1. 
Let Additive Manufacturing Inspire You
Themadag Additive Manufacturing
Mikrocentrum TNO
LayerWise 2012
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6/4/2012
Who we are
“What is the manufacturing potential of
Selective Laser Melting”
Experiences at LayerWise NV
2012
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2. Content
 About LayerWise
 Technology
 Drivers for SLM manufacturing
 Future outlook
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About LayerWise
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
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3. About LayerWise
1989 1991 2001 2007 2008 2009 2010 2011 2012
Phd P. Full Thin Wall
Start of Start of Thin Wall Thin Wall Thin Wall Thin Wall
Mercelis Dense 0.19MM
AM METAL 0.5MM 0.3MM 0.225MM 0.18MM
Metal
Research Research Phd J. Van Samples
Vaerenbergh
RP SLM 0% 10% 50% 70% 90%
SLS Manufac Manufac Manufac Manufac Manufac
Sintering turing turing turing turing turing
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About LayerWise
ISO 9001 & 13485 certified
chemical mechatronics
standard implants
dental prostheses pharma mechanization
customized implants
crowns and copings food solar-lighting
medical tools
pressure & gas electronics
medical modeling
automotive aerospace
consumer tooling
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4. Technology
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Technology
 Directly from 3D CAD
 Layer-wise production
 3D components by successive
connection of thin 2D layers
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5. Technology
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Metal Additive
Manufacturing
Principle
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6. Technology
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Technology
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7. Technology
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Technology
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8. Drivers for SLM manufacturing
Additive manufacturing
Same material
Same characteristics
What is the added value?
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9. Drivers for SLM manufacturing
Manufacturing Cost Total cost of ownership - performance
Type of Driver Mostly small parts Small, medium and large parts
part
SLM feature Tool-less • Monolythic construction
manufacturing • Flow-optimized
• Miniaturisation
• Customisation
• Mass reduction
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Drivers for SLM manufacturing
CFD analysis SLM Manufacturing
Flow type Channel shape Pressure drop Heatex
Laminar Cross section Variable sections Conformal
Turbulent 3D traject restriction Balanced
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10. Drivers for SLM manufacturing
10 mm
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Drivers for SLM manufacturing
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11. Drivers for SLM manufacturing
200 mm
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Drivers for SLM manufacturing
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12. Drivers for SLM manufacturing
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Drivers for SLM manufacturing
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13. Drivers for SLM manufacturing
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Drivers for SLM manufacturing
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14. Drivers for SLM manufacturing
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Drivers for SLM manufacturing
Custom made hip implants with porous structure rigidly connected to the
implant for a severe pelvic discontinuity (left) and separate parts in a multi
component revision (right). Courtesy: Mobelife NV, Leuven, Belgium
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15. Future outlook
“What is the manufacturing potential of
Selective Laser Melting”
Experiences at LayerWise NV
2012
29 www.layerwise.com
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Future outlook
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16. Future outlook
 SLM is here to stay  Technology will shift
– Technology development  Purpose-built AM lines
– Awareness SLM specific  Automation - process control
design
 Cost will decrease
 Standardization is needed  Build rate
– Material  material
– Validation
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Future outlook
Materials : Stainless, super alloys, heavy metals (18+ materials)
Cost : 2008 -> 2012 - buildrate x 4
Upscaling : max dimenions x 5 to circa 500 mm
Surface control : Ra 5 -> Ra 0.9 & Ra 0.1
Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)
Pardigm shift: DfM-> design for function
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17. Future outlook
Sustainable PRODUCTION Sustainable PRODUCTS Sustainable ECONOMICS
Material Weight Sustainability is not
(ex 1/20 BtoF) (ex 30% payl.) the incentive...
Ancilliary consumables Plant footprint
(ex tooling) (ex inj. molding)
but value creation
Re-localized production Process intensification
(ex LayerWise (ex flow reactor)
comes from
sustainable design
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Contact details
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
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