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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
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
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
Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering
Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• Selective Laser Melting• Electron Beam Machining• Direct Metal Laser Sintering
Metal Additive Manufacturing or Metal 3D Printing• Laser Cladding• Laser Consolidation• LaserCusing• Laser Engineering Net Shaping
• 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
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
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
AM: Revolution for Spare Parts in Marine
http://www.seatrade-maritime.com/news/americas/chinas-breakthrough-in-3d-printing-for-shipbuilding.html
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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
What is going on with Metal AM now?
Siemens (2017)
What is going on with Metal AM now?
What is going on with Metal AM now?
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 Success Stories
Commercialization Success Stories
Commercialization ActivitiesClosed face Impeller for military grade pump (Canadian Navy)
Future Projects:OUTLOOK
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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
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Acknowledgements
Thank You!