2. Agenda ESMA - November 8
Design for additive manufacturing – 25 min – Thierry Dormal
AM Technologies for polymer parts – 25 min – Laurent Voets
AM technologies for metal parts – 30 min – Julien Magnien
AM technologies for ceramic parts – 20 min – Tommaso Sforza
Biomedical applications – 20 min – Carsten Engel
Lunch: 13h – 13h30
Lab tour : 45 min – 3 groups (+/- 12 persons)
15 minutes for each lab:
AM metal
AM polymer & ceramic
AJP
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3. Sirris ADD capacities & competencies
ADD (1990 – 2012)
• 15 engineers and technicians
• Two locations: Liège (10 p.) and Charleroi (5 p.)
In-house additive technologies
• Stereolithography (normal & hi-res)
• Paste polymerisation for ceramics and metals (2 Optoform)
• 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal)
• Laser sintering of polymeric powder (PA,…): P360 – P390
• Objet Connex 500: bi-material
• Laser Melting (MTT) SLM 250 HL for metal parts and inserts
• EBM Arcam A2 (Titanium & CoCr)
• Laser Cladding (Irepa Laser EasyCLAD)
• 3D Printing of wax (Thermojet)
• Makerbot Replicator & Fab@home
• 3D scanning & metrology (GOM, Metris, Wenzel)
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4. Raw materials for AM
Liquid Powder Plate or sheet Paste
Stereolithography Laser Sintering (LS) Stratoconception® Optoform
Envisiontec Laser Melting (SLM) LOM, MCor
3D Printing …
…
+ others : spool, cartridges
Objet
FDM, Makerbot, …
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5. Rapid Prototyping Additive manufacturing
• Cost reduction and short leadtime
• High geometrical complexity and freeform design
• Extended customization
• Short series production without any tool
• Compliance with sustainable economical growth
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6. Additive Manufacturing
• Three different ways of using AM technologies
• Prototyping for visual models or functional parts
• Direct production of parts (light redesign, only validation)
• Direct production of parts redesigned for AM
(no way back to conventional production)
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7. Additive Manufacturing % conventional techniques
• With the conventional technologies (milling,
moulding), the design of a new part is
usually limited by the production process
• Technical and economical constraints
• Limitations in the freedom of creation
• With AM:
• Almost no geometrical limitations
• Optimization and customization
• Geometrical complexity is not more
expensive than a simple part
Continuum Fashion : shoes, clothes,… 7
8. Additive Manufacturing Limitations
• Geometrical limitations:
• Wall thickness: 0.3 mm – 1.5 mm
• Length of internal channels (powder removal)
• Max. size: 100 mm 2000 mm.
• Anisotropy (axe Z) for the mechanical properties
• Surface quality (layer thickness, orientation)
• Support structures for 3D building with some AM techniques.
(generation, building, removal)
• Some understanding of the AM processes are required for
• The designer (dimensioning)
• The manufacturer (part orientation, support generation,
shrinkage factor, warping)
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9. Geometrical Complexity (Polymers)
• No tool required for series production:
• No draft angle required for demouldability
• No mould filling problems
Hettich: Rotolavit Blood centrifuge (< 1.000 units / year)
Freedom of Creation 30 % less expensive than with injection moulding
32 components 3 components (2 with LS, 1 with IM)
Manufacturing on demand (customization)
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10. Geometrical Complexity (metal)
• No tool required for series production:
• No draft angle required for demouldability
• Internal walls and details
Steel part (Concept Laser) Wim Delvoye / 3DP metal SIRRIS
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11. Less components - Assembly reduction
• Redesign of a laser collimator for space app.:
• 13 components 2 components
• Cooling system and geometry optimization
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12. Integration of functions
• Integration of snap fits, hinges,...
EOS
EBM - Oak Ridge National Lab Materialise MGX
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13. Integration of functions
• The design of a complex part with
several local functions (spring effect,
damping effect) usually requires the
assembly of components in different
materials.
• With AM, this is possible in one step
with bi-material process like the
Connex machine (Objet)
Zcorp Color Connex (Objet)
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14. Lightweight parts – Lattices structures
• Weight reduction using lattices structures
with minimal strength reduction
• Local variation of lattice types
graded porosity
• Shock damping, vibration reduction
• Biomedical implants: bone regeneration
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[Sirris ADD]
15. Lightweight parts - Topology optimization
• Automated design based on the applied constraints (Topol)
• Same mechanical properties
SIRRIS redesign (Compolight)
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16. Stress verification
Lightweight parts - Topology optimization
Free space definition
Flying Cam example
(Compolight project)
Efforts repartition
Smoothing or redesign
based on the STL geometry
STL file
17. Customization – unique parts & short series
• Unique parts for art, aerospace,
biomedical (hearing aids)
• Mass customization: variants for
each country
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18. Customization – unique parts & short series
• Olaf Diegel
(Massey University)
Design: presets or user defined
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19. Customization – unique parts & short series
Aline Salmon Sac féminin haut de gamme
3DP métal (Sirris) YAMM (200 pièces) 15 avril
Anne Valérie Bribosia
3DP métal (Sirris)
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20. 3D surface texturing
• Library of texturing types available for the designer
• Stone, wood, marble, leather, …
• Visual effect as well as adherence & special grip
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22. Conformal cooling channels - Hipermoulding project
4 injection moulds produced with & without conformal cooling channels
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mm
Drastic reduction of the cycle time (up to 35%)
Enhancement of part quality
Enhancement of tool lifetime
Profitability up to 200.000 euros/year (prod. 6 Mparts)
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23. Catamaran (Hydrauvision) – Compolight project
Hydraulic units with complex internal channels
Reduction of the weight and size of the original part
3DP Prometal (Sirris)
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24. Functionaly Graded Materials
Example with Ti alloys (source OPTOMEC):
3 different Ti alloys with 3
specific functions: impact
resistance, fatigue and creep
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25. Porosity control (3DP Prometal ex-One)
• The porosity is
Investigation ways to manage the porosity:
(not a macro porosity with lattice structures)
• Sintering parameters
• Composition of the powder mixture
• Addition of organic particules
Applications: fluid control, filtering, …
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26. Drilling machine for aerospace
•Technical reasons
Mechanical characteristics of Titanium
Designed for weight optimization
Integration of functions
Vibration reduction
• Marketing reasons
High technology product
Specific design for customers
• Economical reasons
Cheaper solution than conventional
machining or casting.
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27. FLYING-CAM
UNMANNED AERIAL SYSTEMS
Most of the components produced by AM
44 parts in PA + C
31 parts in PA (white, black, painted or not,…)
1 part in Connex500
28. Summary
• AM : huge design freedom
• Some limitations / guidelines need to be known
• AM should be considered from the product conception phase
29. Additive Manufacturing – E-learning & Handbook
• KTRM Leonardo project
• Partners: ASCAMM, SIRRIS, ASERM, iSmithers, Materialise, ULPGC,
ITIA
• Handbook (220 pages) and e-learning courses (17 modules)
• Introduction
• 13 AM Technologies
• Design and Analysis
• AM Materials
• Business models for AM
• Conclusions
Contact: Thierry Dormal thierry.dormal@sirris.be
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