Additive Manufacturing towards 2020 - Lortek · Additive Manufacturing towards 2020 November 27 th 2013, IK4-LORTEK Ordizia (Gipuzkoa), Spain Frits Feenstra

Additive Manufacturing towards 2020

November 27 th 2013, IK4-LORTEK

Ordizia (Gipuzkoa), Spain

Frits Feenstra

Outline

• What is Additive Manufacturing

• Additive Manufacturing processes & materials (focus on metals)

• Applications

• Needs & Trends

• Towards H2020

• AM-Platform

• Conclusions

• Backup slides:

Different projects

Standardisation proposed structure

Achievements from KU Leuven (prof Kruth) on SLM + hybrid

Hybrid manufacturing by TNO (Printvalley)

Additive Manufacturing at TNO

Additive Manufacturing Technologies

“3D Printing”

1. Vat Photopolymerisation (UV curing of (filled) resins)

2. Material Jetting (Printing / Inkjet)

3. Binder Jetting (Zcorp, Voxeljet)

4. Material Extrusion(Fused deposition modeling)

5. Powder Bed Fusion (Selective Laser Sintering)

6. Sheet Lamination (LOM)

7. Directed Energy Deposition (Electron Beam Melting, Laser Cladding)


VAT polymerisation (UV curing of (filled) resins)


Importance of Additive Manufacturing

CAD to Part

Design for customization

Design for function

Design for light weighting

Near net shape manufacturing

Material utilisation

Less pollution

Reduced time to market


Materials (metals) (source TNO)


Materials (metals) (source TNO)


Applications

Aerospace

Hydraulic manifold

Siemens heat shield

Orthophone


Aerospace

Titanium bracket with optimised topology made by using DMLS

technology Image courtesy of EADS Innovation Works


0,95 Kg

80x80x50mm

Hydraulic manifold

Redesign of Hydraulic Manifold


Hydraulic manifold complicated case


Hydraulic manifold complicated case

Part made by Sirris (BE) using Prometal binder jetting technology


Siemens gasturbine heat shield

Heat ShieldMetal: Inconel 939, currently: castAM PBF is a good alternative

Courtesy of Siemens


Orthophone pick-up needles

Small series

Manufacturing on Demand

Minimalistic design

Special material properties:

High stiffness

High Internal damping

Cartridge body made of Titanium with SLM

Steel 1.4404 – 316L & Titanium

A90 cost € 4000,-


Needs & Trends (1) SRA documentavailable at: www.AM-Platform.com

Quality assurance: a.o. in-line inspection

Higher speed for lower cost (parallelising)

Hybrid machines (AM + conventional combined)

Design optimization (Optistruct <-> FEM)

Lightweighting

Standardisation (SASAM, CEN, ASTM-F42, ISO261)

Supply chain & procurement adaptation & optimization


Needs & Trends (2)

- (1999 – 2005) Monomaterial AM

- (2005 – 2018) Multimaterial AM

- (2015 – 2025) Integration of sensors during build

Self condition monitoring of parts (hostile – far away areas)

Parts embedded with conductive tracks –printed on an Objet Connex multi-material 3D Printer (source: Loughborough university, http://www.stratasys.com)


Towards H2020

NMP (2014 – 2015) expected info December 11th 2013

certainly opportunities for AM:

- complex structures

- printing multifunctional materials

- process optimisation of manufacturing assets

- AM tabletop factory (2015)

LEIT (Information and Communication Technologies):

- High-throughput laser-based manufacturing


AM Technology PlatformThe European consolidation of

Additive Manufacturing

A community of European stakeholders of Additive Manufacturing

To achieve European industrial growth & sustainability, by a coherent strategy, condensed research, dissemination and exploitation of Additive

Manufacturing

www.AM-Platform.com

The European collaboration on Additive Manufacturing


Conclusion

AM / Printing combined with other production technologies in a hybrid

setting is the best solution for realising integrated products

No design tools available for integrated AM products!

Polymer, metallic and integrated products all require different

approaches for designs, processes and chains

AM future is nice and emerging!


The Media Hype has already started!


Contact information

TNO Innovation for Life

De Rondom 1

5612 AP Eindhoven

The Netherlands

Bart van de Vorst (technology scout)

E-mail: [email protected]

Frits Feenstra (projects)

E-mail: [email protected]


Participants BackgroundADDFactor “Mini-factories” concept innovates the whole supply chain: the relationship between retailers and the manufacturing technologies will use a new additive manufacturing based production framework concept, founded on central knowledge-based design and local distributed manufacturing. 2 systems for retail as well as for district level (customized complex AM products) will be developed.

FundingAddfaktor is funded by the European

Union within the 7th Framework

Programme nr 609386 2013 – 2016

Budget: 5.9 M€

Further InformationProject coordinated by Synesis

Contact: E-mail: [email protected]


Participants BackgroundHyproline will design, implement and validate a flexible high performance manufacturing line for serial fabrication of customized high quality metal parts that combines innovatively component technologies for net shape manufacture, direct write / structuring, inspection & intelligent automation complex AM products) will be developed.

FundingHyproline is funded by the European


Programme nr 314685 2012 – 2015

Budget: 4 M€

Further InformationProject coordinated by TNO



Participants BackgroundAdvanced production equipment and

innovative systems are needed to

enable ultra-fast and cost-effective

manufacturing of fully customised

products at the location of need, at

exactly the required time (factory in a

container). The integrated additive

manufacturing based modular

manufacturing system with standard

interfaces allows an easy exchange of

process modules. An enables the

system to “3D print” customised

components of virtually any shape.

FundingCassamobile is funded by the European


Programme nr 609146 2013 – 2016

Budget: 5.5 M€

Further InformationProject coordinated by Fraunhofer IPA



Participants BackgroundManSYS aims to develop and

demonstrate a set of e-supply chain

tools; to enable the mass adoption

of Additive Manufacturing (AM). It

will combine all aspects of AM inclu-

ding multiple build platforms (Laser

and Electron-Beam technologies),

modelling, post-processing (Machi-

ning, Finishing and Heat-Treatment)

and 3D scanning techniques..

It will assess and highlight:

- Cost-Savings

- Re-action to Customer Need

- Robustness

- Environmental Assessment

FundingManSys is funded by the European


Programme nr 609172 2013 – 2016

Budget: 5.5 M€

Further InformationProject coordinated by TWI



Source: ISO TC 261, SASAM project, TNO

Source: prof Kruth, KU Leuven 2013





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Additive Manufacturing towards 2020 - Lortek · Additive Manufacturing towards 2020 November 27 th 2013, IK4-LORTEK Ordizia (Gipuzkoa), Spain Frits Feenstra