This document summarizes a presentation about additive manufacturing of metals. It discusses LayerWise's metal additive manufacturing technology, including the ability to produce complex parts with conformal cooling channels. Applications highlighted include supersonic turbine blades for engines, an extruder part for food processing, and conformal cooling inserts for injection molds. Medical applications of additive manufacturing for dental parts are also mentioned. The presentation concludes that additive manufacturing is well-suited for applications requiring increased performance, integrated functions, customization, complexity, flexibility and short time-to-market.

1. 
Additief fabriceren in metaal:
industriële en medische getuigenissen
Jonas Van Vaerenbergh
Themadag Sirris
15 november 2011 Your PARTNER in Additive Manufacturing

2. Agenda
2
 Metal Additive Manufacturing
 About LayerWise
 Supersonic turbine blades
 Food processing extruder
 Injection molding
 Medical applications
 Conclusion
© LayerWise NV, all rights reserved

3. Technology

4. Metal Additive Manufacturing
4
Principle
Powder Feed
System
 Directly from 3D CAD
 Layer-wise production
Laser beam
 3D components by
successive connection
of thin 2D layers
Powder
Feed
Build
Platform
Overflow
© LayerWise NV, all rights reserved

5. Metal Additive Manufacturing
7
 Materials:
LayerWise  Stainless steels (316L, …)  Hastelloy
 Hardenable steel  Co-Cr
 Titanium alloys (Ti6Al4V,…)  Inconel
 Aluminium  …..
 Specifications
Maximum build volume 250x250x420 mm
Density  100 %
Typical part accuracy* ± 50 µm
Typical surface roughness* # 5 µm Ra – 40 µm Rz
Minimal wall thickness 0.200 mm
Resolution 0.005 mm
* dependent on part geometry # can be improved by LayerWise SILC treatment
© LayerWise NV, all rights reserved

6. Who we are

7. About LayerWise
9
Who We Are  LayerWise was incorporated in 2008 as a spin-off from
K.U.Leuven-PMA
 Unique technological expertise in Metal Additive
Manufacturing since 2001
 Developing new AM applications together with clients
© LayerWise NV, all rights reserved

8. LayerWise Mission
10
Who We Are
Increase your added value
through advantages of
Metal Additive Manufacturing
Therefore LayerWise offers its technological expertise realized by
being technology developer as well as technology user
© LayerWise NV, all rights reserved

9. Industrial applications

10. Production parts
13
 Additive manufacturing
 Same material
 Same characteristics
What is the added value?
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11. Innovate!
14
cooling &
heating
enhance flow
isolation
weight reduction
function
integration
save time
save cost
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12. Case: Supersonic turbine blades
Partner: Von Karman Institute, Belgium

13. Supersonic turbine blades
16
Project goal  Scaled turbine vane model
 Improve efficiency:
 achieve higher turbine expansions
 reduction of shock waves at vane edge
 more compact engines
 By pulsated blade cooling instead of
continuous cooling
 Simulations vs. wind tunnel testing
© LayerWise NV, all rights reserved

14. Supersonic turbine blades
17
Functionalities  Complex 3D
 Cooling cavity
 Fine instrumentation
channels
 Thin walls
 No leakage
 Weight saving
 Cost saving
© LayerWise NV, all rights reserved

15. AM manufactured blade
18

200 mm
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16. Case: Food Processing Extruder
Partner: CP Extrusion

17. Case extruder
22
The AM Solution
Stainless Steel 316L material
Ovalized channels with smooth transitions
Single piece construction
Small series production
Cost reduction
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18. Tooling applications

19. Conformal cooling
24
Benefits  Conformal cooling channels
 Cycle time reduction (20 …. 50%)
 Improved quality of molded part
 no hot spots
 eliminate warpage
 eliminate internal stress
 Improved durability of mould
 Cost reduction
© LayerWise NV, all rights reserved

20. Conformal cooling
25
1.2709
50-54 HRC
Complete surface cooling
courtesy De Nayer hogeschool
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21. Medical applications

22. Dental applications

23. Conclusions

24. Metal Additive Manufacturing
31
When applying  Increased product performance
metal AM?
 Function integration
 Customized manufacturing
Courtesy of Diametal
 Complexity
 Flexibility
 Short time-to-market
© LayerWise NV, all rights reserved

25. Contact details
32

LayerWise N.V.
Kapeldreef 60
3001 Leuven
Belgium
tel: +32 16 29 84 20
fax: +32 16 29 83 19
www.layerwise.com
info@layerwise.com
© LayerWise NV, all rights reserved