prof. d.sc. m.sc. gideon n. levy [email protected]...
TRANSCRIPT
TTA Gideon Levy © 09/2014
Additive Manufacturing- meets Sustainable
Environment needs
Prof. D.Sc. M.Sc. Gideon N. Levy
Additive Manufacturing and
Electro Physical & Chemical Processes
AM the enabling space for future innovation
and progress
NSF Workshop: Environmental Implications of Additive Manufacturing
October 14-15, 2014, NSF, Arlington, VA
TTA Gideon Levy © 09/2014
World gov. funding 5`561 Mio € Mio €
Singapore 500 Mio SGD 293 Mio € 293
China 2 Billion USD 1466 Mio € 1466
UK 60 Mio GBP 74 Mio € 74
European Union (approx.) 2 Billion EUR 2000 Mio € 2000
Russia 2 Billion USD 1466 Mio € 1466
Australia AMCRC 250 Mio AUD 171 Mio € 171
Australia AM machines 17.5 Mio AUD 12 Mio € 12
US (NAMII) 30 Mio USD 22 Mio € 22
US America Makes 9 Mio USD 7 Mio € 7
New Zeland
Taiwan
South Africa
South America
Mexico
Mio € 5'561
50
Additive Manufacturing government funding
TTA Gideon Levy © 09/2014
Agenda I
1. What is Additive Manufacturing
2. What is Sustainable Manufacturing
3. Where do they meet?
4. Conclusions
TTA Gideon Levy © 09/2014
5 Senses
Why do have AM a great potential? A
bstr
act
Real
Perc
ep
tio
n
Thinking
Speaking
Writing
Printing
Painting
Crafting
Art, Music
Virtual reality
Software
Film TV
Simulation Modelling
Science: Rules and
equations
Physics, Chemistry
Mathematics
Everything
we have
And more….
TTA Gideon Levy © 09/2014
AM is an Enabling Multidisciplinary Technology
System / Process
Materials
Applications
Up stream/ Down stream
Polymers
Metals
Ceramics
Composite
Biologic
Application dedicated
Automation
Part and powder handling
Batch to continues
……………..
Adaptive control
Closed loop
Productivity
Repeatability
………………
Design for AM
3DP design
tool
Part finishing
Coating
Modifications
…………
Industry
Aviation
Automotive
Jewelry
Medical devices
Scaffolds
Organ printing
……..
TTA Gideon Levy © 09/2014
Terminology - Process Categories I (2012)
1. Vat Photopolymerization Process
Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon
Liquid Photopolymers,
Ceramic or Metal filled photopolymers
2. Material Jetting Process
Multiple nozzles Single nozzles
Thermoplastics, Wax or Photopolymers, Metals,
Optical materials, Electronic materials
3. Binder Jetting process
a liquid bonding agent is selectively deposited
to join powder materials.
Polymer, Metal, Ceramic powders
4. Material Extrusion Process
FDM Polymers, composite
C
C
C
T
T
C Chemical
T Thermal
T Thermal post processing
T
TTA Gideon Levy © 09/2014
Terminology - Process Categories II (2012)
5. Powder Bed Fusion Process
SLS, SLM, EBM
Polymers, metals & ceramics powder
6. Sheet Lamination Process
Bonding, hot melt, glue, US welding
Paper, Metal, Polymers
7. Directed Energy Deposition Process
focused thermal energy is used to fuse materials by melting as they are
being deposited
Metal, polymers, powder, wire
T
T
T
C
C Chemical
T Thermal
T Thermal post processing
TTA Gideon Levy © 09/2014
Hybrid Systems in metal and polymers
TTA Gideon Levy © 09/2014
Process / material matrix
For most process some bio-compatibles
are available.
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https://www.additively.com/en/
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Gartner Hype Cycle of Emerging Technologies, Trends for 2014
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The value chain in product creation
CONCEPT MODELING
RAPID PROTOTYPING
Pre-SERIE / BRIDGING
CONFORMAL COOLING / TOOLING
ADDITIVE MANUFACTURING REVERSE ENGINEERING
The Trend
TTA Gideon Levy © 09/2014
http://sitemaker.umich.edu/ykoren/education
Manufacturing paradigms
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China 2013 $80 million investment in AM
An AM-built beam for use in
aviation, printed at Northwestern
Polytechnical University in China.
Courtesy of Guancha Zhe.
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SME RAPID Detroit 2014
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AM Micro Parts
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http://www.grantadesign.com/ and 3DP materials
3DP
3DP
3DP
3DP
3DP
Food
3DP
Bio-mat
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Applications arrays divide and focus consequently on different quality issues and standards
Entertainment
Movie?
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Main Application areas of AM/ 3DP
Difficulty
Value
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Added Value: Translate process characterization into specific applications
Freedom of Design
Lightweight structures (hollow)
No-Tool production
Assemblies, integrated design
Anatomical personalized
Ergonometric design
Customization individualization
Conformal cooling
Gradual materials (on the way)
Medical scaffolds (on the way)
Bio Materials (on the way)
TTA Gideon Levy © 09/2014
TTA Gideon Levy © 09/2014
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Bio inspired AM fabricated systems
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32
Conformal cooling systems and heat exchanger
A great chance is coming up in moulds!
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Renishaw's additive manufacturing system to boost production capabilities at Directed Manufacturing Inc
TTA Gideon Levy © 09/2014
3D Printers in 30% of Households
Experts Futures Researchers
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Agenda I
1. What is Additive Manufacturing
2. What is Sustainable Manufacturing
3. Where do they meet?
4. Conclusions
TTA Gideon Levy © 09/2014
Venn diagram - Path to sustainable development
"Sustainable development is an
organizing principle for human
life on a finite planet. It posits a
desirable future state for human
societies in which living
conditions and resource-use
meet human needs without
undermining the sustainability of
natural systems and the
environment, so that future
generations may also have their
needs met. Sustainable
development ties together
concern for the carrying
capacity of natural systems with
the social and economic
challenges faced by humanity”. http://en.wikipedia.org/wiki/Sustainability
TTA Gideon Levy © 09/2014
Why sustainable?
"Less than 10 % of global population consume more than
80 % of global resources. With more than 7 Billion
humans on globe we in the early industrial countries carry
responsibility to chance value creation in the direction of
wealth for all global citizens”
Prof. Dr.-Ing. Günther Seliger
TU Berlin
TTA Gideon Levy © 09/2014
LCA Standards
ISO: International Organization for Standardization
LCA standards are voluntary
Part of 14000 Environmental Management Series
• LCA Standards:
– 14040 Principles and Framework
– 14041 Goal and Scope Definition and Inventory Analysis
– 14042 Impact Assessment
– 14043 Interpretation
– 14020 series: Environmental Labeling
TTA Gideon Levy © 09/2014
Life Cycle Assessment (ISO Standards)
According to the ISO 14040 and 14044 standards, a Life Cycle Assessment is carried
out in four distinct phases as illustrated in the figure shown to the right. The phases are
often interdependent in that the results of one phase will inform how other phases are
completed.
http://en.wikipedia.org/wiki/Life-cycle_assessment
TTA Gideon Levy © 09/2014
Reducing Environmental Impact Through Product Life Cycle Assessment
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Fuel consumption per 100 passenger kilometre
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Most car manufacturers on track to meet 2012 CO2 targets
http://w
ww
.eea.e
uro
pa.e
u
TTA Gideon Levy © 09/2014
COMPARE: Is AM a better alternative to Casting e.g.?
TTA Gideon Levy © 09/2014
TTA Gideon Levy © 09/2014
TTA Gideon Levy © 09/2014
Agenda I
1. What is Additive Manufacturing
2. What is Sustainable Manufacturing
3. Where do they meet?
4. Conclusions
TTA Gideon Levy © 09/2014
TTA Gideon Levy © 09/2014
ATKINS Project: a low-carbon footprint manufacturing solution
The £2.7 Million ATKINS Project …
DirectSpare: A European Approach for Spare Parts on Demand
Birth and
youth
problems
Aging and
wear
problems
TTA Gideon Levy © 09/2014
The impact of the DirectSpare concept
Obsolete equipment because of
unavailability of spare parts becomes
useful
Millions of unused
spare parts being
reduced to scrap...
Ordered spare parts
transported around
the globe...
Warehouses
stacked with spare
parts...
TTA Gideon Levy © 09/2014
Autodesk Sustainability Workshop, November 22, 2013
Environmental Impacts of 3D Printing , By Jer Faludi
See more at:
http://sustainabilityworkshop.autodesk.com/blog/environmental-
impacts-3d-printing#sthash.tKT7DEf0.dpuf
TTA Gideon Levy © 09/2014
Light-weight “material“ selection done by geometry
Materials designed with new additive manufacturing techniques exhibit high stiffness
and low density, occupying a previously unsettled area of the Ashby material
selection chart for Young’s modulus (stiffness) versus density. The octet truss
structure recently fabricated by Livermore researchers is a stretch-dominated lattice.
TTA Gideon Levy © 09/2014
Topological Optimizations
Topological optimized design results are:
• Complex geometries
• Conventionally not produce able
• Have to be smoothed
• Highest geometrical freedom
• Agile manufacturing
• New design concepts
Chances for Layer Manufacturing:
TTA Gideon Levy © 09/2014
AM made - (no supports) Heat exchanger
Heat exchanger 450x4050x500 mm
TTA Gideon Levy © 09/2014
Multi Physics-CAD (MP-CAD) Tools are in due
– Light weight
– Ecological design
– Topological optimization
– Flow
– Minimal parts(Diffusor)
– Static mixer
– Aeronautics
– Heat transfer
– Local physical properties
– Digital materials
– Alloyed materials
– Medical
– Biological design
– Engineered surfaces
– Scaffolds
– Life Style
TTA Gideon Levy © 09/2014
Agenda I
1. What is Additive Manufacturing
2. What is Sustainable Manufacturing
3. Where do they meet?
4. Conclusions
TTA Gideon Levy © 09/2014
Construction of a CUBESAT using AdditiveManufacturing
Additive manufacturing
The sky is the limit !
TTA Gideon Levy © 09/2014
Additive Manufacturing has the potential to improve the entire
Life Cycle Engineering
AM is a Green Technology
AM may replace less environmental friendly process
AM can reduce row material consumption
AM can reduce weight by freedom of design
AM can save energy in the use phase
The AM process themselves can and have to be
environmentally improved ( higher efficiency, bettery
recyclability of materials, less waste)
TTA Gideon Levy © 09/2014
Additive Manufacturing has the potential to improve the entire
Life Cycle Engineering
AM is a Green Technology
AM may replace less environmental friendly process
AM can reduce row material consumption
AM can reduce weight by freedom of design
AM can save energy in the use phase
The AM process themselves can and have to be
environmentally improved ( higher efficiency, bettery
recyclability of materials, less waste)
TTA Gideon Levy © 09/2014
67 years ago…
The First Transistor was Invented,
November 17-December 23, 1947
John Bardeen William Shockley and Walter Brattain at Bell
Laboratories
TTA Gideon Levy © 09/2014
30 years ago: The AM was invented
08.08.1984
Dr. Charles W. Hull; born May 12, 1939, is
the co-founder, board member, executive
vice president and chief technology officer
of 3D Systems Inc.( the biggest 3DP
OEM). He is the inventor of the
Stereolithography; he holds more than 60
U.S. patents
Dr. Chuck Hull is recognized as “the
father” of the worldwide upcoming 3D
Printing or Additive Manufacturing
technologies.
TTA Gideon Levy © 09/2014
We are on the right track
TTA Gideon Levy © 09/2014