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How does metal 3D printing disrupt conventional manufacturing technology ?Markus Bürger | 10.04.2019

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GKN Powder Metallurgy – At a glance

£ 1,212mn

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Our global footprint

Hoeganaes manufacturing plant

Sinter Metals manufacturing plant

Corporate / sales office / engineering centre

BRAZIL

1

MEXICO

12019

opening

NORTH AMERICA

42 9JAPAN

1

INDIA

CHINA

1

2

21

28manufacturing

plants

3global innovation

centres

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We are the world‘s #1 in powder metal solutions

#1 global producer

of precision powder metal parts

13 million parts daily

#2 global producer

of powder metal

300,000 tons

of powder sold p.a.

A global market leader

in metal 3D printing

Driving business wins

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GKN ADDITIVE - At a glance

2017: £ 180.0002018: £ 1,4mBudget 2019: £ 4m

STRATEGY 2024:£ 100M

We‘re scaling ourbusiness for massive

future growth!

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THINK Materials

Steels

(GA or WA)

4340

5120

8620

4605

1.2709

20MnCr5

Stainless Steels

(GA or WA)

304L

316L

420

17-4 PH

Nickel Alloys

(GA)

IN 625

IN718

Ni-Ti

Aluminum Alloys

(GA)

AlSi7Mg

AlSi10Mg

Titanium Alloys

(GA)

CP Ti

Ti64

Ti6242

Ti5553

Beta 21S

Copper Alloys

(GA)

Pure Cu

CuCrZr

CuNi3Si

Custom Alloys

Providing Support for materials

develop-ment

Additive manufacturing requires advanced powder with characteristics specific to the application. These materials need to be qualified and guaranteed for consistent performance.

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AM meets PM

OUR STRONG METAL PROCESS PORTFOLIO

PM FinishingSintering SizingCompacting

LASER AM Laser Finishing

BINDER AMPrint /Decake FinishingDebinding Sintering

DESIGN

Limited design

freedomtool needed

Full design freedomno tool

Full design freedomno tool

VOLUME (pcs)

>50.000

<2.000

<50.000

LEADTIME(weeks)

12-16

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2-4

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Design and Process Guidelines – Direct Metal Laser Sintering (DMLS)

Support structure for printing

IT class 11-13 Mechanical properties: better than casting, PM and binder but

worse than forged

Compact & complex design

Build Volume max. 420 x 420 x 400 mm

Materials: 20MnCr5 ,1.2709, 316L

(1.4404), AlSi10Mg, CuCr1ZrWall thickness

>0.5mmSurface: Rz <50 µm

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Design and Process Guidelines – Binder Jetting

Support structure for sintering

IT class 12-14 Mechanical properties MPIF35

Part Size ~ 100 x 100 x max. 80 mm

Build Volume max. 360 x 200 x 80 mm

Material: 316L (1.4404)

Wall thickness 1.5 - 30 mm

Surface: Rz 45 µm

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Expanding our portfolio & creating new markets

UNIQUE METAL PROCESS PORTFOLIO

Component volume

Additive Binder Jet

Additive Laser Powder Bed

Current ‘heartland’

Conventional PM

Metal Injection Moulding

Future opportunities through AM in new markets and with new products

AM offering –Outside of historical accessible segments

Volume Production <50.000

Low Volume Production from 1 to 2.000

Binder Jet

Laser Powder BedProduct life cycle

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AM product solutions

→ Replacement of manualmanufacturing process

→ Higher efficiency andperformance→ 2 weeks delivery

→ Ramping up first series applications

Prototypes Copper Coils Serial Parts

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Why Additive Manufacturing?

Disruptive Points

Customization

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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Full design freedom

Source: EDAG/Genesis

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Customization

Monolithic Design Bionic Design Internal structures

Source: ge.com

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Mass customization

Weight reduction Personalization

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Why Additive Manufacturing?

Disruptive Points

Customization

Toolless

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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Toolless

Plastic componentsPlastic injection moulding- tool costs: 15k – 50k€

Helical gearsPM – surface densified- tool costs: 100 k€

HousingAluminum die casting- tool costs: 100 k€

AxleMachined and broaching- tool costs: 50 k€

Coverdeep drawn sheet metal- tool costs: 20 k€

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Why Additive Manufacturing?

Disruptive Points

Customization

Toolless

Quick time to market

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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Advanced digital systems to support AM

Global Print Network

Shop Floor of the Future

Customer Focus

Virtual Storefront

Advanced planning

Visual shop floor

Global print network

Next

Digital twin (interaction with GQS, Teamcenter)

Backbone (GKN ERP, GKN GQS, GKN Teamcenter)

Databases on premise, Full compliance (e.g. Export)

Management of Laser AM in multiple plants with central intelligence

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Case study – How to reduce complexity in procurement with AM

Plastic componentsPlastic injection moulding- tool costs: 15k – 50k€- lead time: 10 weeks

Helical gearsPM – surface densified- tool costs: 100 k€- lead time: 14 weeks

HousingAluminum die casting- tool costs: 100 k€- lead time: 14 weeks

AxleMachined and broaching- tool costs: 50 k€- lead time: 8 weeks

Coverdeep drawn sheet metal- tool costs: 20 k€- lead time: 8 weeks

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Why Additive Manufacturing?

Disruptive Points

Customization

Toolless

Quick time to market

Reduced inventories

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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Expanding our portfolio & creating new markets

Product life cycle

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Why Additive Manufacturing?

Disruptive Points

Customization

Toolless

Quick time to market

Reduced inventories

GKN PM as one-stop solution provider

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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Expanding our portfolio & creating new markets

UNIQUE METAL PROCESS PORTFOLIO

Laser AMLow volumes < 2.000 pcs

Copper CoilsPrototypes

Aftermarket

Binder AMMedium series <50,000 pcs

Conv. PM & MIM

Large series > 50,000 pcs

Motorsport

From one piece …

… to million pieces

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Uniquely positioned to lead the AM market

From high purity to high productivity Advanced AM materials

Aero and Auto certified

Design to function

Fatigue and topologyoptimization

From high performanceLaser to high productivityBinder

Global footprint

World class production system

Materials Design AM Process

WE OFFER THE WHOLE VALUE CHAIN

Operational Excellence

Automotive (OEMs & tiers)

Industrial

Customers

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Expanding our AM footprint

Radevormwald

Bruneck

Bonn

Danyang

Auburn Hills (opening Q1 19)

Cinnaminson

Germantown

Production site

R&D Sites

Cinnaminson: Materials R&D & Manufacturing Centre Radevormwald: Process R&D CentreBonn, Bruneck, Germantown: Digitalisation Centres

EOS M290Aluminum, copper, stainless

steel

EOS M290Aluminum, Copper, 316L,

Steel

EOS M400Aluminum

Renishaw AM250Steel

Additive IndustriesMetalFab 4 LaserAluminum, 316L

HP Metal Fusion Jet316L

GLOBALLY CONNECTED

HP Metal Fusion Jet316L & low allooyedsteels

EOS M300-4 Q3 19

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Why Additive Manufacturing?

Disruptive Points

Customization

Toolless

Quick time to market

Reduced inventories

GKN PM as one-stop solution provider

ADDITIVE: Why disruptive?

Full design freedom

Monolithic Design

Bionic Design

Internal structures

Weight reduction

Personalization

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THANK YOU