© Fraunhofer IFAM

International Spring Makers Conference | Wednesday, 6th April 2016 | Congress Center Düsseldorf

Additive Manufacturing – Challenges and Opportunities

Prof. Dr.-Ing. Frank Petzoldt Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM frank.petzoldt@ifam.fraunhofer.de

© Fraunhofer IFAM

Outline

Introduction

Fraunhofer Gesellschaft

Additive Manufacturing market situation

Key factors for a successful Additive Manufacturing Business

material and powders

design

process parameters

productivity

Additive Manufacturing hype curve

Conclusions

© Fraunhofer IFAM

The Fraunhofer-Gesellschaft at a glance

The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit to society.

Nearly 24,000 staff

67 institutes and research units

More than 70% is derived from contracts with industry and from publicly financed research projects.

Almost 30% is contributed by the German federal and Länder Governments.

Fin

an

ce

volu

me

€2.1 billion

2015

Co

ntr

act

Rese

arc

h

€1.8 billion

Major infrastructure capital expenditure and defense research

© Fraunhofer IFAM

Fraunhofer Additive Manufacturing Alliance

The Fraunhofer Additive Manufacturing Alliance encompasses thirteen institutes from all over Germany to form the entire additive manufacturing process chain, comprising the development, application and implementation of additive manufacturing methods and processes.

Engineering Design and development, integration and reduction, simulation

Technologies Printing technology, laser-based processes, process chains and subsequent operations

Materials Metals, ceramic, polymers

Quality Process quality, product quality, quality systems

Bionic Handling Assistant Flexible Gripper made from polyamide by SLS © FESTO AG and Fraunhofer IPA Deutscher Zukunftspreis 2010

© Fraunhofer IFAM

IFAM‘s current research topics in Additive Manufacturing

Material development Quality control strategies for powders Component design Development of process parameters Intelligent components Educational workshops

In strictly confidential bilateral projects as well as in publicly funded consortium projects, all aspects of Additive Manufacturing are developed and optimized for our customer‘s benefit.

© Fraunhofer IFAM

A global hype in Additive Manufacturiung technologies

Increased number of patents

Government funded activities

US: National Network for Manufacturing Innovation

Europe: AM Platform

AM standardization committees worldwide (ISO, ASTM)

Start-up companies and new business models

Growing publicity and visibility in mainstream media

© Fraunhofer IFAM

Areas of Application for Additive Manufacturing: Consumer

www.shapeways.com

»the ultimate 3D-printed personalized shoe« http://www.adidas-group.com

© Fraunhofer IFAM

Areas of Application for Additive Manufacturing: Industry

Titanium cabin holder for Airbus A350 © Airbus / LZN

Dental restorations CoCr

Micro turbine wheel IN718 © Fraunhofer IFAM

© Fraunhofer IFAM

Additive Manufacturing market expectations

Metal AM Systems are being placed at rates which surpass even optimistic market forecasts

Substantial decrease in cost and growing productivity expected

Market today is 4.9 billion US $

Source: SmarTech Markets Publishing

© Fraunhofer IFAM

Additive Manufacturing: Production Readiness level

Source: © Siemens, Pictures of the Future

© Fraunhofer IFAM

Dental restorations process chain

Dental lab BEGO Medical

ceramic veneering

• Finish

• Cutting

scaffold

„Medifacturing“

machine data

3D data

data processing

3D data

BEG

O

serv

er

data

CAD system scanning device

model

Additive Manufacturing replaces casting process

© Fraunhofer IFAM

Medical and dental technology

Patient-specific (individualized) components

Implants and dental restoration

Medical instruments

Anatomical models for surgery training and preparation

Tissue Engineering

© Fraunhofer IFAM

Application areas for Additive Manufacturing

Prototyping

Design testing, early elimiation of design flaws

Fit and assembly trials

Functional prototypes

Lightweight Construction

Internal grid structures

Hollow structures

Bionic structures

© FESTO, Fraunhofer IPA

© Fraunhofer IFAM

Application areas for Additive Manufacturing

Tooling

Internal cooling channels (»conformal cooling«)

Temperature control

Modular tooling

CNC milled

AM (Laser Melting)

conformal cooling channels

Venting

Small series of 200 pins with internal cooling channels on a building platform build time : 30 h

© Fraunhofer IFAM

Application areas for Additive Manufacturing

Production

Small and medium scale series production from metal and plastics

Production of spare parts

Production of high complexity components

Heat Exchanger with maximum surface Inconel 718

© Fraunhofer IFAM

Additive Manufacturing: key factors for success

Standardization .

Additive Manufacturing

Mate

rials

fo

r A

M

Desi

gn

fo

r A

M

AM

Pro

cess

Para

mete

rs

AM

Mach

ines

AM Products

AM Materials Powder quality and costs Material properties (static, dynamic, microstructure) Development of “new” materials Design for AM Lightweight design Bionic design Functional optimization AM Process Parameters Process window for new materials Material properties optimization AM Machines Overall productivity Quality management

© Fraunhofer IFAM

Barriers to broad adoption of Additive Manufacturing

Limited range of suitable materials

Process understanding and performance

Part accuracy and surface finish

Limited build volumes = small part sizes

Need for qualification and certification

Lack of AM standards

Manufacturing speed

? ? ? Uncertainties in the input materials

Uncertainties in equipment and process performance

Uncertainties in the final parts

© Fraunhofer IFAM

Geometry Particle size distribution

Particle shape

Purity

…

Laser

Line spacing

Inert atmosphere

Layer thickness

Tolerances

Dimensional accuracy

Surface roughness

Density

Mechanical properties

CAD Data Powder Process Part quality

Influence of powder and process parameters on part quality

© Fraunhofer IFAM

Prerequisites for Selective Laser Melting SLM

Powder

should

be spherical

have a diameter between 20 to 50 µm

be weldable

Particle diameter [µm]

© Fraunhofer IFAM

Importance of powder consistency

1

2

3

1 2 3

D10 [µm] 17,9 4,2 15,6

D50 [µm] 31,6 12,3 29,7

D90 [µm] 51,0 28,6 63,7

Ø Angle of repose [°] 59 68 55

Ø bulk density [g/cm³] 4,23 4,42 4,54

Ø Tap Density [g/cm³] 4,74 5,15 5,12

With powder 2 it is not possible to spread out smooth and even powder layers due to agglomeration of fine particles

© Fraunhofer IFAM

Facts on Selective Laser Melting SLM

Outstanding mechanical properties

Rough surface quality – Post processing possible

0,0

4

0,0

6

0,1

0

0,1

6

0,2

5

0,4

0

0,6

3

1,0

1,6

2,5

4,0

6,3 10

16

25

40

63

10

0

16

0

25

0

Turning

Milling

Polishing

SLM - as built

SLM - after shot-peening

SLM - after polishing

Achievable roughness average Rz in µm

Average Range

Less Frequent Range

© Fraunhofer IFAM

Growing number of materials for metal Additive Manufacturing

Standard materials

Various Steels

Aluminum alloys

Titanium alloys

Nickel alloys

EOS AlSi10Mg

SLM AlSi12

SLM ASTM F75

EOS MP1

CL 91 RW Concept

EOS MS1

Inconel 718

EOS Inconel 625*

CL 20 ES (316 L)

EOS GP1 (SS 17-4) Arcam Ti6Al4V ELI

SLM TiAl6Nb7*

0

200

400

600

800

1000

1200

1400

1600

0 100 200 300 400 500

Hardness Vickers [HV]

Ten

sile

Str

en

gth

[M

pa]

* va lues for annealed samples

© Fraunhofer IFAM

How do I need to design? How do I want to design?

New design opportunities at no additional costs

Part complexity

Design for conventional production

Pro

du

ctio

n c

ost

s

Design for AM

»Complexity for free«

Redesign for Additive Manufacturing

© Fraunhofer IFAM

Design – Prerequisites for Selective Laser Melting

Geometry

Support structure necessary

Building platform required

Inner structure possible – powder removal opening necessary

© Fraunhofer IFAM

Influence of building direction on part quality

Tensile strength and yield stress for SLM 1.4404 stainless steel

MPa

0° lying flat 45° 90° vertical

Source: A. Spierings, Hagen 2013

© Fraunhofer IFAM

Production tests on geometric limitations

Benchmark features

Minimum wall thickness

Minimum hole diameter

Maximum arch diameter

Maximum channel diameter

Minimum column diameter

Minimum gap distance

Reproducibility

Geometrical accuracy

Surface roughness versus leverage angle

© Fraunhofer IFAM

Design for Additive Manufacturing: Hydraulic crossing

Conventionally manufactured by drilling

Hollow structures and cavities made by additive manufacturing on EOS M270

Powder exits

Source: Case study in EU-Project COMPOLIGHT

reduction of pressure

loss to 15%

Burst pressure increase of 260%

Weight reduction to 3.4%

© Fraunhofer IFAM

Support structures – key factor for successful manufacturing

Different supports for different orientations of the parts on the platform

Use of struts, walls and lattice structures

Support structure – dependent on part requirements

© Fraunhofer IFAM

Support structures – key factor for successful manufacturing

© Fraunhofer IFAM

Distortion simulation for SLM process

Simulation Experiment

Courtesy of:

© Fraunhofer IFAM

Process limitations: Build volume sizes and laser power

Concept Laser X line 1000R

Build volume: 630 x 400 x 500 mm³

Source: http://3druck.com/ Source : www.slm-solutions.com

SLM ® 500 HL

Build volume: 500 x 280 x 325 mm³

patented dual beam technology 2 x (400 W + 1000 W)

© Fraunhofer IFAM

Additive Manufacturing: Improving Productivity

SLM PL = 250 W

0

2

6

10

8

4

Bre

ak

ing

Elo

ng

ati

on

A

[%

]

0

100

200

400

500

300

Ten

sile

Str

en

gth

[M

Pa]

Ultimate Strength

0 90

Build Direction [°]

Yield Strength

Breaking Elongation

Min. according to DIN EN 1706

0

2

6

10

8

4

Bre

ak

ing

Elo

ng

ati

on

A

[%

]

0

100

200

400

500

300

Ten

sile

Str

en

gth

[M

Pa]

0 90

Build Direction [°]

High Power SLM PL = 1000 W

Mechanical Properties of AlSi10Mg

© Fraunhofer IFAM

Making the Additive Manufacturing process continuous

Powder

Scanning device Powder deposition

Produced part

Conveyor belt

Patented by:

EP 2289462 B1: Substrate plates on an endless conveyor belt, with powder at an angle α applied. After that, the material is selectively hardened by means of a radiation source

© Fraunhofer IFAM

Additive Manufacturing: Eco-efficient production

Source: Fraunhofer ILT

© Fraunhofer IFAM

A broader use of Additive Manufacturing in production

Challenges for AM

Next Steps

Missing technical standards

Global Standardisation activites

Reproducibility Quality control systems / in-situ feedback control systems

Costs Gained productivity

Education with regard to AM design guidelines

Widely spread teaching of AM principles at universities and in industry

Material variety Material and process development

Source: © Siemens, Pictures of the Future

© Fraunhofer IFAM

Additive Manufacturing hype curve

time

expectations

Innovation Peak of Trough of Slope of Plateau of Trigger Inflated Disillusionment Enlightenment Productivity Expectations

AM for Prototyping

3D Scanners

AM of Hearing Aids

Plateau will be reached in Less than 2 years 2 to 5 years 5 to 10 years More than 10 years

AM Service Bureaus

AM Creation Software

Enterprise AM

AM of Dental Devices

AM of consumable products

Intellectual Property Protection AM

Macro AM

AM-Aided Hip/Knee implants

Bioprinting Systems For Organ Transplants

AM for Oil and Gas

Classroom AM

Retail AM

Bioprinting for Life Science R&D

Industrial AM

AM in Supply Chain

AM of Medical Devices

AM in Manufacturing Operations

Consumer AM

As of July 2015

Source: Gartner Inc., www.gartner.com

© Fraunhofer IFAM

Additive Manufacturing of springs

Is it possible to manufacture a spring by Additive Manufacturing?

In research projects TiAl6V4 different helical springs have been successfully produced via SLM

It was shown that the spring geometry has a significant effect on the mechanical properties

Conventional manufacturing processes will not be substituted

but supplemented by Additive Manufacturing,

especially if the spring is an integral part of an assembly!

© Saleh, Ragab in Proceedings of IMECS 2013

© Fraunhofer IFAM

Additive Manufacturing of springs

Spinal disc prosthesis from titanium

Manufactured by SLM all in one piece, including the double spring. Silicone cushion is injected in a second step.

Actuator spring from TiAl6V4

Originally machined from high-tension steel

Redesigned for AM production: Springs have a hollow coil with triangular cross-section. The entire part consists of top and bottom disks and eight identical spring coils

© Tsunami srl, Concept Laser

© LayerWise, TNO

© Fraunhofer IFAM

Conclusions

Additive Manufacturing is a resource-efficient production technology

CO2 reduced production

No waste (Powder recycling)

Low energy consumption

Additive Manufacturing allows nearly infinite complexity in design for free

Process efficiency and reliability must be improved

Material costs must be reduced

Additive Manufacturing will supplement conventional manufacturing processes

Additive Manufacturing is an important aspect of »Industry 4.0« concept (customized products)

There will be many new business opportunities due to the versatility of Additive Manufacturing