2012 06-21-inauguration-labo-additive-manufacturing Sirris - Umberto Baraldi

The collective centre of the Belgian technology industry

Driving industry by technology

• Mission?
To help companies implement technological
innovations

• Why?
Strengthen the competitive position over the long-term

• For whom?
The Belgian technology industry

© sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 2

The collective centre

Federation Collective centre
for the technology industry of the technology industry
• Nonprofit organisation
• Industry owned

MISSION
“Increase the competitiveness of
companies of the Agoria sectors
through technological innovations”


of the technology industry

Aerospace Automotive Construction products
Contracting & Maintenance Electrical engineering
Industrial automation Mechatronical engineering

Information and communication technologies (ICT)
Metals & materials Metal processing Mounting & cranes
Plastics & composites Security & defence


Sirris members

2450 companies

125 large companies (>250 employees) 2325 SME’s (<250 employees)


Mission statement in practice

Making the right technological choices
for sustainable economical growth

Translating new technologies in
tangible products for a company

value innovation
Taking into account the business through
& technology strategy of the company technology


What does Sirris mean to you?

From individual services
to common research programs

Large partnernetwerk – Optimized projectfinancing (public&private)
Intellectual property stays in company | info@sirris.be | 22/06/2012
© sirris 2011 | www.sirris.be 7

Domains of competence

•Materials Engineering •Additive Manufacturing
•Production Technology •Software Engineering & ICT
•Mechatronics •Technology Coaching


Local presence,
near the companies
Ghent Leuven
Materials Engineering Mechatronics
Technology Coaching
Sirris Leuven Composites Application Lab

Brussels Hasselt
Software Engineering & ICT Materials Engineering
Technology Coaching Production Technology
Smart Coating Application Lab

Liège
Charleroi Additive Manufacturing
Additive Manufacturing Materials Engineering
Biomedical applications Nanomaterials and plasma
Sirris Microfabrication Application Lab

> 120 technology experts distributedsirris 2011 |6 sites |in the 3 |Regions
©
over www.sirris.be info@sirris.be 22/06/2012 9

Partners network

Academics Authorities

Industrials


Facts & figures in 2011

5000 interventions per year (advice, projects, services)

whose 75% for SME’s

within 1840 different companies

2000 payed projects and services for 5.4 mio EUR

2900 free advices subsidized

23M turnover


Sirris In Wallonia :
3 competence groups

• Polymers
Group Materials Engineering • Composites /
Nanocomposites
• Thixo/MIM/PIM
• Light metals
Rational integration • Microtechnology
of advanced materials § Product concept and development
Group in Products and § Thermal Management
Nanopowders & Plasma processes § Multifunctional products
§ Traceability
§ Smart products
Additive
Nanopowders for processes &
demanding specific Group Additive
applications materials
for tool-less
Technologies
§ Nanopowders production by manufacturing
synthesis in a plasma torch • Rapid prototyping
§ Nanopowders characterisation • Rapid tooling
• Rapid manufacturing
§ Nanopowders production units developments § Additive process & post process development
§ Ceramic and metallic nanopowders § Porous and functionally graded materials
§ Handling/safety solutions for nanometric materials § Fast « Time to Market »by direct manufacturing
§nanocomposites § Medical applications


SIRRIS – ADD department
Additive Manufacturing – Layer Manufacturing:
à Rapid Prototyping – Rapid Tooling – Rapid Manufacturing

the collective centre of the Belgian technological industry

1980-1990
Incubation times

Focus : Actions :
Main focus on supporting - Reducing mould costs by beter concept –
Demonstration of CAD (2D/3D) Capabilities
plastic material processor -
- First applications and demonstration of
and plastic material users mould filling simulation( moldflow /
inssight)
- Closed loop control of mould filling
Specific issues : - Reduction of mould costs by new
Injection moulds cost fabrication technology
reduction - Polymer casting, low melting point alloy
projection, …
New polymers in products -
Recycling Recurrent requirement:
- Validation of plastic parts before injection
mould ready
- Availability of model as soon as possible

1990
Starting the activity

Inputs : Actions :
- Technology watch has put
into light new technology - Setting up of consortium with industrial
partners
for direct part fabrication
- FN Browning – Mecasoft – Aspel
from CAD files
Stereolithography - Purchase of SLA machine
- Increasing performances of - 50% cost supported by Sirris
3D CAD software and (Crif/Wtcm)
related interest in industry - 50% cost prepaid services to the
industrial partners

- Machine installed and running in
Septembre 1990

1990-1996
Rapid prototyping years

Activity : Conclusions :
- For industrial partners and for
sectors, realisation of - Because of requirements concerning better
demonstration parts part properties, purchase on own cost of
an FDM machine
- Stereolithography models are key
communication tools for the - Low cost mould production techniques
development of plastic parts. It is based on SLA models not viable. If the
an unambiguous interface future of Rapid prototyping is Rapid
allowing designers, tool makers, Tooling then other techniques are
molders, users to interact quickly required.
and efficiently.
Recurrent requirements:
-Better part properties to provide quick
- In RD projects (local and EC functional validation
funded), valorisation of quick -More precise processes
model making technology to
produce cast or sprayed injection
cavities

1996-2002
Rapid tooling years

- In 1996 purchase of
- - an DMLS machine to produce - Fairly big success of SLS for the production
metal inserts for injection moulds of parts applied in practice (even small
- - an SLS machine to produce series productions !)
functional plastic parts in
polyamide - Tooling applications are quite a challenge
and widespread applications of additive
- RD projects (local and EC funded), technologies for this applications is not
in order to improve the possible on the short term.
applicatbility of additive - Nonetheless important potential for
technologies in the tooling sector solution of critical cooling problems.
(rapid tooling) (with Materilise)
Recurrent requirements:
-Better part properties, faster production
- Demonstration activity to process
sensibilise industrial sectors on -Functional metal and ceramic parts
the potential of theses
technologies (Dito Materialise)

2002-2008
The transition years

- In 2001 purchase of a
revolutionnary machine allowing - Lots of problems with the equipments !
production of metal and ceramic - Beta machines required very important
« green » parts : Optoform efforts to get running satisfactorily.
- In 2004 purchase of a 3D printing - Optpoform out of the market.
machine providing multiple fold
productivity increase for small and
large metal parts : ProMetal - Important interest in the medical and
aerospace sectors (customised
biocompatible applications of short series
- RD projects (local and EC funded), complex parts)
in order to develop specific
materials for aerospace and
medical sectors Recurrent requirements:
-Still better part properties, faster
- Demonstration activity to production process
sensibilise industrial sectors -Functional metal and ceramic parts still not
fully adressed

2009-…
The Rapid Manufacturing years

- In 2009 purchase of an improved
SLS machine (own costs) - In 21 years, the additive manufacturing
- In 2009 purchase of an EBM technology qualified from an anecdotic one
machine (medical applications) shot process to an accepted production
- In 2010 purchase of an SLM technique of hig-value technical parts.
machine for hi tech metal parts - Sirris, always in relation to industrial
- In 2010 purchase of a 5 axis laser interests and inputs, invested a lot to set
cladding unit (graded materials up a unique competence and capabilities
and aerospace applications) team in this area.
- In 2009 purchase of a
multimaterial 3D printer for This technology field is moving forward at a
multimaterial functional parts and constant pace, promising interesting
medical applications capabilities in micro-manufacturing and
- Start of dedicated ceramic spinal mass customisation. These issues interest
implants for « real life » use with our sectors, and we will keep up to date.
the optoform technology

ADD capacities & competencies

SIRRIS – ADD (1990 – 2012)
• 15 engineers and technicians
• Two locations: Liège (10 p.) and Gosselies (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)

• Vacuum Casting of alu, bronze, zamak
• 3D scanning & metrology (GOM, Metris, Wenzel)

20

ADD application areas
Military Architectural Other:
Academic 1% 3% 2%
institutions
14% Motor vehicles
11% Aerospace
22%

Medical/dental
29%

Industrial/business
machines
Consumer 3%
products/electronic
s
15% 21

Laser Sintering of polymer powder


3D Printing Prometal

Post-milling

23

Laser Sintering of metal powder

• Direct Metal Laser Sintering

• Mould inserts in Bronze/Nickel alloy and steel
• Direct Parts
• Layers 20 µm. Accuracy 50 µm.

• EOSINT M250 Xtended


Material properties: 15 years evolution

Electron Beam Melting - Arcam
Applications ─ Aerospace: Functional Parts

Material: Ti6Al4V ELI
Size: Ø 140 x 80 mm
Weight: 2,5 kg
Build time: 16 hours
Pressure Vessel

Heat Reflector
With Cooling Channels

Rocket Engine Impeller

Material: Ti6Al4V
Weight: 4,5 kg
Landing Gear Component


Applications
Functionally Graded Materials (FGM)

Abrupt transition between Ti
6-4 and Ti 48Al-2Cr-2Nb
Ti 48Al-2Cr-2Nb Clean, well bonded fully
dense microstructure.

Interface
Ti 6-4

Functional surface: A-Impact: Conventional Ti alloy
tool steel (Ti 6-2-4-2)
1.2344 (finished)
B-LC fatigue: Orthorhomic Ti alloy
(Ti 22-23)
Basic material:
copper alloy
C-Creep: Gamma Ti-Aluminide
(Ampco 940)
(Ti 48-2-2)

Denis Gravet 15-03-2009

Topology optimization Stress verification

Flying Cam example (Compolight project)
Free space definition

Efforts repartition

Smoothing or redesign
based on the STL geometry
STL file

Weight reduction with the same mechanical result

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

SIRRIS ADD – Actual & Future developments

LightWeight solutions Controlled Porosity Medical
– 3D structures applications

Quality, Functionally Graded
Repeatability, materials and
Standards porosity
Sustainability

Nano particles
incorporation
Composites
SiC+ alu, Connex
digital materials… Titanium, Inconel,
aluminium

30

Sirris Gosselies

the collective centre of the Belgian technological industry

Sirris – Gosselies
Historical recap.

• Since1997 : Close collaboration started with Technofutur in the field of
micro-manufacturing technologies (plastic injection and µSLA), and
composite materials processing.

• Support through Feder and Interreg Funding for development of
Advanced manufacturing technologies (PIM, Rapid manufacturing)
competences and transfer

• 2008 : Strategic focussing of Gosselies dept in the bio-medical field

• BioManufacturing Platform (Feder project support)
Arcam – Titanium & Connex 500 – multimaterial Add process

• Team grows to 5 FTE © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 32

Sirris – Gosselies

• Projet Campus Technologique :
• Closer cooperation with Agoria (offices in “Maison de
l’Industrie”)
• Sirris Lab in the “ Village Plasturgie & Composite”
• Shared workplaces with Technofutur Industrie
(plasturgie) and Cenaero (projet Cilab)

© Sirris | www.sirris.be | info@sirris.be | 22/06/2012 33

Sirris – Gosselies - Strategic partnerships
Partnership management :

• Continuation and reinforcement of collaboration with Technofutur
(equipement sharing, common projects, training support)

• Renforcing partnership with Agoria (win-win industrial impact)

• Renforcing partnership with local key actors (innovatech, Igretec)

• Continuation of Interreg projects and actions (Pristimat, Ecolaserfact)
interreg FRED)

• Develop collaboration with other CRA (Cenaero, Cetic)


Sirris Gosselies - Value for Industry

Service development : direct industrial support

• More then 150 industrial projects/year most in the province
Hainaut/Namur (65%) (direct service income of +/- 200k€)
• Main industrial sectors Manufacturing, Biomedical and
Aeronautic area

• Majority of activities oriented towards product development
support, rapid manufacturing technology applicability

• Applications in MIM and µmoulding ( symbiosis with ING/
SMALL/technofutur)

. © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 35

Sirris Gosselies - Value for Industry

Service development : direct industrial support

• Increase industrial impact with 2 guidances based in Gosselies

Guidance SimADD : promote beter use of additive technologies
in direct manufacturing of hi-value products by integration of
numerical development chain

Guidance Biomediv : in partnership with Centexbel, support
companies in innovative projects in the « medical devices » area.


Sirris – Gosselies - Expertise development

Service development : Projets de recherche en partenariat avec
l’industrie

• Plateforme de bioManufacturing Biofact W

• Projet Interreg Pristimat (champagne/ardenne – Hainaut Namur)
• Domaine médical
• Domaine Transport
• PIM-MIM

• Prospective projet Hennuyer « ECOPOLE » (mécatronique/nanos/surface)


Electron Beam Melting - Arcam
Applications ─ Medical: Implants – Prosthesis - Instruments

Material: Ti6Al4V

Size: 180 x 130 x 5 mm

Material: CoCr ASTM F75
Build time: 8 knees in 20 hours
Material: Ti6Al4V ELI
Build time: 16 cups in 24 hours

info@sirris.be / #Sirris / Sirris_be

WWW.SIRRIS.BE TECHNILINE.SIRRIS.BE

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2012 06-21-inauguration-labo-additive-manufacturing Sirris - Umberto Baraldi

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