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Presentation FabLab practice during the expert seminar in Leuven, July 13th 2010.
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C2C{Network
Study visit Fablab Leuven – July 13, 2010
Additive production technology and sustainability: challenges and opportunities
Prof. Karel Van Acker, K.U.Leuven Materials Research Centre
2
context: Plan C
Flemish Transition Network Sustainable Materials Management
visionary leitbild20xx
strategic visions
2030closing
the circletailor-made
materialsservice
economyconscious
societygreen
plastics
2009
experiments
phase 1
phase 3
phase 2
lear
ning
& u
psca
ling
• Long term vision as framework for short term actions• Room for high risk experiments in niche sectors• System innovation approach• Active role of all relevant actors
context: Plan C
3
knowledge/controlmaterial flows
extended materials
responsibility
reverse logistics
design for cycle
closedmaterial loops
tech
nosp
here b
iosp
here
biomimeticmaterials
biobasedmaterials
2030 smaller transparant material cycles
2008
uncontrollable, obscure, global material flows
1:1production
1000:1 production
revaluelocal production
neighbourhoodlabs
bottom-upproduction
just-in-needproduction
modularproduction
Material wasting production
4
mining production use phase End-of-Life
resources waste
production
• e.g. aerospace industry– classical machining
• buy to fly ratio up to 15:1• cooling lubircants (Germany: 75 ktonnes/yr)
– casting• energy consumption of holding molten materials• tooling
– molding• tooling• cooling and mold release components• design restrictions
5
what is additive manufacturing?(3D printing, rapid manufacturing)
• polymers– Stereolithography (e.g. photopolymers)
– Selective Laser Sintering (e.g. nylon powder)
– Fused Deposition Modelling (e.g. extrusion of ABS)
• metals/ceramics– Selective laser sintering/melting– 3D fibre deposition
Materials used
• General:High density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), unplasticised polyvinylchloride (UPVC), ABS, polylactic acid (PLA) and polycapralactone (PCL)steel, titanium, aluminium, …
• Can the materials cycle be closed?
7
Materials used
• Can the materials cycle be closed?– process waste can be recycled
– use of bio-based materials• PLA• starch• sugar, clay
8
Materials used
• Can the materials cycle be closed?– process waste can be recycled
– use of bio-based materials• PLA• starch• sugar, clay
– use of recycled materials• glass
9
Strenghts of additive production
• material effectiveness• use of biobased and recycled materials – underway• waste/emission minimisation during production
10
11source: ATKINS rapport, Loughborough University, 2007
Strenghts of additive production
• material effectiveness• use of biobased and recycled materials – underway• waste/emission minimisation during production• freedom of design
– further reduction of material need+ very complex geometries possible
– make use phase efficiente.g. complex lightweight constructions
12
Strenghts of additive production
• material effectiveness• use of biobased and recycled materials – underway• waste/emission minimisation during production• freedom of design• repair of components• transport of bytes instead of materials
reduce logistical requirements by shortening the supply chain and minimising the need for waste material disposal or recycling;
13
Strengths of additive production
• material effectiveness• use of biobased and recycled materials – underway• waste/emission minimisation during production• freedom of design• repair of components• transport of bytes instead of materials• economic– stock can be reduced to low value raw material– local production, since labour cost is not decisive
• social– personalised products – more added value ??– you can make almost everything yourself Fablab
14
Weaknesses of additive production
• Energy consumption• Technological drawbacks
– slowness– poor surface precision– cost
15
Weaknesses of additive production
• Energy consumption• Technological drawbacks• Closing the loop
– there is a huge potential to use this technology for C2C,however still a lot of research has to be done
16
Weaknesses of additive production
• Energy consumption• Technological drawbacks• Closing the loop• Potential rebound effect
3D printing = gadget printing?
17
Weaknesses of additive production
• Energy consumption• Technological drawbacks• Closing the loop• Potential rebound effect
3D printing = gadget printing?
• Need for new business models
18
www.additivemanufacturing.be
19
A system innovation approach
To conclude
• material effectiveness• use of biobased and recycled
materials – underway• waste/emission minimisation during
production• freedom of design• repair of components• transport of bytes instead of materials• economic– stock can be reduced to low value raw
material– local production, since labour cost is not
decisive• social– personalised products – more added
value ??– you can make almost everything yourself
Fablab 21
• Energy consumption• Technological drawbacks• Closing the loop• Potential rebound effect
3D printing = gadget printing?• Need for new business models
To Conclude
Additive manufacturing bears the opportunity to be a truly supportive technology for C2C, BUT also to be a new source of unsustainable production
The transition of production technologies towards this (and other kinds of) personalised production is ongoing
How will we make this transition growing into a sustainable direction?
22
Prof. Dr. ir. Karel Van AckerK.U.Leuven Research & Developmentc/o department MTMKasteelpark Arenberg 44BE-3001 Leuventel. +32 16 321271 e-mail: [email protected]
Prof. Dr. ir. Ignaas Verpoest chairman Leuven MRC
department MTMKasteelpark Arenberg 44
BE-3001 Leuven+32 16 321306
contact: www.leuvenmrc.be
realisations @KULeuven
Quality control by industrial X-ray CT
Production of metal components by SLM