Additive Manufacturing: New Opportunities for Prototyping

Mohsen Mohammadi, PhD, PEngAssociate Professor and Director

Marine Additive Manufacturing Centre of Excellence

University of New Brunswick

Fredericton, NBApril 28, 2021

The Evolution of Manufacturing

Next Manufacturing Revolution: Industrie 4.0

What is Metal Additive Manufacturing?

Additive Manufacturing Manufacturing Manufacturing AdditiveHere And there

Additive Manufacturing (AM): A process of joining metals to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies (ASTM F2792 − 12a).

Additive vs Subtractive Manufacturing

The fabrication fabrication fabrication fabrication fabrication fabrication fabrication

Additive Manufacturing (AM): A process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies (ASTM F2792 − 12a).

Subtractive Manufacturing

Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping

• Direct Metal Laser Sintering• Selective Laser Melting• Electron Beam Machining

Hybrid Manufacturing

• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering

Additive Manufacturing: SchematicMore complex shapes with less used materials, which is the case for marine components can be produced using AM

Additive Manufacturing ProcessMore complex shapes with less used materials, which is the case for marine aerospace components can be produced using AM

Metal Additive Manufacturing (AM)More complex shapes with less used materials, which is the case for marine components can be produced using AM

Metal Additive Manufacturing (AM)

Wire Arc Additive Manufacturing (WAAM)

CAD to Part in 3D Printing

AM: Capabilities and Opportunities

• Rapid Manufacturing • Design Freedom • Mass Customization • Added Functionality • Less Tooling• Process Improvements• Environmental Drivers

AM: Complexity is FreeMore complex shapes with less used materials, which is the case for aerospace components can be produced using AM

AM: Single Step Manufacturing

AM: Optimizing Design Structure

Some Facts about Metal AMBy 2020, GE Aviation will be manufacturing well in excess of 100,000 partsvia additive manufacturing for the Leap and other jet engines.

85,000 fuel nozzles from GE for the Leap Engine

http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html

Some Facts about Metal AMAirbus had 1,000 parts 3D printed to meet deadline

3D printed brackets designed by Airbus to save weight

Some Facts about Metal AM

Boeing have had 20,000 3D printed parts for 10 different military andcommercial airplanes (30 parts for 787 Dreamliner).

World’s lightest material from Boeing

Some Facts about Metal AMAuto Industry will be the biggest industrial sector adopting AM for R&D till 2020

Metal AM in Marine ApplicationsTruMarine used additive manufacturing to repair boat engine turbochargers

Metal 3D printed boat propeller

Engine TurbochargerAM can offer corrosion resistant parts suitable for marine applications

AM: Revolution for Spare Parts in Marine

What is going on with Metal AM in these days?

What is going on with Metal AM now?

NORSK Titanium (Norway), Boeing 7XX landing Gear

Siemens (2017)

Commercialization Success StoriesDamaged beveling wheel from a legacy machine in the shipbuilding sector

Commercialization Success StoriesDamaged beveling wheel froma legacy machine in the shipbuilding sector

Material Characterization: • Hardness test• Chemical composition3D Scanning:• Reverse engineering• CAD File• STL File• 3D Printing Process

Commercialization Success Stories

Commercialization ActivitiesClosed face Impeller for military grade pump (Canadian Navy)

Future Projects:OUTLOOK

Commercialization Activities

https://www.businesseventscanada.ca/economic-sectors/advanced-manufacturing

Advanced Manufacturing in Canada

https://www.businesseventscanada.ca/economic-sectors/advanced-manufacturing

Advanced Manufacturing in Canada

Canada’s (CSC), along with the UK and Australia, will share the same combat vessel platform. MAMCE has already established partnerships with research centres aligned with these programs, such as AMRC and the University of Manchester in the UK.

National Shipbuilding Strategy

[Ref. https://lop.parl.ca/content/lop/ResearchPublications/2015-35-e.pdf]

The Centre is an excellent investment for suppliers looking to offset Canada’s Industrial and Technological Benefits (ITB) requirements.

This program is run by the University of New Brunswick (UNB) and will be eligible for the IRB/ IT multiplier. Partnership in the Centre will also give access to cutting edge research on metals important to marine applications. Supporting the Centre will ensure that the workforce is in place for the future of marine manufacturing in Canada

Industrial and Technological Benefits

9:1Potential Offset Benefit

Future Fighter Jet Program

Nuclear Additive Manufacturing• 4th Generation Nuclear Reactors

• Supercritical-Water-Cooled Reactor

• Repair and MaintenanceSteel

Stainless Steel Corrax®Stainless Steel 316 L

NickelNickel Super Alloys, IN625

Zirconium

AM in Isolated Locations

Acknowledgements

Thank You!

Additive Manufacturing: New Opportunities for Prototyping

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