Titel: Die Headline darf maximal zwei Zeilen lang sein ... Production.pdf · Laser-Sintering on...

e-Manufacturing -

Next Generation Technology for Aerospace Production

Udo Behrendt Key Account Manager Aerospace

e-Manufacturing – Next Generation Technology for Aerospace Production : Udo Behrendt – IUM 2008

— No tooling

— Low quantities•

ROI of tooling•

VIP interior

— Long product lifetime•

Storage of tools and fixtures•

Modifications and upgrades•

Spare parts on demand

— Design for function not for production•

Weight saving structures•

Integrated subsystems•

New functionality

— Highest flexibility

— Investing in parts not in tools•

Just in Time Investment

Technology Benefits

SOURCE: EOS

e-Manufacturing™


Laser-sintering eventually means the liberation of design from manufacturing restraints

Paradigm shift in design and manufacturing

Manufacturing- driven design

Design-driven manufacturing

Source: EOS


The final design after re-working - an award-winning innovation thanks to EOSINT P

— The gripper is able to withstand 2 bar permanently (15.000.000 cycles* in

fatigue testing)

— End stops for angle limitation are realised

— High gripping power

— Extremely low weight

— Walter Reis Innovation Award for Robotics 2006

Result

Source: IPA, Messe München

* Test was terminated after 15 Mio. cycles without any part failure

Final Design

Walter Reis Innovation Award for Robotics 2006': Coming in second in the group service robots Dipl.-

Ing. Ralf Becker from Fraunhofer

Institute for Manufacturing Engineering and Automation IPA, Stuttgart. The award was presented by Walter Reis, REIS ROBOTICS, Prof. Dr. Rolf Dieter Schraft, Director of IPA and Dr. Eberhard

Kroth, Managing Director REIS ROBOTICS and Heinz-Dieter Schunk, managing partner of Schunk

GmbH + Co.KG.

Project partner:


Simulation is useful for design verification and layout

— Gripping angle 8°

per gripper finger

— Secure operation at 2 bar

— Low weight

Properties required

Source: IPA

Simulation of the design

=> production in PA 2200 on EOSINT P

Project partner:


Reducing time to market

approx. 2 600 parts p. a.

Minimizing logistics

IPCM-Fixture:Integrated functions of high volume part

Speeding up InnovationTests/Mock-ups

M 270 handle: Livingdesign-driven manufacturing

Offering customized products

Manufacturing

spare parts on demand

98 99 00 01 02 03 04 05 0694 95 96 97

EOS itself is an e-Manufacturing company -

2 600 parts per year manufactured by laser-sintering

Laser-Sintering @ EOS

Source: TOM, AZ

rapid prototyping

e-Manufacturing

07


SOURCE: EOS

Aerospace Ducting

Cooling for Electronic


In aerospace laser-sintering can add value where complexity and individuality coincide

— Content

•Design and manufacture complex geometries

•Meet individual customer needs

•Fit special purpose equipment

— Means

•Flexibility of laser-sintering to create individual

parts

•Fast, industrial manufacturing

— Result

•Improve aircraft reliability

•Boost customer satisfaction

•Target new markets

Series manufacturing - Aerospace

Source: EOS


— Requirement:•novel

products

with

special

functionality

or

pereceived

value

— Solution:•DirectPart

on EOSINT P•Design for

e-Manufacturing

— Result:•laser-sintered fabrics•customized fashion accessories•lighting etc. Examples

of laser-sintered

parts

designed

by

Freedom

of Creation

SOURCE: EOS, Freedom of Creation

project partner: FOC

Unique

Parts with

EOSINT P

-

Freedom

of Creation


— Requirement:•show parts for unique specimen

— Solution:•Laser-Sintering on

EOSINT P

380 system

with PA 2200 material

— Result:•millions see laser-sintered rocket launchers, but nobody knows

JAGUAR XKR Special Bond Edition

SOURCE: EOS, JAGUAR

project partner:

DirectPart

-

Unique Specimen

“On off´s ...”


— PA 2210 FR

•UL 94 V0 confirmed•FAR / JAR qualification•Tested on:•Flammability •Smoke Density •Smoke Toxicity•Heat Release

— New temperature areas

— Improved material properties

SOURCE: EOS

New Materials

Materials for e-Manufacturing


Source: EOS

Flammability for parts in devices and appliances

PA 2210 FR -

for flame resistant parts with high mechanical properties

Burning behaviour

Flammability properties (Aircraft)

Smoke generation (Aircraft)

Toxic gas generation (Aircraft)

FAR 25.853 b(4)ABD 0031 / AITM 2.0002BSS 7230 F2

FAR 25.853 (d), App. F - Part VABD 0031 / AITM 2.0007BSS 7238

ABD 0031 / AITM 3.0005 BSS 7239

UL 94 / HB UL 94 / V-0

Conversion of units: 1.0 mm is equivalent to 0.03937 inches

Property Measurement Method UnitValue

1.1 2.0

1.5 / 2.01.5 / 2.0

0.06 / 0.08

1.5 / 2.01.5 / 2.0

0.06 / 0.08

1.5 / 2.0 0.06 / 0.08

mm mm

mm inches

mmmm

inches

mmmm

inches


— General material data•Bulk density:

0.52 g/cm3

•Density of laser-

sintered parts*: 1.05 ±

0.05 g/cm3

— Mechanical properties•Tensile modulus:

2250 ±

150 N/mm2

•Tensile strength:

45 ±

3 N/mm2

•Elongation break:

5.0 ±

1 %•Flexural strength:

45 ±

2 MPa

— Thermal properties•Melting point: 172 -

180 °C

Source: EOS

PA 2210 FR with flame-retardant additives free of halogens

Essential material properties (1)

* EOS-method

Telemetric housing

Laser-sintered telemetric housing for Tour de FranceProject partner: SRM


— Properties•outstanding mechanical properties•extreme resistance and strength•high stiffness •anthracite-coloured parts•electrical conductivity

— Typical applications•fully functional prototypes with refined surface (e.g. for wind tunnel tests)

Source: EOS

CarbonMide® -

carbon-fibre filled polyamide

Properties and applications

Bearing blockSource: EOS


— General material data•Average grain size:

60 µm•Bulk density:

0.50 g/cm3

•Density of laser-

sintered parts*:

1.04 g/cm3

— Mechanical properties•Tensile modulus x/y/z:

6100/3400/2200 N/mm2

•Tensile strength x/y/z:

72/56/25 N/mm2

•Elong. at break x/y/z:

4.1/6.3/1.3 %

— Thermal properties•Melting point:

172 -

180 °C

— Electrical properties•Specific resistance:

46.3·10-3 Ωm[-5...+5V] x

Source: EOS

CarbonMide® -

for parts under high mechanical load

Essential material properties

* EOS-method

Airduct

Source: EOS


Complex Metal Parts

Source: EOS


Source: EOS

Injection moulding tooling; functional prototypes

Bronze-based mixtureDirectMetal 20

Typical applicationsMaterial typeMaterial name

EOS offers

a wide

range

of application-optimized metal powder

materials

for

EOSINT M

systems

Injection moulding series tooling; engineering parts18 Mar 300 / 1.2709EOS MaragingSteel MS1

Functional prototypes and series parts; engineering and medical

Stainless steel 17-4 / 1.4542EOS StainlessSteel GP1[1]

CoCrMo

superalloyEOS CobaltChrome SP1,2

Ti6Al4V light alloyEOS Titanium Ti64

Pure titaniumEOS Titanium TiCP

[1] Note: this

product

was previously

called

EOS StainlessSteel

17-4For system requirements

please

refer

to information

quotes

or

ask

for

details

Dental restorations (series production)

Functional prototypes and series parts; aerospace, motor sport etc.Functional prototypes and series

parts; medical, dental

Functional prototypes and series parts; engineering and medical

Hardenable

stainless

15-5 / 1.4540

EOS StainlessSteel PH1

CoCrMo

superalloyEOS CobaltChrome MP1 Functional prototypes and series parts; engineering, medical, dental


Fan wheel

geometry

by

Transcat

GmbH

SOURCE: EOS


Small-series production

for

customizing

aircraft interiors

— Requirement:•

customer-specific light frames for 777 aircraft

•

9 light frames per 777 cabin•

good aesthetics (visible part)•

fulfilment of FDA requirements

— Solution:•

DirectPart®

on EOSINT M 270 with EOS StainlessSteel 17-4

— Result:•

implementation of design and manufacture within 30 days

•

flexible manufacturing configuration

Aircraft

Interieur

Source: EOS, Boeing Commercial Aircraft

Project partner:

Boeing 777 with

laser-sintered

light frame

for

the

cabins

of a special

Airlines edition


e-Manufacturing™

— GE

— Pratt & Whitney

— Rolls Royce

— AVIO

— Snecma

— Turbomeca

— Klimov

— MTU

— Engine Alliance

SOURCE: EOS


Prototypes for Test Rigs

Straightener for an helicopter gas-turbine engine.PEP / Turbomeca / Best in Class

Source: PEP / Turbomeca / Best in Class

CobaltChrome MP1 superalloy for fully-functional aircraft engine parts

— Requirement:•functional prototypes for developing helicopter gas-turbine engine components

•capable of running in test-bed conditions, e.g. high strength at high temperature

— Solution:•EOSINT M 270 with EOS CobaltChrome MP1 superalloy

— Result:•can be built fully dense in 82 hours•can be automatically polished•properties fulfil requirements for running on test-bed


Many

medical

devices

are

suitable

to be

produced using

EOSINT M

Complex part´s

in EOS StainlessSteel

17-4

Source: EOS

Laboratory equipment, operation aids etc.

Parts in EOS Titanium Ti64

project

partners: Deka, Darpa

(left) and PEP, DePuy

(right)


Source: EOS, LBC

project

partner: LBC

Application examples

EOSINT M

can

build

tool

inserts

on preforms

or mounted

on a clamping

system

Hybrid insert produced in

EOSINT M270 by

building

on top

of a machined

preformErowa Powerchuck 150 clamping system mounted in EOSINT M system


Which are the field where we got success

Inlet system for aero engine:

Material Aluminium alloy A357

Added value: complex model in few parts

Polystyrene model + investment casting +

heath treatment

Target price is 1500÷2000 Euros/Pc

In production in Italy


Polystyrene model by sintering

Three from investment casting

Finished part


— New Design

— Thin Walls

— Sensor Housing included

Air Inlet SS17-4

Source: ProtoCast


Metal parts can also be cast with moulds and cores built on EOSINT S

— DirectCast®

sand moulds and cores

for metal castings

•Engine blocks

•Pumps

•Hydraulic devices

•Housings

•Special castings

Metal parts via DirectCast

Source: EOS, ACTech


— Requirement:

•

fully functional and certified prototype for testing

— Solution:

•

Manufacture of a core package from cold-

box cores and nearly 100 laser-sintered cores

•

casting in aluminium•

comprehensive quality control according to standard and Avio

s.p.A. own procedures

Development of a gear box housing for a jet engine

Project: Main HousingRollsRoyce

Trent

900 for

Airbus A380Design and Engineering: AVIO S.P.A.Realization: Erreci

Rapid Casting

s.r.l.

SOURCE: EOS, AVIO S.P.A., Erreci

Rapid Casting

project partner:

Sand Casting for Jet Engines


— Result:

•

fully functional housing, ground testing successful, flight approval

•

Lead time: 10 weeks from 3D CAD model to qualified casting

•

60% time saving compared to a process chain using completely conventional tooling

Development of a gear box housing for a jet engine

SOURCE: EOS, AVIO S.P.A., Erreci

Rapid Casting

project partner:

Sand Casting for Jet Engines


e-Manufacturing™ in Aerospace requires Quality Assurance !!!

— Data Quality and Data Preparation•

CAD Data Quality•

Nesting•

Correct Sliced Files

— Material•

Constant Powder Quality•

Mixing and Refreshing

— System Condition and Maintenance•

Service and Calibration•

Parameter Settings•

Recoating•

Thermal Control•

Cooling System•

Laser Power•

Inert Atmosphere

— Part Quality Control Procedure •

Dimensions•

Material properties

Quality Factors for e-Manufacturing


Quality

Control

Procedures

Source: EOS

— Print-out of formated

job reports

— Reports all machine messages

— Surveilance

of the current machine operation

— OnlineLaserPowerControll

1.0

— N2, T, evtl. further

sensors

— Graphical

analysis

— Scanner position

control

— Recoating

control

— Comes with an .dll-interface for third party ERP-systems

Basic functions which are revolutionary


Source: EOS

Documentation and Reporting

Tools for checks, calculations and conversion (examples)

— .dll-interface interface•

to enable data transfer to external tools (like ERP or visualisation tools)

— Economic Information•

Build Time and Costs Calculation (also per part) for Quotations,

Invoices etc.•

Powder Consumption•

Statistics

— Quality Control•

Test Specimen •

Report File per Job•

Measurement and Material Properties•

Part specific Quality Checks•

Statistics


Part Quality Control

— Reference geometry, if possible similar to customer geometry

— Quality control card

— Use statisitics for control of dimensions and initiation of scaling adaption

— Job unload and unpacking Procedure

Dimensional control

SOURCE: EOS


Ultra Light Aircraft's

— Aircraft's below 600 kg

— Invest < 100.000 $

— No FAA Certification

— Max. 2 People on Board

— Remos, Allegro, Cessna….

Aerospace - Market Segments


Unmanned Area Vehicles -

UAV

— Players:•

BAE Systems, Bell Helicopter Textron, •

DRS Unmanned Technologies, •

Israel Aircraft Industries, •

LMCO, RUAG, EADS, Boeing, NGC ....

— No Passengers

— Small and light Weight

— Military and Civil Applications•

Combat•

Surveillance

— Special Requirements•

Size•

Weight•

Technology Integration

— Low Cost

Aerospace - Market Segments


www.eos.info

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