Flexible and efficient production with Additive Manufacturing - Additive manufacturing portfolio @ Sirris (Thierry Dormal, Sirris)

1.  Planning of the event
 15h – 16h30
 SIRRIS Introduction Thierry Dormal
 Jtekt Jean-Louis Dam
 Safran Aero Boosters Olivier Devriendt
 Höganas Olof Andersson
 SIRRIS AM trends Benjamin Denayer
 16h30 – 18h00
 Tour and discussion with experts (10 tables)
 17h30
 Drink
Soon…  email with the link to upload the PDF files
1

2. T-ADD service portfolio
7/06/2016
Thierry Dormal
Program Manager T-ADD
SIRRIS

3. 3
1990 – 2015
Rapid Prototyping
Rapid Tooling
Additive Manufacturing
3D Printing
Direct Manufacturing

4. 4
Prototypes  Direct Part Production
0
1000
2000
3000
4000
5000
6000
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Product and services revenues from AM
Direct part production
Direct Part Production
2010: 20 %
2015: 51 %
Compiled from Wohlers Associates data
M$

5. Evolution of AM
• From prototype to real part production
• From time reduction to higher product performance
• From plastic to high performance alloys
• From shapes to consistent qualified parts
• From 3D Printing to an integrated production process

6. 6
1990
• One of the first stereolithography machine in EU (3DSystems)
1994
• One of the first FDM machine in EU (Stratasys)
• EU projects based on Rapid Tooling & SLA moulds
1996
• SLS : PA Sintering (EOS)
• DMLS: the first direct metal solution (with metal binder)
2000
• Technological breakthrough: Optoform and Prometal
2008
• LBM EBM and Laser cladding – Ti Alu Steel Inconel
• Bi-materials and composite technology (Connex 500)
• Bio-ceramic applications
2015 - 2020
• New strategy towards AM transfer & AM integration
SIRRIS T-ADD - A bit of history
Rapid Prototyping
Rapid Tooling
Rapid Manufacturing
Additive Manufacturing

7. Sirris | 25 years of Additive Manufacturing
Most complete
installed base in
EU
Metals
Polymers
Ceramics
More than 10
additive
technologies in
house
Team of 20
independent
experts
© sirris | www.sirris.be | info@sirris.be | 7

8. 9.06.16© sirris | www.sirris.be | info@sirris.be | 8
1. Material extrusion: the material is selectively dispensed through a nozzle or orifice.
2. Material jetting: droplets of build material are selectively deposited.
3. Binder jetting: a liquid bonding agent is selectively deposited to join powder materials.
4. Sheet lamination: sheets of material are bonded to form an object.
5. Vat photopolymerization: a liquid photopolymer in a vat is selectively cured by light-
activated polymerization.
6. Powder bed fusion: thermal energy selectively fuses regions of a powder bed.
7. Directed energy deposition: focused thermal energy is used to fuse materials by melting
as the material is being deposited
4 selected processes in the ASTM/ISO list

9. ICT&
Design
tools
Process
Leading-edge
Applications
/ Components
Materials Post-
Process
© sirris | www.sirris.be | info@sirris.be | 9
Sirris T-ADD projects
Process
Leading-edge
Applications
/ Components
Materials Post-
Process
Certification
Validation
Company
stimulation

10. VIS – Design for AM
FEDER – Iawatha Riatas
ICT&
Design
tools
Process
Leading-edge
Applications
/ Components
ESA - AM Nano satellites
ESA - AGHP
ESA - Siam
Materials Post-
Process
Any-Shape 4.0
© sirris | www.sirris.be | info@sirris.be | 10
Sirris T-ADD projects
Process
Leading-edge
Applications
/ Components
Materials Post-
Process
FEDER – TipTopLam
FEDER – Iawatha
Exiatas
ESA Scamp
Cornet TCAM
Skywin Aero+
Skywin FASAMA
Skywin 3SA
Skywin INHex
Skywin FasOPT
Skywin AMassy
GreenoMat - Recylclad
Marshall ThermAM
EraNet - Ceracell
RW Collective - QUALAM
First - OSAM
InterReg PolyValves
CORNET Opp3D
Biowin Bioptos
Certification
Validation
Company
stimulation
GT AVATAR
Vanguard
InterReg NWE VITAMIN Cwality EasyAM (GeonX)
Antenne Norme
Prénormatif POWDERAM

11. 11
T-ADD 2015 - industrial activity
- 500 industrial projects
- 150 companies
- > 25 new companies / year discovering AM
- Growing demand in
- Performance (materials & processes)
- AM Design of new products or services based on AM
- Technology transfer for specific technology and materials
- Qualification (technology, materials & products)
- Post-processing (surface quality, accuracy,…)
- AM integration (internal needs or service providers)

12. AM transfer
• Scan opportunities
• Cases 1on1
• Educate
• Qualification
AM integration
• Chain automation
• Chain
demonstration
• Chain integration
Efforts
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2015 2016 2017 2018 2019 2020
AM Integration AM Transfert AM Demo
AM demo
• Sensibilization
• Demonstration
• Benchmarking
TRL 7-9
TRL 6-9
TRL 4-9
Sirris ADD : Effort evolution 2015 - 2020
TRL 4-8Digipreneurship

13. 13
• AM oriented design based on specific AM rules
• Prototypes for development and then real direct AM production
• No way to go back to conventional way of working for series production
• Lattice Structures, topology optimization and components reduction
• After 3 years: 80 % components of the helicopter are produced by AM
Flying Cam

14. 14
Test bench for anti-ice system
• Trials and validation of the anti-ice process in flight condition
• 46 parts & 112 sensors
AM benefits:
• Hollow components with
cables and sensors
• Flexible & functional
• Much faster to build
• No 2D drawings required
Safran Aero Boosters

15. 9.06.16 15© sirris | www.sirris.be | info@sirris.be |
Safran Aero Boosters
Challenge
• Positioning in additive manufacturing
Sirris contribution
• Support for technology selection
• Technology transfer (process, powder handling)
• Understanding of pros & cons of metal AM
• Case studies with real parts
Business impact
• AM Integration in the company with a long term
development plan

16. 16
Smart drilling machine for
aerospace applications
•Technical reasons to use AM
Mechanical properties of Titanium
Designed for weight optimization
Integration of functions
Vibration reduction
• New company (integrated in BMT Aerospace)
created for one single product.
AMT Titastar

17. Intervertebral cages with bioceramic material
17
• Material formulation : HA/TCP (Bone substitute)
• Process development: paste polymerization
• 0.1mm tolerance / Fully controlled porosity
• ISO13485 compliance
• >10.000 parts / year in 2012 2013 2014
• New company created by Kasios in Gilly for production + Cerhum
Intervertebral bone replacement (HA/TCP)
Kasios

18. 18
Date : 14-07-
15
Validation of LBM with Titanium material for space parts
• Feasibility – Aerospace Qualification – Traceability
• Integration in the building process
• Set up of a certification methodology
• Topology Optimization
• 5 axis Post milling on AM parts for surface quality
and high local accuracy 153 x 144 x 50mm
Vol = 56cm³
Propriété
Thalès Alenia Space
Fabrication: Sirris
Propriété
Thalès Alenia Space
Fabrication: Sirris
Thales Alenia Space

19. Sirris 2016 – Service offering
 Explore the potential of AM
- Feasibility study, benchmarking,
- New applications and opportunities, new business models,…
 Design for AM
- Design rules for each AM technology,
- Weight reduction, process simulation,
- Topology optimization, lattice structures, channels,…
 Optimize, implement & transfer AM Technologies for production
- Enhance the use of AM technologies, materials, powder handling, post processing
- Enhance process reliability and repeatability with certification procedures
- AM integration and automation of the full chain
 Reduction of repetitive projects with low added value
>> transfer to Service Providers, creation of new start-up
19

20. 20
Thierry Dormal Program Manager T-ADD
Thank you That’s it for now…
Any questions ?

21.  Planning of the event
 15h – 16h30
 SIRRIS Introduction Thierry Dormal
 Jtekt Jean-Louis Dam Managing Director Jtekt Torsen Europe
 Safran Aero Boosters Olivier Devriendt Projects & Incubation, Dept Innovation
 Höganas Olof Andersson Manager Biz Dev High Alloy powders
 SIRRIS AM trends Benjamin Denayer Senior Biz Developer
 16h30 – 18h00
 Tour and discussion (10 tables)
 17h30
 Drink
21

22. 22

23. 20/12/2007© sirris 2007 | www.sirris.be | info@sirris.be | 23