© 2018 Autodesk, Inc.

Manufacturing Industry Futures

By Nick MarkovicSenior Technical Consultant, Autodesk Research

© 2018 Autodesk, Inc.

MANUFACTURING INDUSTRY FUTURESWho we are

Our team

OUR VISIONRealize the future of manufacturing with our customers and partners so we can make more and better products, all with less negative impact on our world.

OUR MISSIONMake our customers successful by exploring and providing innovative technology solutions that enable them to make new things in ways they never could before.

multi-discipline

optimization

advanced casting

methods

generative design

Manufactur-ing process simulation

materials science

hybrid manufactur-

ing

composite materials

designreverse

engineering

non-linear and

dynamic simulation

Electro-magnetic

simulation

IoT, sensors and

instrument-ation

Intelligent automation /

machine learning

Our research areas

automotive

aesthetic design

multi-function

components

complex light-weight

parts

aerospace and space

biomedical applications

conformal cooling tool

design

multi-physics

problems

hybrid manu-

facturing

complex machining problems

robotic automation

large scale additive

Our innovative applications

adaptive manufactur-

ing

robotics program-

ming

wire-arc additive

manufactur-ing

build verification

and inspection

composites manufacture

sheet metal nesting

resin-transfer molding

process optimization

precision applications

large scale deposition

robotic machining

and polishing

toolpath optimization

Manufacturing capabilities

© 2018 Autodesk, Inc.

MANUFACTURING INDUSTRY FUTURESConverging design and manufacturing

AUTODESK GENERATIVE DESIGN

DESI GN EXPLORATION

MODE COST TRAVEL LEAD ETC

SHIP

PLANE

RAIL

TRUCK

OPTIMIZATION

60 % FASTER

HOW IS AUTODESK GENERATIVE DESIGN DIFFERENT?

DESIGN CONSTRAINTSEXPLORE

Style

Space claims

Objectives

Manufacture

MULTI-OBJECTIVE OPTIMIZATION

TRADE-OFFS

Convergence of design & manufacture workflow

Materials

VERIFICATION

Strength and stiffness

Structural stability

Dynamic response

Prove that we can make it

MULTI-OBJECTIVE OPTIMIZATION

Autodesk technology centers

© 2018 Autodesk, Inc.

MANUFACTURING INDUSTRY FUTURESTechnology focused areas

Hybrid manufacturing

CHALLENGE:

• Can we break the barrier using AM techniques on structural critical components?

• How do we exploit new manufacturing technologies for further weight savings?

Hybrid manufacturing in aerospace

Generative Design & Optimization

Additive manufacturing

Metal casting manufacturing

+

+

BENEFITS:

• Significant fuel savings and reduction in CO2 emissions over lifetime of part

OUR SOLUTION:

• Additive manufacturing plus generative design opens up a whole new design paradigm

• Use lattice optimization and 3D-printing to dramatically light-weight the seat frame

• The seat frame is made out of Mg alloy.

Extracting pattern & securing onto tree

Slurry dipping

Sand coating

Burn-out

Burn-out

Metal pouring

visDe-shelling

Investment Casting

Key outcomes:

• 56% lighter

• 557kg Weight savings

• $~2mil fuel cost savings

Adaptive manufacturing

Fancy hand polishing?

Robotics manufacturing

Who / What is RAMLAB?

Met al part s on demand

© 2018 Autodesk, Inc.

TECHNOLOGY SOLUTIONS DfAM in injection molding

Why 3D print metal mold tools?

• Allows very high resolution and precision (layer thickness 20-100mm)

• Allows the user to produce very complicated parts (Generative Design or latticed optimized structures)

• More design freedom with increased performance

• Unused feedstock can be recycled and minimise waste (e.g. buy-to-fly ratio is low)

• Competitive costing for low production

• Part consolidation (e.g. GE fuel nozzle from 20 parts into one)

Benefits of AM

AM fuel nozzle Source: www.ge.com

The next steps? Fatigue characteristics of AM metals

Varying thickness with varying build angles Post processing exploration

EBSD mapping of SLM S316L Source: Riemer A et al, Eng Fract Mech 2014;120:15–25

As-built HT HIP

Surface roughness effects

~1mm

The next steps? Fatigue testing

• We are looking to conduct testing according to:

• ASTM E466 – The relationship between stress and

number of cycles

• ASTM E647 – The relationship between Fatigue crack

growth rate and stress intensity factors

Data used for safe life design

• We are currently working on publishing material data soon for:

• Ti-6AI-4V

• Inconel 718

• AlSi10Mg

• Maraging steel

Data used for Damage tolerance design

What is the Future of AM? Larger powder beds

Aerosud Aeroswift - Build plate 2000x600x600 (mm)

Reduced costs

Xact Metal XM200C L-PBF machine – Build plate 127x127x127 (mm)

Reducing labour & improve process quality

Additive Industries – Ranging from 3 to 11 modules)

Hybrid machining

Matsuura - Matsuura LUMEX Avance-25

Hybrid milled internal features

As-built outer walls

? Price ~120k euro

What is the Future of AM? Improved capability

3D Microprint – Layer thickness 1-5 μm

Laser wavelength

Trumpf – L-BPF print copper parts

Higher production rate

Evobeam SLaVAM

• Larger machines

• Multiple laser machines

• Robotic post processing

High temperature L-PBF

AM fuel nozzle Source: www.ge.com

Build chamber reaches up

to 1000 degrees Celsius!

Better performanceHow can this be related to mold tooling?

Bigger powder beds• Consolidate parts• Make more parts

Reducing labour & improve process quality• Less overheads • Cheaper to make• Improved part quality

Affordable Metal printers• good for rapid prototyping and testing • easier to ask your boss to buy one

Explore new materials• Copper is very conductive!

High temperature L-PBF• Less distortion

Hybrid manufacturing • Reduced lead time and costs

• Production – the existing tool can be modified • Maintenance – able to repair damaged tool

• Surface finish • Smooth cooling channels• Minimise surface defects • Increase tool life

Table referenced from International Journal of Fatigue - Fatigue characteristics of steels manufactured by selective laser melting

MORE. BETTER. LESS.

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