beyond the hype - 3dmpmag.com€¦ · beyond the hype what does the journey to metal am production...
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Beyond the Hype
What does the journey to metal AM production really look like?
August 2016
Adam Rivard [email protected] 207-756-5544
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Beyond the Hype: How to get there?
The Best Machine
Control
Integrate Quality
Standardize
Dig into the details
Gartner.com
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The Big Question
Build Chamber
Materials
Process Configuration
Monitoring
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Build Chamber – Envelope Size
M280 9.9 x 9.9 x 12.8”
SLM 500 HL 19.7 x 11.0 x 12.6”
Q20 14.2 x 14.2 x 12.6”
ProX 320 10.8 x 10.8 x 16.5”
M400 15.8 x 15.8 x 15.8”
ProX 400 19.7 x 19.7 x 19.7”
X Line 2000 R 31.5 x 15.8 x 19.7”
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Why Go Bigger?
>5000 Parts!
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Is Bigger Really Better?
>5000 Parts!
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Is Bigger Really Better?
IN718
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Is Bigger Really Better?
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Is Bigger Really Better?
Qualified & Controlled
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Build Chamber - Environment
7
N Nitrogen
18
Ar Argon
Inert Gas
Laser Electron Beam
Vacuum
8
O Oxygen
& Laser
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Build Chamber - Temperature
Stress
Structure
Time
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Process Configuration - Scanning
200 W
3000 W
7 m/s
8000 m/s
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How Fast is Fast Enough?
Source: Appl. Phys. Rev. 2, 041304 (2015)
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Process Configuration – Powder Distribution
Build Platform
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Process Configuration – Powder Distribution
Build Platform
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Process Configuration – Powder Distribution
Build Platform
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Process Configuration – Powder Distribution
Build Platform
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Process Configuration – Powder Distribution
Build Platform
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Rake Configuration – Rigid
Build Platform
Pros: Precision Thin Layers Consistency Cons: Unforgiving
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Rake Configuration – Flexible Metal
Build Platform
Pros: Forgiving
Cons: Thicker Layers
Variation?
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Rake Configuration – Flexible Non-Metallic
Build Platform
Pros: Forgiving
Fine Detail Features Cons:
Thicker Layers Debris?
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In-Situ Inspection
Build Platform
Solidified Layer
Metal Powder
Layer Thickness Melt Pool
Beam
Previous Layers
Atmosphere
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Material Availability
Aluminum Cobalt Nickel Steel Titanium Gold ?
X Line 2000 R
Pro X 400
Pro X 320
Q20
M290
SLM 280 HL
M3
Mlab
Aluminum Cobalt Nickel Steel Titanium Gold
X Line 2000 R
Pro X 400
Pro X 320
Q20
M290
SLM 280 HL
M3
Mlab
Aluminum Cobalt Nickel Steel Titanium
X Line 2000 R
Pro X 400
Pro X 320
Q20
M290
SLM 280 HL
M3
Mlab
Understand & Characterize
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Turnaround Time
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Service and Support
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You bought a machine. Now what?
STL File Material Machine
Geometry Material Machine Process themes
Post Processing
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Stop Building –
Feedstock Material
Build Analytics
Pedigree
Contamination Control
Build Quality & Validation
Calibration & Maintenance
Configuration Management
Equipment & Process Certification
Start Producing
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Feedstock Material
Standard Work
Material Specifications
Reuse Strategy
Contamination Control
People
Consumables & Tools
Process Related
Calibration & Maintenance
Above & Beyond OEM
Recommendations
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Machine Qualification
Process Change Control
Standard Work
Equipment & Process
Certification
Models
Build Files
Hardware
Software
Themes
Configuration Management
Design Rules
Design Report
Lessons Learned
Build Analytics
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CAD Files Models
Build Files Powder Input
Build Logs Post Process Data Inspection Data
Start
Finish
Pedigree
Machine & Build Diagnostics
Visual Inspection Standards
Effects of Defects Understanding
Quality & Validation
Standard Work
Machine Data Collection
In-Process Monitoring
Visual Inspection
Build
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Certification & Validation
Align Contribute
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A chain is only as strong as it’s weakest link…
Beyond the Hype
What does the journey to metal AM production really look like?
August 2016
Adam Rivard [email protected] 207-756-5544