AM Markets - Klaipėdos mokslo ir technologijų parkas AM Business and Markets Industrial... ·...

Additive Manufacturing – 3D printing

AM Markets

Antti Salminen

Laboratory of Laser Processing (LUT Laser)School of Energy Systems

Lappeenranta University of Technology (LUT)

1Klaipeda 10.4.2017

”…3D printing that has the potential to revolutionize the way wemake almost everything…the next revolution in manufacturing isMade in America. We can get that done.”

Barack Obama, President of USA

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4resilience-economics.comKlaipeda 10.4.2017

General process from CAD to part

5Gibson et al., Additive Manufacturing TechnologiesKlaipeda 10.4.2017

Terminology

Additive manufacturing of metallic materials can be divided into(according to F2792-12a):

1. Directed energy deposition (DED) an additive manufacturingprocess in which focused thermal energy is used to fusematerials by melting as they are being deposited.Methods using dynamic wire feed or dynamic powder feed tolaser beam are included to these technologies.

2. Powder bed fusion (PBF) an additive manufacturing process inwhich thermal energy selectively fuses regions of a powder bed.Methods using laser beam or electron beam source of thermalenergy are included to these technologies.

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Terminology

Additive manufacturing of metallic materials can be divided into(according to F2792-12a):

3. Material jetting an additive manufacturing process in whichdroplets of build material are selectively depositedThese methods are based on binder which is jetted to metalpowder. Binder is removed from work piece in post-processing,and this way formed porous material is filled with infiltrator.

4. Sheet lamination an additive manufacturing process in whichsheets of material are bonded to form an object.Work piece is manufactured from thin, joined steel plates.Joining happens for example via ultrasound or friction welding.


Principle of powder bed fusion

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• Direct Energy Deposition (DED) process is based on laser cladding

• Additive material is fed dynamically during the process• In DED cladding process is used to build shapes in 3D

DED

Laser cladding – 2D Direct Energy Deposition – 3D

Vs.


10

DED

Outer surface

Filling

More layers:Hatch distance is changed for each layer

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11

DED

− Cross section as cut− Solid material− Even heat effect

− Side view shows the layers− Accurate surfaces are

machined

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DED enables higher speed High productivity means typically loss of accuracy

− So called micro 3D is done with separate lab systems

High accuracy requires typically machining

Building speed

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Powder bead fusion: 1- 3 mm3/s DED: 3 - 10 mm3/s

AM Markets

Hype curve of Gartner

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Expectations given by hypeMaturity of technology

Hype curve

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Gartner hype curve

15http://www.ecampusnews.com/top-news/the-hype-cycle-of-mooc-courses/

Maturity

Visi

bilit

y

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Gartner hype curve 2011

16

Idea management

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Suitability of AM: size – batch size


Stratasys stock price history


3D Systems stock price history


Arcam stock price history


3D systems and Stratasys acquired:− During last five years both 5-10 companies manufacturing 3D-printers

2014 GE acquired:− Morris technologies, an American 3d printing subcontractor

2015 DMG Mori Seiki acquired:− DMG Mori a manufacturer of hybrid PBF systems

2015 GE acquired:− Avio Aero, an Italian 3d printing subcontractor

10/2016 Oerlikon acquired:− 3D printing subcontractor

11/2016 GE acquired:− Arcam, the manufacturer of EB based PBF machines− Concept laser, a manufacturer of laser based PBF machines

4/2017 DMG Mori Acquired:− Realizer, a manufacturer of laser based PBF machines

Recent activity


Global sales of AM materials

28Klaipeda 10.4.2017 Wohlers report, 2013

Industrial systems unit sales


World market


Markets by number of systems

31Wohlers report, 2013Klaipeda 10.4.2017

3D printer average selling price


33

84%

BK30A0900 Additive Manufacturing

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3D printed electronics market


0

200

400

600

800

1000

1200

2014 2019 2023

Rest of the market forAM in AerospacePowder beadequipment

AM market for aviation

35

Sales to the aerospaceindustry of AM equipment andassociated software, servicesand materials

Milli

on U

SD

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Metal AM machine market

36

Increase 2012- 2014 = 76%

Increase 2013- 2014 = 55%

Klaipeda 10.4.2017 Wohlers report, 2015

Emergence of AM


Gas turbine blades Development time for prototype -90% Test environment:

− 13000 rpm− 1600 km/h− 1 250 oC− Force of 11 tons.

Turbine blades


Stealth keys


The three structural elements shown are all designed to carry the same structural loads and forces.

The potential of 3DP in construction


http://www.arup.com/news/2014_06_june/05_june_construction_steelwork_makes_3d_printing_premiere

"This is not only an exciting development for the construction sector, but many other industries as well. In the case of this particular piece, the height is approximately half that of one

designed for traditional production methods, while the direct weight reduction per node is 75%. On a construction project that means

we could be looking at an overall weight reduction of the total structure of more than 40%. But the really exciting part is that this

technique can potentially be applied to any industry that uses complex, high quality, metal products.“

— Salomé Galjaard, Team Leader at Arup

The potential of 3DP in construction


http://www.arup.com/news/2015_05_may/11_may_3d_makeover_for_hyper-efficient_metalwork

http://www.arup.com/news/2014_06_june/05_june_construction_steelwork_makes_3d_printing_premiere

http://www.arup.com/news/2015_05_may/11_may_3d_makeover_for_hyper-efficient_metalwork

Design potentia


The global economy is worth 70 trillion USD Manufacturing more than 15% of that, 10.5 trillion USD If AM takes 1% of global manufacturing the volume is 105 billion

USD ( over 100x the estimate of 2021)

Market opportunity and forecast

43

Wohlers report, 2013

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Market opportunity and forecast

44

Milli

ons

of U

SD

Wohlers report, 2013

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Current and future potential

45ey.com/3DprintingKlaipeda 10.4.2017

Heat exchanger design

Optimised heat exchanger:Repeated freely designed optimized

elements.Self supporting drop shaped

channels.Turbulence generator inside tubes

maximise the heat exchange.

Material: EOS Aluminium AlSi10Mg Equipment: EOSINT M 270Building time: n. 85 h

Industrial applications

Golf ball mould

Conformal coolingCooing channels follow the geometry of

mould improved coolingIncrease in productivity 20 %


Robot gripper

Gripper lifts four ball bearings at timeTraditional structure as several pneumatic componentsWith AM one component, which acts as pneumatic

gripper, is made


Robot gripper

Traditional gripper

AM gripper

Weight: 1 542 g 215 gPrice: 2 670 € 1 700 €Height*: 87,5 mm 30 mmSpare partdelivery

3 weeks 4 days

Life time 10 M cycles 5 M cycles


* From C-joint

Hydraulic bloc

Combines two input channels to one output channel.

Original design:Four holes drilled into solid block of

material

Front Top


4

Drilled holes

Blogged holes1

2 31

4

2 3

Hydraulic bloc

AM structure:Struts carry the mechanical loads FEM optimized structure carries the optimized flow channels


Specialist software exist that allows internal structures of the 3Dmodel to be optimized for AM manufacturing

For example Within and Netfabb Selective Space Structures(Autodesk), SolidThinking Inspire (Altair), nTopology etc.

Usually expensive software, however nTopology Element can be downloaded for free.

Internal structure optimization


- Weight bearing manifold- Structure optimized with

Within and manufactured by PBF

Agile project management and Integration of AM software in process chain

Amorphous metals and multimaterial combinations

Multi laser concepts, process control, automation, new processes

Micro machining process (MMP) and computed tomography

Repair of high value components and mobile applications

What can be expected


Engineering & software

Materials

Machines

Post processing

Services

Impact

AM part cost will drop significantly

AM market will grow

exponentially

AM stock prices are approaching

fair valuation

AM Costs

Case landing gear

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Main landing gear of the Italian aircraft P180 Avant II by Piaggio Aero Industries S.p.A.

Atzeni & Salmi, 2012Klaipeda 10.4.2017

Re-designed to utilize potential provided by AM, unhanged pars with orange color

a) General view of landing supportb) Image from topc) Detail from side

Case landing gear support

56

a)

b)

c)

Atzeni & Salmi, 2012Klaipeda 10.4.2017

Cost with investment casting

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Cost with investment casting


Cost with AM


Total costs

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Case Teeth adjustment

Unaesthetic, bad for self consistence Uncomfortable and solid Requires constant follow up by orthodontics dentist Cost of treatment 3 000 – 5 000 €

Current technology


Use of AM

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http://www.zrdental.com/Klaipeda 10.4.2017

http://www.zrdental.com/

Started 1997 80-miljon tools made 2011 delivery of 309 335 set Typically 30 - 40 tools per patient Treatment plan 18-24 months Production currently 34 000 tools per day (24/7 with 85%

efficiency)

AM orthodontics


Case Virgin Atlantic: monitor support

How to optimize weight

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Model 1: Cutting from solid billetWeight 0.8 kg

Model 3: AM optimizedWeight 0.37 kg

Model 2: AM lattice structureWeight 0.31 kg

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Lifecycle analysis

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Example with 90 Mkm travel in a long route

Cutting 100 kg 2 kg 5 kg 43 779 kg 43 886 kg

AM Lattice 16 kg 5 kg 1 kg 16 238 kg 16 260 kg

AM Optimum 18 kg 7 kg 2 kg 20 339 kg 20 366 kg

ProcessRaw

materialsCO2

ProductionCO2

DeliveryCO2

UsageCO2

Life-cycleCO2

Raw materials Production Delivery/

salesConsumer

usageDisposal/ recycling

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Lifetime CO2 emission

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Model 1: Cutting from solid billet100%

Model 3: AM optimized46%

Model 2: AM lattice structure37%

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Price of machined part $500 Price of AM part $2,500 Return of investment 2 years. 0.49 kg weight saving per piece $ 1 500 savings on fuel consumption per annum $ 45 000 savings on fuel consumption during the 30 years

lifecycle of plane Product life cycle 5-7 years (estimate) Lifecycle savings $ 6 500 - $ 9 000

Costs


Build speed 10 cm3/h 40 cm3/h 80 cm3/hMachine cost 500 k€ 700 k€ 800 k€Share of monitoring 5% 2% 0%Machine utilization 86% 84% 81%Steel powder price 89 €/kg 70 €/kg 30 €/kgPost-processing work 1.52 h/kg 1.05 h/kg 0.96 h/kg

Forecast: metal AM costs in euros/cm3


Renishaw wanted to design bottle opener which would be light, strong and impossible to made with other manufacturing methods.

Case study - Eliminating supports

72Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw

Second step included modifying the model so that it would support itself.



Manufactured bottle openers.



• Manifold blocks are complex components where numerous pipes come together and intersect.

• Traditionally, manifold blocks are created by cross drilling from a solid metal block.

Case – Minimizing manifolds

75Klaipeda 10.4.2017Source: Marc Saunders, Renishaw

• One way to prevent clogging and make the flow slightly better is to use internal plugs.



DfAM step 1- extract the essentials that are needed.



DfAM step 2 - Optimize flow



DfAM step 3 – Define wall thicknesses and add supports



• Result : Flow and weight optimized part• Original part made out of aluminum, optimized one out of

stainless steel. Still 50 % weight savings.



Part consolidation


Manufacturing large parts, DED


Repair of bearing surfaces of cam

shaft

On-site repairing –corrosion wear in turbine

Manufacturing large parts, DED

86www.3ders.orgKlaipeda 10.4.2017

Lappeenranta University of Technology

Laser Processing Laboratory

For more information:www.lut.fi/laser

Contact person:Professor Antti Salminen [email protected]. +359 40 767 4387

87

Thank you for your attention!

Klaipeda 10.4.2017

http://www.lut.fi/laser

mailto:[email protected]

www.lut.fi/laser


AM Markets - Klaipėdos mokslo ir technologijų parkas AM Business and Markets Industrial... ·...

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