Miguel Godino Martinez, sirris, esitys "3D-tulostuksen mahdollisuudet liiketoiminnassa"-seminaarissa Porissa 4.5.2016.

1. Metal Additive Manufacturing
Manufacturing & case
studies.M.Sc. Miguel Godino Martinez

2. Agenda for today
1.What does Sirris do?
2.Why Metal Additive Manufacturing?
3.Which metal AM technology fits me?
4.Several metal AM case studies for aerospace
5.An innovative case study for the automotive sector
6.More case studies
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3. What does Sirris do?
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4. What does Sirris do?
2485 SME’s (<250 employees)
2500 companies
115 big companies (>250 employees)
> WHAT ?
To help companies implement technological innovations
> WHY ?
To reinforce the long-term competitive position of companies
> TO WHOM ?
Belgian technology industry and at European level
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5. Within four domains of technology
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METALS
COMPOSITES
PLASTICS & HYBRIDS
COATINGS
NANOMATERIALS
ECO-MECHATRONICS
SENSORIZED FUTURE
MODEL BASED DESIGN
FACTORIES OF FUTURE
WORLD CLASS TECHNOLOGIES
ADDITIVE MANUFACTURING
SOFTWARE ENGINEERING
CLOUD COMPUTING
DATA INNOVATION

6. TEAM OF 20 INDEPENDENT EXPERTS, 25+ YEARS OF
EXPERIENCE
METALS, POLYMERS & CERAMICS
MORE THAN 10 Additive Manufacturing
TECHNOLOGIES IN-HOUSE
ADDITIVE MANUFACTURING AT SIRRIS
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7. Why metal additive
manufacturing?
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8. Some things to remember about metal AM…
Redesign, understand possibilities & limitations
of technology
Full chain from design, process/materials
optimization, AM technology & post treatments
Get CAD Design, Press print and done!
You are fully done by buying a metal machine
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

9. Re-design Design, optimize, convert
Technology Selective Laser Melting and
Electron Beam Melting
Orientation Right 3D position for the
right process
Support Heat transfer and structural
support
Manufacture Process parameters,
material optimization
Thermal treatments Residual stresses
Post-finishing Surface finishing
Some things to remember about metal AM…
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Process chain example for additive manufacturing of metals
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

10. Advantages
• ‘Reduced time design-to-manufacturing’
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CAD
• Design your CAD
.STL
conversion
and edit
• .STL is the format used for Additive Manufacturing
• Edit your part, redesign it, place support structures
Slice
your part
• Slicing for a given layer thickness and hatching
Manufacture
• Depending on several factors, a normal built will
take between 6-60h
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

11. Advantages
• Complex geometries possible
– Avoid welding and assembly steps for your part.
– Internal channels.
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‘Almost no geometrical constraints anymore’
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

12. Advantages
• Reduce material
Only melt powder where needed to build the 3d part.
Powder not meltedpowder recupered & reused.
• Produce ‘overnight on Sundays’
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EOS center

13. Which metal additive manufacturing
technology fits me ?
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14. 4 main metal additive manufacturing
technologies in a nutshell
1- Metal Binder Jetting
‘Similar to paper2D printing.
Able to produce big parts very fast by joining metal layers together thanks
to a binder. Gives a green part that needs to be sintered afterwards.’
2- Direct metal deposition/ cladding
`A moving nozzle deposits and melt powder at the same time. Very useful
for difficult welding reparations. Naval industry.`
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ILT, Fraunhoufer M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

15. 3- Selective Laser melting
Powder bed technology that melts
layer by layer using a laser beam.
Highly complex parts with a high
resolution, limited in size
4- Electron Beam Melting
‘ Powder bed technology that melts
layer by layer using an electron beam.
Highly complex metal parts limited in
size, fast.’
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4 main metal additive manufacturing
technologies in a nutshell
Video: Solid Concept
Video: Oak Ridge LabM.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

16. EBM (ARCAM A2 available at Sirris) SLM (SLM 250HL available at Sirris)
1. Re-Design 2. Technology 3.
Reorientation
4. Support
generation
5.
Manufacture
6. Thermal
treatments
7. Post-
finishing
Electron beam source
High preheating Temperature
(~700C)
Need less supports
Less as-built thermal stresses
Difficult for building internal channels
Laser beam source
Low preheating Temperature (<200
C)
More need of supports
Finer resolution
Wider material pallet (Al,Ti,Inox,tool steel…)
16M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
picture: EOS

17. A more detailed comparison: Some numbers
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SLM EBM
Size building
chamber
(mm)
typical 250 x 250 x 350 Ø 210 x 350
up to 500 x 280 x 325 Ø 350 x 380
Layer thickness (µm) 30 to 90 50 to 90
Min wall thickness (mm) 0.2 0.6
Accuracy (mm) +/- 0.1 +/- 0.3
Build rate (cm³/h) 5 - 20 80
Surface roughness (µm) 5 - 15 20 - 30
Type of parts High resolution, difficult
for massive parts
More massive parts, less
detailed.
1. Re-Design 2. Technology 3.
Reorientation
4. Support
generation
5.
Manufacture
6. Thermal
treatments
7. Post-
finishing
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

18. 1. Re-Design
2.
Technolo
gy
3.
Reorienta
tion
4. Support
generation
5. Manufacture
6. Thermal
treatments
7. Post-
finishing
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‘Need of support structures for EBM and SLM technologies’
Support goal Importance
for SLM
Importance
for EBM
Hold part against thermal stresses-
avoid delamination
*** *
Conduct the heat away-thermal
transfer
** **
Physically hold the surfaces >45
over the powder bed
*** *
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

19. © sirris | www.sirris.be | info@sirris.be |
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4/16/2015
1. Re-Design
2.
Technolo
gy
3.
Reorienta
tion
4. Support
generation
5. Manufacture
6. Thermal
treatments
7. Post-
finishing
‘Supports will decrease the quality of the surface’
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

20. >45°
© sirris | www.sirris.be | info@sirris.be |
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1. Re-Design
2.
Technolo
gy
3.
Reorienta
tion
4. Support
generation
5. Manufacture
6. Thermal
treatments
7. Post-
finishing
‘So orient the part in the way that less supports will be
needed’
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

21. ‘Aluminium Alloys compared to casting: Some data’
AlSi10Mg, SIRRIS data
SLM SLM
CAS
T +
AGE
CAS
T +
AGE
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1. Re-Design
2.
Technolog
y
3.
Reorientat
ion
4. Support
generation
5.
Manufacture
6.
Thermal
treatments
7. Post-
finishing
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

22. Lightweight and aerospace
case studies
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23. M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
Case1. Redesign for Additive Manufacturing:
A satellite part
Initial part
Initial Mass ~ 457 g
Targeted reduction by
AM ~ 200 g!
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‘Unlock the potential of Topology Optimization thanks to the
design freedom of Additive Manufacturing’

24. Volume space
Initial part
Non-modifiable
areas
Load cases
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Case1. Redesign for Additive Manufacturing:
A satellite part
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

25. After Topol iteration and FEA analysis
240g< 457g x2 weight saving !
Size and massivity Suitable to be produced by Additive Manufacturing
Final part
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Case1. Redesign for Additive Manufacturing:
A satellite part
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

26. An innovative case study for
the automotive industry
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27. A cylinder head. An innovative solution for the
automotive industry
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‘Lighter, complex and faster from design to
manufacturing than conventional production’
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

28. Everything start with the redesign to get the
most of the technology
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

29. Correct orientation, correct support structures
• Powder is less conductive than molten metal.
• So supports are built below massive zones to dissipate
the heat and avoid over-melting.
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

30. Part after removing supports
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

31. 3D Scan comparison
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

32. More applications
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33. Drillers AET-BMT
‘Smart drilling machines made of Titanium using EBM’
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Why metal additive
manufacturing?
Production cycle reduced up to 70%
Maintenance cost reduced 80%
Save of weight: high strenght vs weight
ratio.
Integration of functions
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

34. Laser collimator: simplifying the assembly
and adding performance
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M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference

35. Orthopedics, customized implants by Metal additive
manufacturing
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‘Production of complex patient specific implants’
Play on porosity, roughness and randomness lattices to replicate bone
conditions and promote cell growth
M.Sc. Miguel Godino @ Pori 3D-tulostaminen Conference
picture: ARCAM

36. Miguel Godino
Process Engineer in Additive Manufacturing of Metals
miguel.godino@sirris.be
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