Associate Professor Yonghua Chen

Professor Manoj Kumar Tiwari

Professor Grier Lin

Professor David L. Bourall

Dr Allan E. W. Rennie

Associate Professor Salih Akour

Dr Rajesh Ranganathan

Dr Pulak M Pandey

Rob Snoejis,

Department of Mechanial Engineering, School of Technology and ManagementLeira, Portugal

Manufacturing Engineering Ingram School of EngineeringTexas State University- USA

IRCCyN, Ecole Centrale de Nantes, France

Nanyang Technological University, Singapore

Department of Engineering Design, Indian Institute of Technology Madras

Rapid Prototyping and Manufacturing Institute (RPMI)Georgia Institute of Technology, Atlanta USA

University of Pittsburg, USA

The University of Hong Kong, Hong Kong

Indian Institute of Technology, Kharagpur

International Leadership Institute, South Australia

University of Texas at Austin, USA

Lancaster Product Development Unit, Lancaster University

University of Jordan, Amman

Department of Mechanical Engineering, Coimbatore Institute of Technology

Indian Institute of Technology, Delhi

Layerwise, Belgium

Additive Manufacturing Society

of India (AMSI)French Rapid Prototyping Association

Portugese Rapid Prototyping Association

Standard and Industrial Research Institute of Malaysia

The AM Magazine is also endorsed by the following associations and organisations as a leading resource for information on the latestdevelopment of Rapid Product Development Technologies

3D Systems, USAVoxeljet Technology Gmbh, Gmbh

Optomec Inc. USA Nikon Metrology Arcam AB, Sweden

EOS Gmbh, GermanySchultheiss Gmbh, Germany

The AM Magazine

# 42, BSK 3rd Stage, 3rd Block, 3rd Phase, 9th Cross, Banagalore-560085, INDIARAPITECH Solutions Inc.

EDITORIAL

Stratasys Inc, USAFARO, USA

Publisher

RAPITECH Solutions Inc., is a leading edge service provider in Rapid

Prototyping (SLA/ SLS/ FDM /3D Printing), Rapid Tooling (Vaccum

Casting), Rapid Metal Casting and Reverse Engineering.

www.rapitech.co.in

Central Metallurgical Research & Development Institute

ExOne, GmbH

EFESTO LLC, USA

Layerwise, Belgium

RAPITECH Solutions Inc., aims to disseminate the research and development work in the field of Additive Manufacturing Technologies.The Objectives are-

To undertake and support Additive Manufacturing research projects.

To disseminate knowledge on state-of the–art Additive Manufacturing technology through training courses, organising seminars, symposia and workshops.

To network and tie up with best the Additive Manufacturing institutions/Organisations in the world to tap best ideas and transfer best practices from around the world.

Interact and collaborate with international Additive Manufacturing institutions and organisations to pursue research projects.

The AM MagazineThe AM Magazine AM - 14/15 Vol.05 AM - 14/15 Vol.05 Issue Issue 2929

CONTENTS

Latest Updates

15 Press Release - EOS GmbH Marks Its 25th

Anniversary with a move into a new new

technology and Customer Centre at its

Headquarters in Krailling

16 Press Release - ZERO – G PRINTER - A

Historic Revolution in Space Access -– The Sky

is no longer the limit – “The Machine Shop for

Space”

17 Press Release - Reconstructing cylinder

heads for Porsche legends Upcoming event

3D Printing and Additive Manufacturing

Applications Symposium, Bangalore, INDIA

Regulars

04 Editorial

05 Special Article - The metal foundry uses ExOne 3D

Printing processess

07 Defence & Space Case study – Aerospace Company

Airbus Defence and Space Uses Additive Manufacturing for

the Production of Satellite Parts

10 Unmanned Vehicle System – Advanced Aerials removes the mystery from Unmanned Vehicle System development with an assist from Quickparts®

12 Biomedical Applications of 3D Printing – Saving a newborn with the support of 3D Printing

14 3D Printing of Sand Moulds

AM Magazine online www.ammagazine.in

http://issuu.com/rpdmag

3

AMMagazine Nov 2014

Editorial

Pumps being the basic equipment for every sphere of the national economy Pumps are the vital elements in an enormous range of fluid handling applications & range from small household pumps to immense units utilized in the water, chemical and energy industries. Pump performance requirements and duties vary considerably in terms of material of construction, wide range of temperature, pressure, viscosity, density etc.

For many years pump industry have been using traditional manufacturing methods for fulfilling the demands of market and in th is large demand from various sectors it is not easy to cater all the industry fastly and with consistent improving quality. In such a high demanding and competitive environment it is required to move to new advanced fast manufacturing methods and ‘3D Printing is one of them’.

3D printing is an ideal tool for volute shapes like impeller casings etc. For the pump industry, ExOne offers digital part materialization for patternless, digital production of sand molds and cores. Regardless of size or complexity, ExOne provides the fastest and most cost -effective way to produce cores for prototyping, replacements parts, and low volume production using foundry materials. Various other additional benefits of 3D printing technology are impeller Core Accuracy up to +/- 0.3mm, Superior Blade Registration, Better Hydraulic Performance, Ease of Dynamic Balance etc.

All these features of this 3D printing technology make it a versatile tool for Pump Industry. This will enhance the dependability of OEM’s on suppliers for better quality and fast deliveries. In coming future this technology is going to lead the whole pumping industry and will prov e itself a milestone.

- GlobalAxis(PartnertoExOneGmbH)

NewDelhi,India

3D Sand Printing – A Milestone for the Pump Industry

4

SPECIAL ARTICLE

“Schüle foundry partners with ExOne to deliver fast and flexible solutions”

“The main advantage is definitely the time savings,” says Ronald Spranger, Head of Sales and Project at

Schüle GmbH.

The German based foundry company cooperates with three-

dimensional (“3D”) printing specialist ExOne to supply automotive

sector customers as well as other business areas with success.

Automotive manufacturers are faced with the challenge to produce

parts more efficiently and at a lower cost. Meanwhile, the demand

for more complex parts in increasing and development cycles are

decreasing. Automotive manufacturers must keep an eye on every

production step to keep up with this ever-changing industry. The

advantages of the 3D printing process are apparent to automotive

manufacturers as they assess these changes.

ExOne, based in Gersthofen, specializes in the additive 3D printing

technique, which applies consecutive thin layers of sand to a

working platform. The sand is bonded by inorganic or chemical

binders and results in casting molds made without time-consuming

and cost-intensive tool production directly from a CAD-file. This

method is especially suitable for two application fields: to produce

new products via rapid prototyping or low volume production and to

avoid storage whenever possible. Therefore the ExOne™

technology provides an excellent complement to the portfolio of

Schüle.

The aluminum sand casting foundry specializes in complex, core-

intensive parts. Amongst them are ambitious parts, such as

gearboxes or engine blocks, for more than 200 customers in

different locations.

About half of the parts being produced by the Schüle foundry are

prototypes. The foundry employs 80 people and uses 500 tons of

aluminum per year. As a mid-sized company, Schüle can react

flexibly to the needs of the customers. Their company offers,

depending on the customer requirements, a fully automatic core

package molding line down to a furan hand molding line with optimal

results. They also provide pre- and post-processing steps such as

modeling and casting construction, in addition to comprehensive

quality testing.

“Our customers have different requirements," says Schüle. “When it

comes to serial production, the delivery reliability is most important.

What counts in this field, are feasibility and short lead time solutions.

Prototypes should still have all the relevant characteristics of a

production part.”

The metal foundry uses the 3D Printing process

AMMagazine Nov 20145

3D printing suitable for rapid prototyping and small scaleproduction

Designers are completely free to develop an experimental design

without any concerns related to casting production. In fact, the more

complex design of the core, the better it is to 3D print the part. For

example, a highly complex casting such as a twelve bore cylinder

block, where the water jack core often needs to be produced in

various sections, can be 3D printed as one complete part.

The cooperation with ExOne started just three years ago when the

company was looking for a foundry to cast samples with their sand

cores. Since then, Schüle orders more and more cores from ExOne,

30 to 50 pieces per month currently. Most of them are special molds

for complicated and core-intensive casting parts like engine blocks,

gearboxes, compressor housings and heat exchangers. They are

mainly used in pilot tests in the automotive branch and during the

initial prototype assemblies in machine and industrial plant

installations. In this case, Schüle uses ExOne’s so called

“Production Service Center“(PSC). The PSC is part of their core

business in addition to the manufacturing of 3D sand printers.

ExOne has offered the production of parts since the year 2000 and

maintains several PSCs worldwide. ExOne is growing their PSCs to

reduce delivery time and be closer to the customers.

Schüle can react quick and flexible to customer

inquiries

The integration of 3D printing into Schüle’s established casting

processes was simple and without problems. “The cores and/or

mold packages which are delivered by ExOne are very similar to

conventionally produced parts” said Mr Spranger, “This means: The

workflow is comparable and extensive changes were not

necessary.” It is also valid for the materials used.

Rainer Höchsmann is General Manager of ExOne Europa andChief Development Officer of ExOne

The unprinted sand, which contains an activator, can be recycled for

further use. In general, Mr.Schüle has come to the conclusion that,

“The cooperation is very good, thanks to the knowledge of ExOne,

who are world leaders in their field.”

Rainer Höchsmann has developed his expertise since 1999, when

he co-founded the company Generis, the predecessor of ExOne. He

is now the General Manager of ExOne Europe and the Chief

Development Officer. Generis developed world’s first 3D printer for

sand molds that has been in use since 2001 in the automotive

industry. To date, ExOne has installed more than 100 printers and

has become the market leader of 3D sand printing. It offers a large

variety of materials which meet the requirements of various casting

materials, such as aluminum, magnesium, iron and steel. The

company developed furan, phenolic and silicate binder systems

which can be used in conjunction with silica or ceramic sand.

In this year’s exhibition in Hannover, the Europe premiere of the M-

FLEX 3D metal printer took place. In addition to the production of

the 3D printers, ExOne also offers print services in its product

portfolio.

Schüle has considered buying its own printer. 3D printing is mainly

utilized for prototyping, but the technique has been growing in use

for serial production too. One attractive application is the use of

conventional methods for the production of the relatively simple

mold halves and 3D printing of complex cores that would be

expensive to produce by conventional techniques. “We have

already gained positive experiences,” confirms Schüle. “And the

printing of molds and parts will establish itself more and more and

become an inherent part of the foundry business.” One thing that

will not change: The know-how and experience of the casting

experts will still be required even though the design of the

molds/cores will play a key role in future production.

AMMagazine Nov 2014

SPECIAL ARTICLE

6

CUSTOMER CASE STUDY DEFENCE & SPACE

AMMagazine Nov 2014

Telecommunicationsatellite:thethreeadditivemanufacturedbracketseasilywithstandatemperature

rangeof330°Candmeetthehighdemandofpermanentspacemissions(Source:AirbusDefenceandSpace).

Aerospace Company Airbus Defence and

Space Uses Additive Manufacturing for the

Production of Satellite Parts

The literal translation of the word satellite (companion) does

not come close to explaining how complex these technical

devices are and what they do for our daily lives. Their tasks

range from weather forecast to message transport and

navigation information. The Airbus Defence and Space

division is one of the world‘s leading suppliers of satellite and

space transport technology. Its Spanish subsidiary is part of

the satellite business and the largest aerospace company in

its home market.

The portfolio ranges from satellite systems to components for the International Space Station ISS. A competence centre for composite materials is also located at the headquarters in Madrid – because innovative materials and production methods play an important role in the a erospace industry. The requirements for the devices are particularly high because of the tremendous temperature differences and external forces involved. To achieve the best results in component manufacturing, Airbus Defence and Space relies, among other t hings, on Additive Manufacturing technology by the German company EOS.

Facts

Challenge

Cost-effective production of optimized retaining

brackets for the connection of components in

telecommunication satellites.

Solution

Faster production of thermally highly stressed

components by using Additive Manufacturing

technology for metal parts offered by EOS.

Results

• Robust: temperature resistance meets

highdemand of permanent space

missions

• Economic: production costs reduced by

more than 20%

• Light: weight reduction of the retaining

brackets is about 300 g

• Paving the way: lighthouse project as

the pioneering role for other

applications in space

Advanced Manufacturing Process by

EOS Optimizes Satellite Technology

Short profile

Airbus Defence and Space is a division of Airbus

Group formed by combining the business activities

of Cassidian, Astrium and Airbus Military. The new

division is Europe’s number one defence and

space enterprise, the second largest space

business worldwide.

Address

Airbus Defence and Space Avda. Aragón

7

Challenge

The current generation of satellites includes specific

brackets that serve as a link between the body of the satellite

and the reflectors and feeder facilities mounted at its upper

end. The engineers at Airbus Defence and Space faced two

key challenges with regards to the construction of these

retaining brackets: on the one hand, the brackets must

fix the securely to the body. On the other hand, however, the

task of the brackets is to mitigate the extreme temperature

fluctuations in space. The brackets are very important as a

layer of insulation: the temperature ranges from –180 to +150

°C, so the stress on the material is extremely high.

Very few materials are able to meet these requirements. As

so often in the aviation and aerospace industry, titanium

turned out to be the appropriate cho ice. In addition to its well -

known advantages with regards to weight and thermal

conductivity, it offers an acceptable density. After all, every

kilogram to be carried into space costs many thousand

dollars; the exact amount depends on factors such as the

carrier system and the orbit to be reached. However, six-

figure sums and higher are not uncommon.

The brackets manufactured in the conventional way and

especially their connection with the carbon components of the

satellite –

a function subject to high thermal stress – did not meet the

expecta- tions of Airbus Defence and Space. In addition,

subsequent installati- on on the satellite component was very

time-consuming so

costs needed to be reduced. The engineers therefore began

looking for alternatives. Special attention was paid to the fact

that the design of future components could be optimized

accordingly.

Therobusttitaniumbracketsweremanufacturedusing

anEOSINTM280.Theyeasilyandpermanentlywithstandthehightemperaturesandexternalforcesin

space(source:AirbusDefenceandSpace).

Solution

The choice fell to the Additive Manufacturing technology for

metal parts offered by EOS. This meant that titanium was

still usa- ble as a tried and tested material. It also allowed

the design of the components to be adapted easily. As

Otilia Castro Matías, who is responsible for the area of

antennae at Airbus Defence and Space, explains: ”The

solution now found by us has two advantages. For once

we were able to optimize production itself. In addition, we

have improved the design, so the entire workpiece can be

manufactured in a single step. Hewn from a single block so

to speak, even though technically speaking it is the opposite

of this traditional technique.“

After the design was established, the well established

process followed: the engineers loaded the 3D construction

plans from the CAD software into the production machine

– an EOSINT M 280 – and started the manufacturing

process: a laser beam precisely melts and hardens the

deposited metal powder layer by layer, so when the

precision- made workpiece is complete, no excess material

remains except for re-useable raw material.

Results

The new devices meet all expect - ations of the experts

involved. Most important of all is the improved temperature

resistance of the entire structure, which now can easily and

permanently withstand a margin of 330 °C under a force of

20 kN. In addition to this, the Spanish aerospace experts

were able to reduce production time of the brackets during

assembly of feed and sub reflector units by five days.

Production time of the three brackets required for each

satellite is now less than a month.

”These improvements signifi- cantly reduce thermally

induced failure during the qualification test campaign. The

cost of space activities is relatively high, so it is even more

important to protect any hardware from possible failures,“

adds Castro Matías. ”The Additive Manufacturing method

brought measurable benefits to critical aspects of the

project, without requiring cuts to be made elsewhere. No

compromises - this is something engineers like to hear, but

don’t get to hear very often.“ In addition to the technical

advantages, targeted cost reductions were achieved:

savings in production alone amount to more than 20%.

What is more, the engineers success - fully put the part on a

diet: the weight advantage is about 300 g, which means

nearly one kilo per satellite.

Incidentally, European Space Agency (ESA) supported this

program. Its successful completion it allows further use of

this efficient production technology in the aerospace field.

AMMagazine Nov 2014


8

”The use of titanium as the material for the retaining brackets of our satellites has proven highly effective. The main

weakness, however, was the connection of the brackets with the carbon panel of feed and reflector assembly because

here the thermal stress was negative factor. Thanks to Additive Manu- facturing, we were able to redesign the bracket

and eliminate this vulnerability. There were other benefits, too, such as shorter, more cost-effective and more lightweight

production.“

- Otilia Castro Matías, COC Antennae at Airbus Defence and Space



12

In an industry typically shut off by red “Top Secret” stamps and

closed-door meetings, Advanced Aerials is doing things a little

differently. They’ve put a welcome mat on their door in an effort to

not only supply Unmanned Vehicle Systems (UVS) but to

perfect their designs and innovate through open-source

collaboration. Think of Advanced Aerials’ work as the launching

point for creating affordable UVS designs that fulfill the exact

requirements of users from military intelligence units to first

responders

“There’s a lot of forcing of designs that aren’t fully baked. We don’t

want to force technology because it inevitably falls short,” says

Advanced Aerials founder Bert Wagner. “We’re crowd sourcing UVS

design by sending prototypes to end users so they can collaborate

and build something that fits a need perfectly. We want to solve

problems, not sell products.”

Wagner, a former professional photographer, taught himself CAD

and vehicle design in order to make drones for aerial photos. Over

the years, that side project morphed into Advanced Aerials. For a

homegrown business like this, it’s sometimes difficult to fulfill

manufacturing requirements: tooling and injection molding are far too expensive and owning a 3D printer would be cost prohibitive at

this point. At the same time, the advantages of 3D printing fit

perfectly with Wagner’s needs. “I had to focus on design intent and

less on how to provide enough clearance for a given tool. I didn’t

want to worry about a machinist.”

What Wagner needed was his own 3 D printing manufacturing unit, a

way to produce parts quickly and iterate design without equipment

and labor overhead. That’s where Quickparts—the on-demand

printing service by 3D Systems—came in. Ten years later, Wagner

still uses Quickparts, which produces Advanced Aerials’ ready-to-

use vehicle components using 3D Systems’ Selective Laser Sintering (SLS®) technology.

“We use Quickparts for anywhere between $3,000 and $10,000

worth of parts per year,” says Wagner. “The beauty is that if I’m in a

rush, I can get parts in a couple of days. You can’t beat that.”

Bear in mind, these are not concept model parts or casting patterns,

as is sometimes the case with robotics developers. Instead, they are

characteristically tough SLS parts, made in Duraform® and

Duraform Flex materials, that Advanced Aerials installs onto their

UVSs for direct field use. “Our parts have held up under crashes.

We’re real happy with that,” says Wagner.

SLSpartsfortheMSEV

Above,BertWagnerassemblestheMSEVBelow,MSEVparts

madewithDuraform®EXBlack

Take the Miniature Surveillance Expendable Vehicle (MSEV), for

instance, a UAV made largely of SLS components from Quickparts

and being developed for one of Advanced Aerials’ DoD customers.

MSEV, a deployable, four -rotor vehicle, will eventually aid in

situational awareness. Other Advanced Aerials vehicles will support

short-range, short- duration counter IED operations. The company is

also supporting software and vehicles that would allow users

to operate UVSs in environments where external guidance signals,

e.g., GPS or RF, are weak, unavailable or actively jammed. These

could drastically improve the safety of soldiers and first responders

as they inspect buildings or other dangerous enclosed areas. And

that’s a huge goal for Advanced Aerials —improving safety and

saving lives.

As Wagner puts it, “We want our vehicles to go from A to B in some

pretty brutal environments.” But there’s so much more to it; they’re

democratizing UVS development, and using the speed and

affordability of Quickparts SLS manufacturing to do it.

Advanced Aerials removes the mystery

from Unmanned Vehicle System

development with an assist from

UNMANNED VEHICLE SYSTEM


UVSs don’t have to cost so much or be so shrouded in

red tape to be effective, and Advanced Aerials is

proving it. Down the road, they even see educational

opportunities brought about by their open-source

model, giving students the opportunity to discover,

explore and contribute to the emerging science of

robotics. All in all, that’s how you build a better UVS:

accept ideas from all around, appeal to the next

generation of engineers, and find the perfect partner

to help you make it.

UNMANNED VEHICLE SYSTEM


12

BIOMEDICAL APPLICATIONS OF 3D PRINTING

AMMagazine Nov 2014

Saving a newborn with the support of 3D Printing

Finding out that you are going to have a baby may be one of the happiest days of your life. Sadly for one family in Ne

York, the joy quickly turned to fear and uncertainty when they found out their baby would be born with a complex form

of congenital heart disease. Having already diagnosed the condition in the womb, the doctors at NewYork-

Presbyterian/Morgan Stanley Children’s Hospital had time to plan how they would save the baby’s life before it even

began with the support of 3D printing and Materialise’s Mimics Innovation Suite of software.

In July, a baby boy was born with a complex form of

congenital heart disease in which both the aorta and

pulmonary arteries arise from the right ventricle. Also

present was a large hole in the heart called a ventricular

septal defect (VSD). On the first day of his life, an extremely

low dose chest CT scan was acquired to better understand

the complex 3D relationships of the heart and defects. From

the images alone it was difficult for the doctors to formulate

the optimal surgical plan, especially considerin g that the

baby’s heart was no bigger than a walnut! They turned to

the 3D printing experts at Materialise for a solution.

Starting with the baby’s image data, Todd Pietila,

Cardiovascular Business Development Manager at

Materialise, created a 3D model of his heart using Mimics

Innovation Suite of software. The team at NewYork-

Presbyterian/Morgan Stanley Children’s Hospital worked

closely with Mr. Pietila to achieve an accurate reconstruction

of the heart, which would allow the surgical team to best

visualize the complex defect. The result was a 3D

representation of the heart with the small details of the

congenital defects captured accurately.

The file was then 3D printed at the medical production facil ity

at Materialise’s U.S. headquarters in Plymouth, Michigan.

Only 2 days after receiving the data, a replica of the baby’s

heart was delivered to the hospital!

Supporting an Unprecedented Procedure

The Power of Holding the Tiny 3D -Printed Heart The complex 3D relationships of the newborn’s defects were

not apparent from the ultrasound and scan data

alone. Fortunately, with the 3D-printed model in hand, the

team of clinicians at NewYork -Presbyterian/Morgan Stanley

Children’s Hospital found an ideal solution for repairing all of

the defects during one procedure, instead of three or four

surgeries.

12

The Standard in ‘Engineering on Anatomy TM’

The Mimics Innovation Suite turns 3D image data into high -quality digital models in an accurate and efficient way.

Starting from optical scan, CT or MRI data, the Mimics Innovation Suite offers the most advanced image segmentation,

the broadest anatomical measurement options, powerf ul CAD tools for Engineering on Anatomy and 3D Printing, and

accurate model preparation for FEA and CFD.

“The baby’s heart had holes, which are not uncommon with CHD, but the heart chambers were also in an unusual

formation, rather like a maze,” said Dr. Emile Bacha, a congenital heart surgeon and Director of Congenital and

Pediatric Cardiac Surgery at NewYor k-Presbyterian/Morgan Stanley Children’s Hospital. “In the past we had to stop

the heart and look inside to decide what to do. With this technique [using a 3D printed model], it was like we had a

road map to guide us.”

Dr. Emile Bacha performed the surgery when the week-old baby weighed just over 7 lbs. His single procedure approach

allowed the baby to avoid the typical series of palliative operations which can be life threatening. The clinical outcome was

ideal and the baby is on his way to a healthy life.

The 3D printed heart model also allowed the surgeons’ to explain the baby’s condition and their plan to the worried parents.

By seeing the model and understanding what needed to be done, the parents became as confident as the surgi cal team.

The baby’s father commented, "In discussing the necessary surgery with the doctors it was unclear how it would be

performed and if it would be accomplished with one or two surgeries. We were told that they are working on getting

a 3D-printed model of our son’s heart, which the team hoped would clarify the surgical plan. Upon receiving the

model, everything changed. After studying the model, the surgeon got a clearer picture of what needed to be done

and was very optimistic that he could do the repair in one surgery. Our baby was saved from subsequent surgeries

and interventions and all the side effects and developmental delays that come with it. This is truly an amazing

advancement in surgical planning and outcome. We are so thankful!"

The Future Looks Bright

The 3D printed HeartPrint® model proved to be so valuable that the clinicians at NewYork -Presbyterian/Morgan Stanley

Children’s Hospital are already working with Materialise on additional cases. Dr. Bacha added, “After the success of this

surgery, it’s hard to imagine entering an o perating room for another complex case without the aid of a 3D printed

model. It’s definitely going to be standard of care in the future and we’re happy to be leading the way.”

12

BIOMEDICAL APPLICATIONS OF 3D PRINTING


12

AMMagazine Nov 2014

3D PRINTING OF SAND MOULDS

CAD-file of the wheel carrier Sand casting form of the wheel carrier Race Tech in action Mounted wheel carrier

Sandcasting: fast, patternless, close-to production

voxeljet produces moulds for casting from dataset. Through implementing the Generis Sand Process the user benefits from

crucial time and cost savings. Based on 3D CAD data the moulds are made fully automatically without tools using the layer

building method in the required mould material. The laborious and costly route to the otherwise necessary mould set -up is

dispensed with. Our ability to produce moulds with dimensions of 4 x 2 x 1 meters is unique worldwide.

SandMoulds Castings

Totalsize(mm) 697x523x353 Totalsize(mm) 520x205x390

Weight(kg) 1.2 Weight(kg) 3.4

Individualparts 1 Material AIuminium

Material Sand Leadtime(weeks) 3

Layerthickness

(mm)

0.3

Leadtime(days) 5

Buildtime(hours) 3.5

Project description:

The car must be faster, and also lighter. Also in the formula student projects is the focus on the weight optimization of the new racing cars. In this case, a magnesium and an aluminum wheel carrier were compared.

• Purpose: Prototyping

• Challenge: Production of complex wheel carrier in a few weeks

• Solution: Production of 2 sand casting molds for the aluminium and magnesium castings

14

PRESS RELEASE

Dr.HansJ.Langer,founderandCEOEOS

Customers and long-term companions over the

last 25 years congratulate the company on its

anniversary:

• Christoph Weiss, Managing Partner of the

BEGO Group: "We have enjoyed a good and

close partnership with EOS since 2008. Their

systems represent the current benchmark in

selective laser-melting system engineering in

the dental market and have facilitated our great

success over three continents – Europe, Asia

and America. contact that we have to the

developers in Finland.

EOS GmbH Marks Its 25th Anniversary with a move into a new new technology and Customer Centre at its Headquarters in

Krailling

EOS Additive manufacturing (AM) now allows industrial applications in series production

Krailling, 17 July 2014 – EOS, the technological and market leaders

in design-driven, integrated e-manufacturing solutions in the field of

Additive manufacturing (AM), has now moved into its new Technology

and Customer Centre in the Krailling Innovation Mile (KIM). Dr. Hans

J. Langer, founder and CEO of EOS comments: "This new building

represents a further milestone for EOS and is an expression of our

company's growth and success story over the last twenty-five years.

We operate in a market that is high ly dynamic and which offers a huge

potential. In the past we almost exclusively served the area of Rapid

Prototyping, whereas now, Additive Manufacturing enables industrial

applications in series production." And he adds: "This new building

gives us more space in which to grow, allowing EOS to continually

adapt to new market conditions and customer segments. Moreover,

the new customer centre gives us the spatial flexibility we need to

allow us to jointly develop current and future application solutions in

Additive Manufacturing together with our customers." A few facts about the new building

With the construction of this new building, EOS underlines its loyalty to its location in the west of Munich. Christian

Kirner, the company's COO, stresses: "With a floor space of 17,000m², the building is able to accommodate an

additional 300 employees, while its design follows specific architectural, spatial and workplace concepts. The

architectural concept renders the three key principles of the company's business strategy – innovation, quality and

sustainability – both visible and tangible. The facility operates on the basis of an integral, sustainable energy

concept." He continues: "In line with our corporate objectives, right from the start the emphasis was placed on the

building's functional and ecological efficiency. Both its construction and operation were conceived with all due

consideration for the efficient use of resources and energy-efficient building. In this way, the EOS building concept

already complies with the requirements of tomorrow –

apt reflection of the nature of the technology offered

NewEOSTechnologyandCustomerCentreinKrailling

• Thanks to the sophisticated EOS technology and our BEGO processes and alloys, we are able to restore the

smiles to the faces of patients worldwide – and it is this that drives us on every single day."

• Bart Van Der Schueren, Executive Vice President Materialise: “We want to congratulate EOS with their

25th anniversary. We have been successfully collaborating with EOS over their entire history, both as a

software partner and as a user of their technology. Looking back over these 25 years it is without saying

that EOS has had a huge impact on the industry. Thanks to the effort of EOS, production is changing in a

fundamental way and is giving unseen new opportunities for new produc ts and businesses.”

• Terry Wohlers, Wohlers Associates: “ EOS has played an important role in the history of Additive

Manufacturing and industrial 3D printing worldwide. Without the company, the landscape of the industry

would be much different today. We expect laser sintering to serve a wide spectrum of organizations in the

future, especially as they uncover the vast potential of the technology.”

12


The Zero-G Printer is the first 3D printer designed to

operate in zero gravity. Launched into orbit on September

21, 2014, the printer was built under a joint partnership

between NASA MSFC and Made In Space. Contracted as

the “3D Printing in Zero-G Experiment,” this first version

of the Zero-G printer will usher in the era of off-world

manufacturing.

This initial version of the Zero-G Printer will serve as a

test bed for understanding the long-term effects of

microgravity on 3D printing, and how it can enable the

future of space exploration. It is a culmination of contracts

and development dating back to 2010 including

microgravity tests with NASA’s Flight Opportunities

Program, R&D contracts under NASA’s SBIR Programs,

and development contracts with NASA MSFC.

This “machine shop for space” will mark the first time that

a multi-purpose manufacturing device will be utilized off -

world to create parts, tools and emergency solutions.

Developed by Made In Space, Inc., under a contract with

NASA Marshall Space Flight Center (MSFC), the 3D

printer is part of a technology demonstration intended to

show that on-site, on-demand manufacturing is a viable

alternative to launching items from Earth. “Everything

that has ever been built for space has been built on the

ground. Tremendous amounts of money and time have

been spent to place even the simplest of items in space to

aid exploration and development,” said Aaron Kemmer,

Chief Executive Officer of Made In Space. “This new

capability will fundamentally change how the supply and

development of space missions is looked at.”

Following delivery to ISS, the 3D printer is scheduled to

be installed in the Microgravity Science Glovebox (MSG)

to conduct its series of prints. The printer will create a

series of test coupons, parts, tools, use case examples

and even STEM project designs by students as part of the

3D Printing in Zero-G Experiment. This experiment,

intended to demonstrate additive manufacturing

capabilities in space, was developed through a

partnership between Made In Space and NASA MSFC.

Made In Space is working with busin ess partners to

formulate additional use case examples to demonstrate

printer capabilities.

www.madeinspace.us

ZERO – G PRINTER - A Historic Revolution in Space Access -– The Sky is no longer the

limit – “The Machine Shop for Space”

Zero-GPrinter

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AMMagazine Nov 2014AMMagazine Nov 2014AMMagazine Nov 201416

Reconstructing cylinder heads for Porsche legends

Anyone who owns a legendary Porsche 550 Spider, 904 or

356 Carrera can count himself lucky. These cars have

experienced an enormous increase in value over the last

few years. Unfortunately special parts like cylinder heads

are no longer available. In the event of damage, the only

remedy is through customized parts reconstruction or

reverse engineering, and 3-D printing turned out to be the

cheapest way.

Reconstructing complex components is a challenge for e very

design engineer, because drawings are not available in most

cases and they are not provided by the OEM-manufacturers. In

this particular case, the reconstruction of a Carrera cylinder

head made of aluminum started with measuring and scanning

of the defective head.

Valve guides, seat rings, camshaft bearing, intake and exhaust

ducts, cylinder head screws etc. had to be set up as 3D base

bodies in a meticulous detailed process. The next step was the

transfer to superordinate functional models and the adding of

design features from casting technology like site measuring,

bevels and fillets.

Affordable sand cores from the 3D printer

After the geometric reconstruction made by the company CAD

Support from Mössingen, Germany, the production of the sand

cores was the next item on the agenda. The project

implementation with conventional cores based on core-making

tools was impossible for cost reasons. The only solution was

creating the cores in a 3D printer.

The order for printing the entire core package with eleven cores

in total went to the voxeljet service center in Friedberg which

has many years of experience in project of this kind. Thanks to

the excellent printing quality of the voxeljet printer, it was also

possible to outline the thin-walled cooling rib measuring 2 mm

without additional supporting structure in the inner and outer

cores.

The molding was made by the foundry Rauleder & Rudolf

based in Schwäbisch Gmünd, which specializes in constructing

unique components. The hot isostatic pressing (HIP) treatment

led to a tremendous improvement of the mechanical properties,

as well as a reduction of pores.

The final T6 heat treatment provided the ultimate strength of the

cylinder head. The finishing of the components was made on

the basis of the 3D CAD files in a 5-axis machining center. After

completion, the aluminum cylinder head was ready for

assembly.

CylinderHeads

PRESS RELEASE 12

AMMagazine Nov 2014AMMagazine Nov 2014AMMagazine Nov 201417

Advanced Aerospace Applications:

Production of fully functional, highly

complex parts directly from electronic data.

e-Manufacturing™ means

the fast, flexible and cost-

effective production directly

from electronic data for

product development and

manufacturing. Laser sinte-

ring is the key technology

for e-Manufacturing. With

systems from EOS, the

worldwide leading manu-

facturer of laser sintering

systems, you can achieve

weight and material savings,

turn your most complex

design ideas into reality

and enable functional

integration. Directly by

solidifying metal or plastic

powders.

With e-Manufacturing you

can secure your competitive

advantage in a business

environment that is facing

ever increasing and chal -

lenging targets around

emission reduction and

conservation of natural

resources.

www.eos.info

EOS Additive Manufacturing:

Fuel Injector & Swirler,

Material: CobaltChrome MP1

(Source: Morris Technologies)

EOS e- Manufacturing Solutions

AM magazine 29th issue

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Transcript of AM magazine 29th issue