PRI Concept Laser EN Web viewpress release-interview-concept-laser-report Jung ... a few pilot...

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█ Powder-bed-based laser melting with metals (LaserCUSING ® )

Spare parts on demand for the beverage industry using 3D metal printing

One-shot technique reduces parts and amount of assembly required for a can filler valve

High availability and shorter overhaul times for filling plants

3D metal printing changes the spare parts logistics for beverage filling plants

PR+Interview 12-2016 Words: 1,861 | Characters: 9,754

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Lichtenfels (Germany) 12/05/2016: Users of 3D metal printing are increasingly discovering the new possibilities and freedoms offered by Additive Manufacturing. 3D designs are leading to new product solutions. Occasionally, manufacturing and logistics concepts are completely reconfigured. Jung & Co. Gerätebau GmbH, a specialist in stainless steel components, relies on Additive Manufacturing to ensure that spare parts for beverage filling plants are available more quickly. This approach is very popular in an industry in which “time is money” is more than just an empty phrase. We spoke to Thomas Lehmann, Managing Director of Jung & Co., about the application and the advantages of 3D metal printing.

When it comes to processing stainless steel/alloys, various aluminum alloys or titanium,

there are good reasons to choose Jung & Co. The processor of stainless steel boasts

material know-how, state-of-the-art CNC machines and provides support with expert

advice. The service it offers includes efficient production planning and consistent quality

assurance in order and subassembly production. It caters for an array of sectors ranging

from the food and beverage industry, pharmaceuticals and chemical engineering, plant

engineering, aviation through to the fossil fuels extraction industry. One specialty is the

production of spare parts made of stainless steel for beverage filling plants.

Transfer of know-how delivers real synergiesAt Jung & Co. the primary focus is on using stainless steel, aluminum and titanium as

materials. This know-how has been transferred to numerous sectors over the course of

40 years. The traditional methods of machining have now been expanded to include


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https://www.jung-co.de/



additive manufacturing using the metal laser melting process. In production there is an

M2 cusing Multilaser machine from Concept Laser. Thomas Lehmann: “We deliver

stainless steel solutions across all processes and consistently focused on the

application. The parts or assemblies that we produce are conventionally machined,

manufactured in hybrid fashion or completely additively. The customer receives a

precision end product from one single source providing a full service.”

Example of the beverage industryAfter its initial experiences of additive manufacturing, Jung & Co. went one step further.

The magic phrase was “Spare parts on demand.” Thomas Lehmann says: “Initially our

customers thought: What a crazy idea. Far too expensive. Won’t work. So we first had

some persuading to do.” The concept of “spare parts on demand” caught on because

the economic facts were undeniable. The idea of the Additive Manufacturing of spare

parts for beverage filling plants caught on.

Beverage filling plants in constant useA filling plant in the beverage industry should be renowned for its high availability. What

is often important is the flexibility of the filling plant because different sizes of bottles or

cans need to be filled. Filling plants need to perform the following tasks: supplying

bottles or cans, filling them, sealing them and ultimately transferring them to the post-

processing stations. Food law dictates that cleanliness and hygiene are the most

important requirements. This is why stainless steel is one of the preferred materials

used in the industry. Production rates of 40,000 – 80,000 bottles or cans per hour are

not unusual. The industry “thrives” on speed. If a plant is shut down, its profitability

quickly diminishes. Finding the fault, requesting a spare part, shipping and installing it –


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http://www.concept-laser.de/en/home.html

http://www.concept-laser.de/en/machines.html


in a worst case scenario this can take a few days and result in delays to deliveries to the

trade. Depending on the size and output of the entire filling line, an hour of lost

production may cost from around €4,000.00 up to around €30,000.00. The filling

company must then find some way of switching to other filling lines and then first adapt

them to handle the particular bottles or cans. These are stressful situations for a

production manager, and he and his team are of course keen to avoid them. Thomas

Lehmann: “We said to customers: Things don’t need to be like this. Additively

manufactured stainless steel parts can be printed as required and also have their design

optimized. Most customers were initially disbelieving because we were presenting such

a revolutionary idea.” In actual fact, Jung & Co. was quickly able to sell the idea of

Additive Manufacturing to its long-standing customers in the beverage industry. Thomas

Lehmann also cites the example of a can filler valve for beverage filling plants.

Fewer parts in the assembly and high availability during useThomas Lehmann, who engaged with the laser melting of stainless steel in collaboration

with the technology pioneer Concept Laser at a very early stage, was clear: An additive

solution can mean great freedom of geometry, coupled with a CAD design that suits the

process. In addition, parts or entire assemblies can be created as a one-shot design. If

the filling company requires a new can filler valve, the components can be manufactured

promptly using CAD data and fitted at the customer’s premises so that the downtimes

are drastically reduced. Thomas Lehmann: “3D metal printing enables short machine

downtimes for the beverage fillers that previously seemed impossible. A new 3D design

and rapid availability saves the customer time and money.” The example chosen by

Lehmann relates to a filler valve in a can filling plant. The production of spare parts for

beverage filling plants is one of the specialties of the company from the German town of

Pinneberg. Many of these spare parts are not standard components, but rather


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customer-specific solutions. If it is manufactured by conventional means, the assembly

consists of seven components made of stainless steel 1.4404 which need to have the

necessary seals added. The stainless steel parts had to be initially milled or turned with

precision machining on CNC machines and then fitted manually. The assembly was

then placed into storage so that – in the event of a failure – a quick response was

possible and the filling plant could be back up and running again. “The can filler valve

was redesigned so that it could be manufactured in one operation on an M2 cusing

Multilaser machine. This means there is no longer any need for the seals and interfaces

that are otherwise an inevitable consequence of the joining process. The fact that no

assembly work is required is not only cheaper, but also saves time for our customers.

Manufacturing of the part by conventional means takes around 8 – 10 weeks including

the procurement of the required precision cast part, whereas the Additive Manufacturing

takes around one week. In principle, this means we can manufacture spare parts on

demand and then deliver them on time when the demand suddenly arises. The benefits

that arise with such a precision part are extremely interesting for both us as the

manufacturer and for our customers if the desire is to keep overhaul times or machine

downtimes as short as possible.” In addition, spare parts do not need to be purchased in

advance and kept in storage, thus tying up less capital.

New part solutions and high reproducibilityNevertheless, the development of the assembly was a minor feat of endurance. The

load demands of a highly dynamic filling plant are suitably challenging, as the staff at

Jung & Co. are very well aware. This is why the can filler valve was subjected to

intensive load tests. In addition, there were also topology optimizations and

modifications to the design as well as investigations into the amount of reworking and

the release of tension from the parts. Thomas Lehmann: “Part development is an


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exciting process. The development reveals new option paths which can be explored in a

targeted way. The finished 3D part not only looks different to the conventional one, but

is also around 35% lighter. But it is also usually capable of doing more, and this is very

easy to factor into the price because what matters is what effects actually result overall

in terms of time and money.” The additive approach ultimately results in overhauled

solutions which can boost performance. According to Jung & Co., the possibilities are

very diverse: It is possible to incorporate lightweight design approaches or functional

integrations, such as cooling, temperature control or sensor technology. Hybrid

approaches to manufacturing are also relevant. For example, simple geometric areas

can be machined in a conventional way while complex geometric areas of a part can be

additively manufactured. Another important point is the high reproducibility. Once

process parameters have been found, they guarantee a consistent level of quality

including the documentation that is also supplied. Thomas Lehmann: “The many

different aspects of 3D metal printing demand an in-depth analysis of the performance

requirements in a discussion with the customer. Talking to the customer reveals

possible solutions which, adapted to the process, result in new solutions which can

deliver more than the previous parts. The crucial factor when it comes to costs is

ultimately what the part is capable of and how quickly it is available.” In the beverage

industry, there was another key argument in favor of Additive Manufacturing for the

filling companies: In the case of conventional cast parts made from stainless steel,

cavities are not exactly popular in the food industry as they are a potential source of

contamination. Thomas Lehmann: “Cavities are to be avoided in this particular

application, which is another important benefit of the 3D metal printing process.”

Prospects for 3D metal printing at Jung & Co.


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Additive Manufacturing has been added to the CNC manufacturing range at Jung & Co.

since 2015. Additive manufacturing currently takes place on an M2 cusing Multilaser

machine with 2 x 400 W laser sources from Concept Laser. There are plans to expand

the production capacity because there is such great demand. Thomas Lehmann: “The

demand for 3D-printed metal components is expected to rise steadily and stable. I am

thrilled that many of our customers are recognizing the benefits of additive parts. But I

am just as delighted that we in house are able to familiarize our own employees and in

particular the apprentices with the new technology. As a medium-sized enterprise,

gaining more expertise is always a vital argument when talking to customers.” In

addition, Jung & Co. is also planning to purchase a mobile laser scanner in the coming

year. This will enable the company to adopt a completely new approach in supplying

spare parts rapidly to its customers. Laser measurement allows the relevant component

that needs to be replaced to be digitized in situ in the customer’s machine. Once the

corresponding 3D files have been sent to Jung & Co. online, the production on the laser

melting machine can also commence there immediately in urgent cases. Thomas

Lehmann: “Additive Manufacturing opens up a whole host of opportunities when it

comes to delivering spare parts for filling machines in the beverage industry. A laser

scanner is the next logical step toward full digitization of the process chain. It does of

course also have the appeal that we detach ourselves a little from the element of time

and space in the supply of spare parts.”

- End of the press release –


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Questions to Thomas Lehmann, Managing Director of Jung & Co.

Editor: Mr. Lehmann, how did you come up with the idea of producing spare parts on

demand?

Thomas Lehmann: This has actually always been a dream at Jung & Co. With

traditional machining, we have certain lead times for delivering a can filler valve, for

example, to the customer. Manufacturing the component by conventional means takes

around 12 - 15 weeks including the procurement of the required precision cast part. The

question was how can we act faster. When we began to look at Additive Manufacturing,

this changed the way we look at our products. Different geometries became possible, as

did quick solutions and a decrease in the number of assemblies. Instead of the seven

assemblies that were required previously, the spare part which has been described can

now be manufactured in one operation, thus doing away with interfaces and seals in the

assembly and reducing the weight by around 35%. It is now possible to manufacture the

optimized additive part in one week. The idea of producing spare parts on demand thus

emerged from the wealth of options that 3D metal printing offers.

Editor: How did the customers from the beverage industry react?


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Thomas Lehmann: As in any industry, they were initially conservative and reserved. In

a second step, the question immediately arose of whether this was also cheaper. This

question is actually less important. What matters more in this sector is short machine

downtimes and a rapid start-up of the machine following an overhaul. The monetary

benefit of a 3D solution can be found here and in functional or qualitative aspects. So

first of all we needed to explain the additive world. This was sometimes laborious.

Laborious because in principle you have to suppress many of the things you are familiar

with from traditional machining. This is because Additive Manufacturing follows different

rules.

Editor: How did you get the first references?

Thomas Lehmann: In every business there are customers that maintain a close dialog

in which each party is good at listening to the other. We were ultimately able to secure a

few pilot customers for this project. These customers were surprised at how quickly we

were actually able to supply a can filler assembly – and with the usual precision and

density. If you calculate how much an hour it costs for a high-performance filling plant to

be shut down, then a 3D solution is much cheaper than a conventional solution. It is

easy to see how this pays off. In addition, the customer gets a solution that suits the

process and is qualitatively and functionally persuasive.

Editor: How did you end up choosing Concept Laser as the plant and machine

manufacturer?

Thomas Lehmann: Our motives were at very different levels. We embarked on the

process of selecting a partner with a fully open mind. In trials with another German


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provider, it became clear that the laser tracks tended to overlap, which was not

acceptable to us in this form. This problem did not arise with the M2 cusing Multilaser

machine from Concept Laser. As we also work with titanium, Concept Laser’s safety

concept with physical separation of the process chamber and handling chamber was a

crucial factor for us, and also helps to make the machine more convenient to use. Yet it

was not just the technology and the safety but the overall package that won us over. Our

two companies are essentially “makers.” To this extent, Concept Laser was a very good

fit for our corporate philosophy: perfect solutions, value-based, cooperation based on

partnership, great reliability of statements and strong soft factors that enable a long-term

working relationship.

Editor: What are your future plans for Additive Manufacturing at Jung & Co.?

Thomas Lehmann: We are thinking ahead in very different directions. It is now possible

to have additive solutions but also hybrid solutions in which traditional machining

processes are combined with laser melting. At the same time, we can now set about

modifying the geometries to suit the process so that parts or assemblies can be

manufactured more quickly or easily or embrace new performance criteria or functional

integrations. When it comes to functional integrations, temperature control, cooling or

even sensor technology can be incorporated. These are all very interesting topics.

Specifically, we will shortly be employing a mobile laser scanner. This will enable us to

measure the part that needs to be replaced in situ at the customer’s premises and then

construct a fully digital process chain, from the scan to the 3D part ready for installation.

Editor: Thank you for the interview.


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About Jung & Co.

For more than 40 years, Jung & Co. has been setting demanding standards in stainless

steel and aluminum processing and also with high-alloy steels such as Hastelloy and

Inconel. It employs highly efficient manufacturing strategies to manufacture parts or

even entire assemblies. What began as a small business – Hans Jung started out as an

individual entrepreneur with a small lathe – has evolved to become a renowned

company and system supplier that generates sales running into the tens of millions. The

company focuses on the contract manufacture of sophisticated parts and assemblies in

small and medium batch sizes and the almost complete production and assembly of all

components for your full twin screw pump range.

Nowadays many people refer to the Jung Group because the 1990s saw the foundation

of FAS Fuellanlagenservice GmbH, which for many years has been one of the best-

known and most efficient suppliers of spare parts and components for bottle and can

fillers as well as bottle cleaning machines and beverage mixing installations in the

international beverage industry. In 2009, another company was added to the Group in

the form of Jung Process Systems GmbH. As a specialist in twin screw pumps made

from stainless steel, Jung Process Systems supplies pumps from the Hyghspin brand to

the international market.

Jung & Co. manufactures high-quality components and assemblies in more than

2,000 m² of production space and employs more than 100 workers.


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Print approved – copy requested

Captions ████████████████████████████████████████

Caption 1: Time is money: The overhaul of a modern high-performance filling plant must

take place very quickly. Depending on the size and output of the entire filling line, an

hour of lost production may cost from around €4,000.00 to around €30,000.00.

Caption 2: A conventionally manufactured can filler valve consists of seven assemblies,

seals and screw connections, and takes a great deal of effort to assemble.

Manufacturing the part by conventional means takes around 8-10 weeks including the

procurement of the required precision cast part.


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Caption 3: An additively manufactured can filler can be manufactured in one operation,

so without any assembly, and on demand in one week. Deployment at the plant

operator is very prompt, and overhaul times are reduced significantly. The optimized

additive part is also around 35 % lighter than the conventional one.


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Caption 4: The nucleus of 3D metal printing production in Pinneberg: a M2 cusing

Multilaser machine at Jung & Co. The overall package of technology, safety concept

and partnership tipped the balance for Concept Laser.

Caption 5: Thomas Lehmann, Managing Director of Jung & Co.: “If you calculate how

much an hour it costs for a high-performance filling plant to be shut down, then a 3D

solution is much cheaper than a conventional solution.”


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All pictures courtesy of Jung & Co. (unless indicated otherwise)

Contact ███████████████████████████████████████

Concept Laser GmbHAn der Zeil 8

D-96215 Lichtenfels

Germany

Phone +49 (0) 9571 / 1679-0

Internet: www.concept-laser.de

Press contact:Daniel Hund

Phone: +49 (0) 9571 / 1679-251

E-mail: [email protected]


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mailto:[email protected]

http://www.concept-laser.de/


Jung & Co. Gerätebau GmbHAuweg 2

D-25495 Kummerfeld / Pinneberg

Germany

Thomas Lehmann, Managing Director

Tel.: +49 (0) 41 01 / 79 58-211

E-Mail: [email protected]

Internet: www.jung-co.de

LaserCUSING® background information ██████████████████████

Key word: LaserCUSING®

The patented LaserCUSING® process from Concept Laser is used to create high-

precision mechanically and thermally resilient metallic components. The term

"LaserCUSING®," coined from the C in Concept Laser and the word FUSING, describes

the technology: The fusing process generates components layer-by-layer using 3D-CAD

data.

In this process, fine metal powder is fused locally by a high-energy fiber laser. The

material solidifies after cooling. The contour of the component is created by redirecting

the laser beam using a mirror redirection unit (scanner). The component is built up layer


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mailto:[email protected]


by layer (with a layer thickness of 15 – 500 μm) by lowering the bottom of the build

chamber, applying more powder and then fusing again.

Source: Concept Laser GmbH

What makes systems from Concept Laser unique is stochastic navigation of the slice

segments (also referred to as "islands") which are processed successively. This

patented process ensures a significant reduction in stress when manufacturing very

large components.

Concept Laser at a glance ██████████████████████████

Concept Laser GmbH from Lichtenfels, Germany is today, unlike almost any other

company, one of the real pioneers and key drivers of powder-bed-based laser fusing

with metals. The technology driver here is the patented LaserCUSING® process, also

referred to as 3D metal printing, which over the course of 15 years has evolved the

additive manufacturing of 3D components from a rapid technology to the stage of

industrial series production.


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When Frank Herzog founded Concept Laser GmbH back in 2000 in Lichtenfels, a metal

laser fusing machine was an entirely unknown quantity in the market. How is a 3D

geometry created from metal powder using a laser? What does 3D printing or a digital

process chain mean for the manufacturing of the future?

The answer was industrial machine technology: Concept Laser unveiled the first

machine of this type in 2001 at Euromold in Frankfurt. With 65 patents granted today

and over 120 patent applications, Frank Herzog and his workforce of around 190

employees continue to champion and develop the LaserCUSING® process. The

company caters for the global market for laser fusing machines across all different

sectors from sites in Germany, the USA and China and through a network of more than

35 distribution and service partners.

Concept Laser's high quality standards, expertise in processes, applications and

materials deliver reliable and cost-effective solutions which prove their effectiveness in

everyday production and are primarily aimed at reducing part costs. In addition to

commercial aspects, the process offers a large number of other benefits compared to

conventional methods of production: The components are lighter, the designer has new

freedoms, the topology and geometry are optimized, additional functions can be

integrated, and less raw material is required. What this means is components that were

previously manufactured using machining processes are now being redesigned to fully

exploit the new potential offered by additive manufacturing.

Concept Laser offers a range of small machines (50 x 50 x 80 mm3) right through to the

machine with the world’s largest build envelope (800 x 400 x 500 mm 3). Machines from

Concept Laser that are equipped with multilaser technology are among the fastest,

safest and highest-quality laser fusing machines in the world. Around 650 installed


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machines and prestigious references and projects of this Franconian “hidden champion”

around the globe send out a clear message and symbolize an outstanding technology

for the future sealed with the endorsement “Made in Germany”.

For example, today the aerospace industry, automotive industry, medical technology,

dental technology, toolmaking and other sectors focus strategically on 3D metal printing

as the economical and high-quality production strategy of the future that embraces the

notion of "Industry 4.0.”

Prizes & awards ██████████████████████████

2001 Presented with the EuroMold Silver AWARD for the M3 linear

LaserCUSING® machine

2008 Presented with the Bavarian Innovation Prize for the M2 cusing


2012 Presented with the EuroMold Bronze AWARD for the X line 1000R


2014 BAVARIA’S BEST 50 prize-winner

2014 Finalist in the “Large Companies” category for the German Industry

Innovation Prize in the shape of Frank Herzog, Managing Director of

Concept Laser GmbH


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Project: “The first 3D-printed titanium component on board the A350 XWB”

2015 The “European CEO of the Year Additive Manufacturing” award was

presented to Frank Herzog, Managing Director of Concept Laser GmbH

2015 Nominated for the German Future Prize – Prize awarded by the German

President for technology and innovation

Project: “3D printing in commercial aircraft engineering – a manufacturing

revolution is taking off” in the shape of Frank Herzog, Managing Director of

Concept Laser GmbH

2015 FOCUS Growth Champion

2016 Winner of the International Additive Manufacturing Award with the QM

Meltpool 3D quality monitoring tool, which was developed in-house

The art of LaserCUSING® by Concept Laser


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