Metallien lasersintrauksen haasteita
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Metallien lasersintrauksenhaasteitaFirpan pikavalmistusseminaari
Aalto-yliopisto, Dipoli, Espoo22.5.2013Olli NyrhiläEOS Finland
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EOS: Technology and Market Leader for Design-Driven, Integrated e-Manufacturing Solutions
EOS Headquarter in Krailling
EOS ManagementEOS GmbH Electro Optical Systems: family-owned, founded in 1989Hidden champion headquartered in Krailling near Munich, GermanyEOS is an integrated solution provider for additive manufacturing Solution portfolio: Additive Manufacturing (AM) systems, materials – both plastics and metals, software and services Complete end-to-end solutions: from part design, data generation to part building and post-processingEOS enables competitive advantages for a variety of industries, such as medical, aerospace, tooling, industry, lifestyle products and automotiveEOS is committed to Innovation – Quality – Sustainability
Dr. Hans J. Langer Dr. Adrian Keppler Christian Kirner Peter Klink
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NorthAmerica
~ 13%
Europe and Rest of World~ 70%
Asia~ 17%
EOS: Global Presence
EOS worldwide installed base* EOS global footprint
~ 1.100 systems• 1/3 Metal systems• 2/3 Plastic systems
• 210 customers with > 1 system
Customers in more than 30 countriesEOS sales/application/service offices in 11 countries, distribution partners in 22 countriesWorldwide staff of ~440 (~ 340 in Germany)Strong patent portfolio: More than 700 active patents in nearly 100 patent familiesR&D Spendings of ~15% of Sales
Source: EOS, *approx., number as per July 2012. Staff figures as per 30 Sep 2012.
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EOS: A Continuous Success Story
Source: EOS; Numbers for fiscal years as per end of fiscal year 2011/2012.
162 177 208 232 252 284 328 332 390 440
Turnover (in m €)
Number of Employees
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Picture
Additive Manufacturing: “The Manufacturing Technology that will Change the World”
Source: The Economist 12/02/2011; EOS
Picture
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EOS Finland
EOS Finland was founded October 2000
• Origin• Development and metal powder sourcing group of Electrolux Rapid
Development• Development partner of EOS from 1994 on, the beginning of commercial
DMLS (Direct Metal Laser Sintering)• Joint development of materials and processes for EOS metal platforms
• As result of outsourcing activities of Electrolux the development and sourcing group was acquired by EOS
• Foundation of EOS Finland• Fully owned by EOS
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EOS Finland in EOS Group
EOS Finland has several functions in EOS
• Global sourcing of metal powders• Metal powder manufacturing• Development of EOS metal powder products
• Commercialization through EOS GmbH• Development of EOS metal process products for EOS metal systems
• Commercialization through EOS GmbH• Competence center of medical applications
• Complete Solutions for medical industries• Hardware, software, material, process, instructions for use• CE certified SP2 powder and manufacturing process for dental copings and
bridges• ISO 13485 certified
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EOS Finland
Organization
• 20 people• Management 1• Quality 2• R&D
• Metal materials & process development 3• Medical applications development 4
• Service 1• Supply chain 2• Laboratory 2• Operations 2• Admin 3
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Additive Manufacturing (AM) Offers Various Advantages
AM technology key differentiators compared to conventional manufacturing processes
Freedom of design Cost advantages CustomizationOrganization
Time to market
LightweightStatic: weight of partsDynamic: moving, accelerated parts
Complex componentsE.g. alternative structures of heat exchangers (see below)
Integrated functionalityEmbedded functionality without assembly
Individualized partsCustomer specific adaptationsCost efficient small series up to"lot size one"
Rapid prototyping and serial applications
Fast feasibility feedback of virtual modelsHaptic feedback
Image sources: WITHIN Labs, EOS, Hettich
Laser adjustment unit Finger implantsHeat exchanger Washing rotor
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Additive Manufacturing (AM) Opens Two Roads to Success
Enabling a completely new design approach
AM can enable design that in conventional manufacturing environments has not been possible beforeLeading to completely new solutions, e.g
Move from metal to plasticMaking a part lightweight, yet functional
AM can resolve constraints of the conventional design of an existing solution by e.g.
Reducing part complexityReducing costs normally caused by e.g. tooling needed after manufacturing
Resolving the constraints of conventional manufacturing
1 2
Example: Washing rotor (Hettich)
From 32 components to 2 laser-sintered parts + 1 steel ring
No tooling necessary
Functional integration, product customization, production on demand
Example: Load-bearing engine block (WITHIN Labs)
New design not possible with conventional methods
Integrated conformal cooling channels, lightweight design
Reduced cycle times, increased part quality, weight reduction
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Automotive
EOS Offers Solutions for Many Industries
Tooling
Industry
Sources (top, left to right): Morris Technologies; M. Kandler, Frauenhofer IPA; Festo; (bottom l. to r.): WITHIN Labs/EOS; EOS; BKL
Medical
Aerospace
Lifestyle
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EOS Additive Manufacturing (AM) Aerospace Application Examples
Sources Images (left to right): Morris Technologies, EOS, University of Southampton
Jet Engines UAVInteriors
Challenge: For University of Southampton, to design an aircraft to demonstrate the use of leading-edge manufacturing technology in UAVsSolution: Manufacturing of a flight-capable prototype within one week, using EOSINT P 730
Optimised: functional integration simplifies assembly and excludes the need for fastenersFreedom of design: production of complex structures to achieve the best-possible flight characteristicsSpeedy: from sketch to maiden flight in less than one month
Challenge: Build highly complex design (fuel injection swirler) as ‘one piece’Solution: Manufacturing with DMLS using EOS technology and EOS CobaltChrome MP1
Optimised: Improved design, no brazed joins, increased robustnessSpeedy: Reduction in time to create – 2 weeks (vs. 6 weeks)Economic: Significant cost reduction – at least 50% less cost
Challenge: Build air duct for mixing and distribution of cabin ventilationSolution: Manufacturing with EOS plastic laser-sintering technology
Optimised: Meets performance requirements – flame retardancy, low toxicity of smoke, light weightWide range of use: Already used in several aircraftsEconomic: Significant cost and fuel reduction through light weight
Morris Technologies Swirler Airduct SULSA aircraft made of PA 2200
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EOS Additive Manufacturing (AM) Automotive Application Examples
Individualised partsLightweight, complex components Integrated functionality
Sources Images (left to right): University of Warwick; Fraunhofer IPA; Rennteam Uni Stuttgart
Challenge: Build a reliable, lightweight axle pivot with high rigidity in short timeSolution: Production of topology-optimised steering stub axle using EOS technology
Optimised: Perfect form and contouring – weight reduced by 35%, rigidity increased by 20%Speedy: Significantly shorter development and production time Safe: Reliable on the track
Challenge: Build lightweight drive shaft for Formula Student racing carSolution: Carbon-titanium drive shaft with laser-sintered double-walled ends
Flexible: Part design without design restraintsEconomic: Weighs only 350 g (length 50 cm). 70% weight reduction (vs metal version), supports trend towards reducing CO emissions
Challenge: Create light-weight car seat with innovative ergonomic designSolution: Functional integration via laser-sintered plastic elements
Comfortable: Thanks to anatomical seat adjustmentEconomic: Significant weight reductionFunctional integration: Reduces installation costs – pneumatic actuators replace servomotors; integrated heating and ventilation
University of Warwick drive shaftRennteam Uni
Stuttgart axle pivotConceptual
car seat
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EOS Additive Manufacturing (AM) Industry Application Examples
Heat exchanger: complex and scalable components
Gripper: Lightweight and complex components
Special purpose machinery: Integrated functionality
Sources Images (left to right): Festo; kuhn-stoff; EOS; components built into EOS systems; 3T RPD/WITHIN Labs
EOS FORMIGA Laser adjustment unit
Challenge: Production of a bionic gripper that can reliably pick up and safely put down objects gently and flexiblySolution: Small batch production using EOS FORMIGA P 100
Optimised: Function integration reduces number of single parts and assembly expenditureEconomic: Light-weight and long-lasting through innovative manufacturing method Efficient: Tool-less production saves time and money.
Festo gripper Bionic Assistance System
3T RPD/WITHIN LabsHeat exchanger
Challenge: Create heat exchanger that can efficiently increase or dissipate heat; geometry to be adapted to part that needs coolingSolution: Production on EOSINT M 270 with EOS Aluminium AlSi10Mg
Optimised: Self-supporting, integrated cooling fins on outside surfaces. Tear drop tubes, fully self supportingEconomic: Turbulators inside cooling tubes disrupt flow of cooled fluid to maximise heat transferSpeedy: Build time ca. 85 hours
Challenge: For EOS FORMIGA, produce device to adjust laser mirror in Y and Z directionSolution: Production with EOS plastic laser-sintering technology using EOS material PA2200
Optimised: Functional integration:Integrated cam levers to fix regulating screwsIntegrated control angle markings (no stickers required)
Economic: Manufacturing on Demand possible, enabling adjustments and offering spare parts
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EOS Additive Manufacturing (AM) Lifestyle Products Application Examples
Footwear & Sports Fashion/Accessories Architectural Models Interior Design Jewelry
Ross Barber shoesContinuum Fashion/
Shapeways bikini Foster+Partner: British Museum Digital Forming Lamp
Sources Images (left to right): Ross Barber, Continuum Fashion/Shapeways, Foster + Partner, Digital Forming, Cookson
Cookson gold jewelry
Challenge: DMLS suitable for goldSolution: New technology capable of series production offering design flexibility
ResultSpecially built laser optics and raw mat.Less raw material requiredCompletely new possibilities for designers
Challenge: Provide customer with option to online-customise complex design of a lampSolution: EOS plastic laser-sintering technology
ResultCustomer is free to change the basic design within defined parametersMass customisationpossible: combines personalization and mass production
Challenge: Produce high-fashion men footwear with a complex designSolution: EOS plastic laser-sintering of sole and cushioning structure
Result8 unique designs with organic structureDesign could only be manufactured with EOS technology
Challenge: Produce model of complex architectural designsSolution: Laser-sintering of dedicated plastic material
ResultShort production timeExact replication of CAD-created designHigh-profile architects use the technology: Foster + Partner, Zaha Hadid
Challenge: Wearable and printable fabric to produce customised bikinisSolution: Manufacturing on FORMIGA P 100 using EOS PA 2200
ResultMaterial enables thread-like connectionsComplex, yet customised designInnovative and affordable fashion
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EOS Additive Manufacturing (AM) Medical Application Examples
Dental ApplicationsOrthopedic Devices, and Implants Surgical Instruments Medical Devices
Sources Images (left to right): EOS; WITHIN Labs/3T;L FHC Inc.; Hettich
STarFixMicroTargeting™ platform Hettich wash rotor RotolavitIndividualised finger implants
Challenge: Simplify production of washing rotor ROTOLAVITSolution: Laser sintering on EOSINT P 380 with PA 2200as series material
ResultHigh functional integration3 parts (laser-sintered parts plus 1 steel ring) instead of 32 partsFinish and assembly effort reduced
Challenge: Manufacturing of patient-matched frameless stereotactic fixturesSolution: Small-batch production of precision surgical components using EOS FORMIGA P 100
ResultCustumised design shortens OR timeParts consolidation resulting in in simpler designs with more featuresUses less material, faster manufacturing turnaround
Challenge: Economic production of patient-specific restorations made of high-performance alloySolution: Manufacturing fully dense restorations w/o porosity using EOSINTM270
ResultFast and cost-efficient manufacturingProvided accuracy of units is +/- 20 micronsRestorations are durable, capable and have a consistently high quality
Challenge: Production of individualised implants, e.g., hip, skull and spinal disc implantsSolution: DMLS using EOS technology and EOS metal materials
ResultLighter, more strain-resistant design (shape, structure)Improved functionality: Grid structure enables optimised coalescencesCost reduction
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EOS Additive Manufacturing (AM) Tooling Application Examples
Sources images (left to right): Innomia, Ecoparts, LBC, PEP
Smarter design of conformal cooling channels: cost savings, cycle time reduction, increased performance, scrap rate reduction
Injection Molding Repairing Die Casting Rapid Tooling
Innomia mug holder tool LBC tool insert for die castingPEP (Pôle Europeen de Plasturgie)
Tool insertEcoparts Tool insert
Challenge: Building a tool insert for a mug holderSolution: Using EOS Direct Metal Laser Sintering
Result2 cooling towers (instead of 8)Cooling time 16 s (28.5 s)Cycle time 26,5 s (38.9)Tool building time 13 days (23 days)
Challenge: Repair a partially damaged tool insert Solution: Generation of a new reference surface; Positioning of part in EOS machine; On-top construc-tion of missing parts
ResultSave costs of a complete new insert constructionReduction of lead time: partial construction instead of complete construction
Challenge: Injection moulding tooling for 50,000 electrical component partsSolution: Redesign of inserts with conformal cooling channels; inserts built in EOS MaragingSteel MS1
ResultLead time and cost reductionHigher mould productivity Better thermal management
Challenge: Build an insert for a die casting applicationSolution: Cooling system optimisation; insert built via DMLS on EOSINT M 270 in EOS MaragingSteel MS1
Result20% cycle time reduction180,000 parts manufactured in serial production
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EOS Plastic Laser-Sintering Systems
Source: CDR
FORMIGA P 110 EOSINT P 395 EOSINT P 760 EOSINT P 800
Build size Width 200 mmDepth 250 mmHeight 330 mm
Laser CO2 laserNominal power 30 WWave length 10.6 µmLaser spot size ~0,4 mm
Layer thickness0.12 mm 0.10 mm0.06 mm
Build size Width 340 mmDepth 340 mmHeight 620 mm
Laser CO2-LaserNominal power 50 WWave length 10.6 µmDigital scanner
Layer thickness PA 2200: 0.06 mm; 0.10 mm; 0.12 mm; 0.15 mm; 0.18 mm All other materials: 0.15 mm
Build size Width 700 mmDepth 380 mmHeight 580 mm
Laser 2 CO2 laserNominal power 50 W eachWave length 10.6 µm
Layer thickness PA 2200: 0.06 mm; 0.10 mm; 0.12 mm; 0.15 mm; 0.18 mm All other materials: 0.12 mm
Build size Width 700 mmDepth 380 mmHeight 560 mm
Laser 2 CO2 laserNominal power50 W eachWave length 10.6 µm
Layer thickness Standard: 0.12 mm
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EOS Metal Laser-Sintering Systems
Data Preparation
SoftwareMaterialise MagicsEOS EOSTYLE Support GenerationEOS RP ToolsEOS PSW
Quality Assurance
Recording & ReportingEOSTATE BaseEOSTATE QAEOSTATE ControllingEOSTATE MPM
Part Production – Material and Processes
EOS MaterialsMaraging Steel Stainless SteelNickelAlloyCobalt Chrome Titanium Aluminum
EOS Parameter SetsSurfacePerformanceSpeed
EOSINT M280 200 WEOSINT M 280 400W
IPCM Material & Platform Handling Modules
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EOS Plastic MaterialsComposition Trade name Colour of laser-
sintered partsMain feature Typical applications
Polyamide 12 PA 2200 white • Multipurpose material• Balanced property profile• Variety of certificates available (Biocompatibility, Food
contact, ecological)
• Functional parts
PrimePart PLUS (PA 2221)
natural • Economic multipurpose material• Balanced property profile
• Functional parts
PA 2202 black anthracite black • Balanced property profile• Anthracite black colour
• Functional parts in anthracite black colour
Polyamide 12,glass bead filled
PA 3200 GF whitish • High stiffness• Wear resistance• Improved temperature performance
• Stiff housings• Parts with requirements on wear and abrasion• Parts used under elevated thermal conditions
Polyamide 12,aluminium filled
Alumide® metallic grey • Easy post-processing, good machinability• High temperature performance• Thermal conductivity (limited)• High stiffness
• Applications with metal-like look• Parts which need machining• Parts with thermal loads
Polyamide 12,carbon fibre reinforced
CarbonMide® anthracite black • Extreme strength and stiffness• Thermal and electrical conductivity (limited)• Best strength/weight-ratio
• Light and stiff functional parts• Metal replacement
Polyamide 11 PA 1101 Natural • Very high ductility / elongation at break• 100% from renewable sources (castor/ricinus oil)• Acceptable tensile strength
• Functional parts which need impact resistance• Parts with functional elements (film hinges)
For special applicationsPolyamide 12 PA 2201 natural • Multipurpose material
• Material certificates available (Food contact)• Medical, food
PA 2105 Gum colour • High surface quality and detail resolution • DentalPolyamide 12,flame retardant
PA 2210 FR white • Economic flame-retardant material• Halogen-free
• Aerospace• Electric & Electronic
Polyamide 12,flame retardant
PrimePart FR (PA 2241 FR)
white • Economic flame-retardant material • Aerospace• Electric & Electronic
Polystyrene PrimeCast® 101 grey • High dimensional accuracy• Low residual ash-content
• Patterns for investment casting• Master patterns for vacuum casting
Polyaryletherketone EOS PEEK HP3 beige-brown • High performance material• Excellent temperature performance, strength, stiffness
and chemical resistance• Excellent wear resistance• Inherently flame retardant• Biocompatibility and sterilizability
• Metal replacement• Aerospace• Automotive and motorsports• Electric & Electronic• Medical• Industrial
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EOS Metal Materials
Material Group Trade name Material type Typical applications
Maraging Steel EOS MaragingSteel MS1 18 Mar 300 / 1.2709 Injection moulding series tooling; engineering parts
Stainless SteelEOS StainlessSteel GP1 Stainless steel
17-4 / 1.4542Functional prototypes and series parts; engineering and medical
EOS StainlessSteel PH1 Hardenable stainless15-5 / 1.4540
Functional prototypes and series parts; engineering and medical
Nickel AlloyEOS NickelAlloy IN718 Inconel™ 718, UNS N07718, AMS
5662, W.Nr 2.4668 etc.Functional prototypes and series parts; high temperature turbine parts etc.
EOS NickelAlloy IN625 Inconel™ 625, UNS N06625, AMS 5666F, W.Nr 2.4856 etc.
Functional prototypes and series parts; high temperature turbine parts etc.
Cobalt ChromeEOS CobaltChrome MP1 CoCrMo superalloy,
UNS R31538, ASTM F75 etc. Functional prototypes and series parts; engineering, medical, dental
EOS CobaltChrome SP2 CoCrMo superalloy Dental restorations (series production)
Titanium EOS Titanium Ti64 Ti6Al4V light alloy Functional prototypes and series parts; aerospace, motor sport etc.
Aluminum EOS Aluminium AlSi10Mg AlSi10Mg light alloy Functional prototypes and series parts; engineering, automotive etc.
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System Set-up & Production
Removal &Cleaning
ProductionMonitoring
EOS EOSTATE
EOSHardware
SYSTEMSEOS FORMIGA P110EOS EOSINT P395EOS EOSINT P760EOS EOSINT P800
PERIPHERYEOS IPCM / IPCM+EOS Unpacking /Sieving station P1/P3/P7EOS Cooldown Station P7
EOSMaterials
EOS PA 2200EOS PA 2221EOS PA 2202 black
EOS PA 3200 GFEOS Alumide®EOS CarbonMide®
EOS PA 2201EOS PA 2105EOS PA 2210 FR
EOSSoftware
EOS EOSTATE
EOS SINTAFLEX 201EOS PrimeCast® 101EOS PEEK HP3
EOS Process PortfolioProduction Plastic
EOS Blasting CabinetNormfinish
Partner Solutions
Miniature Basting System Type Micro Tip 1
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LS-SYSTEMSEOS EOSINT M280 200W/400WEOS EOSINT M270 Dental
PERIPHERYEOS IPCM MEOS Comfort Powder Module
EOS MaragingSteel MS1EOS StainlessSteel GP1EOS StainlessSteel PH1
EOS NickelAlloy IN718EOS NickelAlloy IN625EOS CobaltChrome MP1
EOS CobaltChrome SP2EOS Titanium Ti64EOS Aluminium AlSi10Mg
EOS EOSTATE
EOS Process PortfolioProduction Metal
EOS QA for Laser Power
EROWA Alignment System
EOSHardware
EOSMaterials
EOSSoftware
Partner Solutions
System Set-up & Production
Removal &Cleaning
ProductionMonitoring
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Technical Services
System installationMaintenanceRepair Spare parts logisticsSystem upgradesSoftware updatesRemote support
Training Services
Trainings for operation of EOS systems
at EOS training centerat customer location
Application Services
BenchmarkingFeasibility studiesDesign consultingCustomer material qualificationApplication consultingCustomer-specific development
Quality Management Services
Factory Qualification Installation QualificationOperation QualificationPerformance Qualification
EOS: Consistent Service Offer
EOS supports customers
throughout the relationship
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EOS: Global Service Organisation
Regional Service Hub
Local Service Site
EOS HeadquarterKrailling (Germany)30 Field Technicians
9 2nd Level Support Technicians4 Hotline Employees
EOS North AmericaNovi (USA)
14 Field Technicians
EOS Asia-PacificSingapore
13 Field Technicians
EOS has Regional Service Hubs on three continents
Service resources are managed from regional hubs, but located in national markets
Local Service Sites with own depots ensures customer vicinity in key markets
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A Peek into the Lab: EOS Intends to Extend the Platform-based DMLS Strategy
1) Requires dedicated business case * In development, subject to technical changes
Larg
e sc
ale
Prod
uctio
n Pl
atfo
rm*
R&D
/Sm
all s
cale
Pr
oduc
tion
Plat
form
Appl
icat
ion
spec
ific
1)
Manufacture application in production environment
Develop & qualify applicationsFreeze system settings for productionProduce small scale volumes
Derive application-specific system, e.g. PRECIOUS M 080
Focus on productionSemi-automated processesModular conceptSingle field with 1kW laserMulti-field with 200/400W lasersXL build chamber (400x400x400mm)
Focus on flexibilityDesigned for flexible material exchanges200 / 400 W laserBuild chamber (250x250x325mm)
Focus on applicationAdapted system to match requirements of specific applications 1)
Dedicated materials and parameters (e.g. gold)
Scale up for production
Adapt to application
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A Peek into the Lab: Depending on Application, EOS will offer a Single or Multi-Field Solution
1) Laser power can be adapted for similarity purposes (e.g. 200 W) * In development, subject to technical changes
Single field*Multi-field
with overlap*Multi-field
without overlap*
1 x
1,00
0 W
4 x
400
W 1)
4 x
400
W1)
Focus on speed
Big & bulky partsSurface roughness allowedFunctional surfaces typically finished
Focus on accuracy
Rather small partsHigh resolution requiredDirect similarity to M 280
Application-specific approach
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A Peek into the Lab: Micro Laser-Sintering (MLS)
No investment for product variantsCost benefits for small seriesReduced time-to-market
Complexity for free
Small feature size
Micro gears designed by Morris Technologies, Inc.
Complex designs without extra costOptimised functionalityAdditive manufacturing on a micro scaleSmallest feature size around 50 µm, depending on geometry
Customization, functional integration, miniaturization
Freedom of design Freedom of design
Tool-less manufacturing
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Kiitos !www.eos.info