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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
2Klaipeda 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.
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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.
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10
DED
Outer surface
Filling
More layers:Hatch distance is changed for each layer
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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
12Klaipeda 10.4.2017
Powder bead fusion: 1- 3 mm3/s DED: 3 - 10 mm3/s
Hype curve of Gartner
14
Expectations given by hypeMaturity of technology
Hype curve
Klaipeda 10.4.2017
Gartner hype curve
15http://www.ecampusnews.com/top-news/the-hype-cycle-of-mooc-courses/
Maturity
Visi
bilit
y
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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
26Klaipeda 10.4.2017
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
Gas turbine blades Development time for prototype -90% Test environment:
− 13000 rpm− 1600 km/h− 1 250 oC− Force of 11 tons.
Turbine blades
38Klaipeda 10.4.2017
The three structural elements shown are all designed to carry the same structural loads and forces.
The potential of 3DP in construction
40Klaipeda 10.4.2017
"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
41Klaipeda 10.4.2017
http://www.arup.com/news/2015_05_may/11_may_3d_makeover_for_hyper-efficient_metalwork
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
Klaipeda 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 %
Industrial applications
Robot gripper
Gripper lifts four ball bearings at timeTraditional structure as several pneumatic componentsWith AM one component, which acts as pneumatic
gripper, is made
Industrial applications
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
Industrial applications
* 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
Industrial applications
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
Industrial applications
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
52Klaipeda 10.4.2017
- 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
53Klaipeda 10.4.2017
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
Case landing gear
55
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
Unaesthetic, bad for self consistence Uncomfortable and solid Requires constant follow up by orthodontics dentist Cost of treatment 3 000 – 5 000 €
Current technology
63Klaipeda 10.4.2017
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
65Klaipeda 10.4.2017
How to optimize weight
67
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
68
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
69
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
70Klaipeda 10.4.2017
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
71Klaipeda 10.4.2017
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.
Case study - Eliminating supports
73Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
Manufactured bottle openers.
Case study - Eliminating supports
74Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
• 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.
Case – Minimizing manifolds
76Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
DfAM step 1- extract the essentials that are needed.
Case – Minimizing manifolds
77Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
DfAM step 2 - Optimize flow
Case – Minimizing manifolds
78Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
DfAM step 3 – Define wall thicknesses and add supports
Case – Minimizing manifolds
79Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
• Result : Flow and weight optimized part• Original part made out of aluminum, optimized one out of
stainless steel. Still 50 % weight savings.
Case – Minimizing manifolds
80Klaipeda 10.4.2017 Source: Marc Saunders, Renishaw
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