Additive Manufacturing
Multi-Axis / HybridBerlin, Jun. 21, 2018
© Siemens PLM Software 2017
3DMP® FORUM
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It’s time to rethinkEVERYTHING
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Innovation: Incremental progress isn’t competitive enough
STATUS QUO
Manufacturing transformation
Pro
du
ct
tran
sfo
rmati
on
Shift from prototyping / experimentation to mainstream industrial production
Sh
ift fr
om
co
nve
ntio
na
l d
esig
n to
inn
ova
tive
DF
AM
Reinvent manufacturing
Reimagine products
• Reduce weight, material
• Scan-to-product
• Expand performance
• Accelerate innovation cycles
• Eliminate molding/castings/tooling
• Eliminate/simplify assembly process
• Reduce supply chains
• Affordable low volume production
Rethink business
• Individualization, personalization
• Zero inventory – on demand printing
• Design anywhere. Print anywhere.
• Accelerate innovation
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»SIEMENS goes ADDITIVE 4.0«
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First 3-D printed bladein “hot” part of gas turbine by
Siemens - PG
‒ Travels at over
1,000 mph
‒ Carrying 11 tons
‒ Surrounded by gas
at 1,250°C
https://www.youtube.com/watch?v=8vtLtu4ZYsQ
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Burner tip
repair
Complete burner
manufacturing
Faster product
innovation
600 pieces delivered
90% faster
20,000 operating hours
Simplification:
12 to 1 partsTime to market
2 yearswith conventional technologies
down to
2 monthswith AM technologies
Benefits of Additive Manufacturing
3 times longer
lifetime!
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Inspiration
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Siemens Brennerdüse
Simulations-getriebenes Design
Design-Auslegung (HEEDS)
Simulation Kühl-Flüssigkeit (STAR-CCM+)
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Industrialize Additive Manufacturing
Applicable Hardware Technologies
EDAG Image
Hybrid additive
Directed energy
deposition
Multi-axis
Fused deposition
modeling
Powder bed fusion
Laser material
fusion
Multi jet fusion
Agent jetting/
inkjet technology
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Multi-Axis Deposition – Customer Base
More than 100 seats
Distribution Tube
ENGINEERING
Turbine Housing
AEROSPACE
Rocket Nozzle
AEROSPACE
Die Cut
AUTOMOTIVE
Blade
AEROSPACE
Tube with inner cooling
ENGINEERING
Cooled Infection Mold
DIE & MOLD
Drill Bit
OIL & GAS
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Source: GEFERTEC
Multi-Axis Deposition„3DMP“ – ARC Welding
Creation of blank-parts
• Very high build-rates
• Excellent material quality
• Various raw materials
• Cheap material
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Modell Preparation – Feature Recognition and ModificationModifying of non parametric Geometry!
Open (CATIA/CREO/STEP/…) File
Generates NX non parametric GeometryDelete small holes
Change diameter or chamfer size
Change fillet radius
Offset
Move faces
… und viele weitere
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Part Decompose into additive features
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Planar and Rotary Additive Pattern
Planar Additive Profile with Zigzag Fill
Planar Additive Spiral Helical
Planar Additive Thin Wall Helical
Rotary Additive Spiral HelicalRotary Additive Helical
Around Part
Rotary Additive Thin Wall Helical
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Freeform & Tube Additive Pattern
Freeform Additive Coating
Freeform Additive Buildup
Freeform Additive Thinwall
Tube Additive Thinwall
Freeform Additive Buildup
Freeform Additive Thinwall
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Freeform & Tube Additive Pattern
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Multi-Axis Deposition – Wide range of capabilities
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Merge Path
• Combine two or more operation into one toolpath to get the optimum deposition pattern
• Combine operation with different pattern, step over, layer thickness
• Deposit layer by layer to avoid collision between operations
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Additive Geometry Objects
Additive operations will go under the “HYBRID_GEOMETRY”
group, as well as subtractive operations that work on the
additive feature (truing up a surface before the next additive
operation, for example) AM Raw
Material
Initial Workpiece
Finished Part
GeometrySubtractive operations on the finished part geometry will go
under the “WORKPIECE” group (note that it is a milling group
here, but there may be a turning geometry group on machines
that support it
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Additive Hybrid Programming
A typical Hybrid program will look similar to this:
Additive operation
Machining operation to clean
up additive feature surface
before next additive op
Completion of additive
operations
Completion with milling
operations
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Multi-Axis DepositionRaw-Material
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Simulation3DMP
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Benefits of Multi-Axis Deposition / Metal
High Build rate
ARC
Welding
+
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Multi-Axis Deposition & Hybride ManufacturingNo Support Structure!
MachineSinumerikNX CAM Software
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SpaceX
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Robotic Composite 3D Demonstrator