Dr.-Ing. Wilhelm Meiners Fraunhofer Institute for Laser ... · Dr.-Ing. Wilhelm Meiners Fraunhofer Institute for Laser Technology Aachen, Germany Additive Manufacturing with laser

Dr.-Ing. Wilhelm Meiners

Fraunhofer Institute for Laser Technology

Aachen, Germany

Additive Manufacturing with laser melting on it´s way to series production


Agenda

Cost calculation4

New materials3

New machine concepts2

Fraunhofer, facts and figures1

© Fraunhofer ILT

Agenda

Cost calculation4

New materials3




Facts and Figures of Fraunhofer ILT € 31.1 M operating budget (without investments)

in 2014

75% contract research revenue and 25% base funding

€ 3.4 M in investments in 2014

405 employees in 2014, of this 152 scientists and

engineers, and 178 student assistants

DQS certified according to DIN EN ISO 9001

One patent application per month on average

One to two spin-offs per year on average

(More than 30 ILT spin-offs in the last 25 years)

Approx. 10-15 participations in trade fairs and

more than 20 organized events (conferences,

seminars) per year

Approx. 15 Ph.D. graduates at RWTH faculties

per year

Over 70 diploma, master, bachelor degrees

per year

Technology Focus

MEDICAL TECHNOLOGY AND

BIOPHOTONICS

LASER MATERIAL PROCESSING LASER MEASUREMENT

TECHNOLOGY

LASERS AND OPTICS

Products and Services

Laser Cutting

Laser Welding

Soldering

Heat Treatment

Cladding

Laser Metal Deposition

Rapid Manufacturing

Process and Beam Control

Machine and Control Technology

Plastics Cutting and Welding

Cleaning

Marking

Drilling

Micro Joining

In-Volume Structuring

Polishing

Thin Film Processing

Ultrashort Pulse Processing

Micro Structuring

Nano Structuring

Simulation

LASER MATERIAL

PROCESSING

Products and Services: Rapid Manufacturing

Process

Selective Laser Melting

Powder bed process

Processing of serial material

Part density approx. 100 %

Process Development

Enlargement of processable materials

Improvement of part quality

Increase of productivity

Enlargement of feasible structure sizes

Manufacture of components with new design

(e. g. hollow structures)

Application Development

Application of SLM in different branches

and for custom specific tasks

SLM for series production

SLM-compatible part design

Implementation of SLM in existing process chains

Machine- and Component Development

Special purpose machines

Machine modification

Integration of additional components

© Fraunhofer ILT

Slide 8

Selective Laser MeltingNaming and common Confusion

Direct Metal Laser Sintering (DMLS)

Selective Laser Melting (SLMTM)

LaserCUSING® Laser Metal Fusion (LMF)

Direct Metal Printing (DMP)Metal Additive Manufacturing

Selective Laser Melting (SLM®)

Same

Process

Laser-powder bed fusion (L-PBF)

© Fraunhofer ILT

Slide 9

The AM (R)evolution @ ILT

Basic Patent

2003

First Implant

...to SeriesProduction

...fromPrototyping

1996First Production

2008

2015

2001

First Tool Insert

SLM as one of the key enablers of AM

Lowering ofbuild platform

Laser Melting ofpowder material

Deposition ofpowder layer

First series Production

???

© Fraunhofer ILT

Slide 10

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 11

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 12

Scalability of size and build rate

Costs per part

Product Complexity


Conventional Manufacturing

Costs per part

Lot Size

Conventional Manufacturing


High Power Selective

Laser Melting

High Power Selective

Laser Melting

Laser radiation is the energy source

Increasing build rate needs increased laser power

© Fraunhofer ILT

Slide 13

SLM processPL = 200 W

High Power SLM PL = 1000 W

Aluminum (ALSi10Mg)

New machine conceptsIncreased laser power in a single laser beam

© Fraunhofer ILT

Slide 14

SLM process PL = 400 W

High Power SLM process (skin-core)PL = 400W (skin) 1000 W (core)

New machine conceptsSkin core principle

© Fraunhofer ILT

Slide 15

New machine conceptsMultiple laser scanner systems

© Fraunhofer ILT

Slide 16

Approach

Basis: Laser cutting machine

1 kW laser power with variable

spot size

Movable process chamber with

local shielding gas systems

Advantages

Scalable, modular concept

Almost unlimited part size

Optical system independant

from platform size

© Adira Metal Forming Solutions S.A.

New machine conceptsExpanding build envelop

© Fraunhofer ILT

Slide 17

x

y

New machine conceptsMulti-Spot processing

x

y

Conventional SLM New Multispot concept

© Fraunhofer ILT

Slide 18

x

y

Conventional SLM New Multispot concept


© Fraunhofer ILT

Slide 19

Main advantages as a matter of principle:

Use of diode lasers

Easy upscaling in productivity (higher number of laser spots)

Easy upscaling in build size (larger axes)

Local shielding gas flow, local process control units


© Fraunhofer ILT

Slide 20

New machine conceptsLow Cost SLM System

SLM fabber system:

single diode laser

gantry system

component cost < 30 k€

10mm

© Fraunhofer ILT

Slide 21

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 22

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 23

500 µm

Densitiy > 99,97 %

Crack free without preheating

Bainitic mircro structure

Hardness > 720 HV1 after

heat treatment

MaterialIncreasing material range – steel 16MnCr5

© Fraunhofer ILT

Slide 24

High heat conductivity and

reflection coefficient

Approx. 100% density

Mechanical properties and heat

conductivity within specifications

given by alloy manufacturer

MaterialIncreasing material range – copper alloys

© Fraunhofer ILT

Slide 25

MaterialIncreasing material range – magnesium alloys

Biodegradable Scaffold (WE43) Topology Optimized Triple Clamp (AZ91)

1:4 Scale Model

© Fraunhofer ILT

Slide 26

MechanicalDeformation

100µm

Heating

Heating

Heating

Pseudoplasticity (shape memory effect) or super elasticity adjustable by choice of process parameters

Smallest feature size:approx. 30µm

Surface roughness Sa:< 2µm

MaterialIncreasing material range – shape memory alloys NiTi

© Fraunhofer ILT

Slide 27

Laboratory system with platform pre-heating up to 1000oC

5 mm

5 mm

MaterialIncreasing material range – high temperature preheating

© Fraunhofer ILT

Slide 28

surface roughness Sa

downskin < 45µm

upskin < 25µm

side < 10µm

dimensional deviation <77µm

0.100

-0.100

0.05

10 mm

-0.05

0

MaterialIncreasing material range – Titanium Aluminide (TNM)

© Fraunhofer ILT

Slide 29

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 30

Agenda

Cost calculation4

New materials3




© Fraunhofer ILT

Slide 31

Simple: Cost calculation

Input

• Part

• Support, Orientation

• Machine

• Material

• Parameter

Output

• Job duration

• Part cost

Advanced: Production planning scenario

Job composition

(parts & arrangement)

Staff presence

(e.g. shift system,

public holidays etc.)

Automated modelling of series production over arbitrary evaluation

period for each scenario & result comparison

Output

• No. of parts produced, part costs, cost split

• Time split & staff requirement

• Added value and machine productivity

• Optimization of job layout for maximum machine utilization*

• Recommendations for action

*) currently under development

Manufacturing

(e.g. machine, material,

parameter set)

Vscan = 500 mm/s Vscan = 1000 mm/s

DS = 50 µm DS = 50 µm

Ys = 70 µm Ys = 70 µm

Lv = 5 mm Lv = 5 mm

„Stripes“ „Stripes“

Increment: 90° Increment: 45°

Cost calculation

© Fraunhofer ILT

Slide 32

Results (example!)

Overview about input data, job composition and evaluation period

Part costs and cost split

Machine utilization and time split

Cost calculation

Fraunhofer Institute for Laser Technology ILT

Steinbachstrasse 15

52074 Aachen

Dr.-Ing. Wilhelm Meiners

Tel: +49-(0)241/8906-301

Fax: +49-(0)241/8906-121

[email protected]

www.ilt.fraunhofer.de

Documents

Dr.-Ing. Wilhelm Meiners Fraunhofer Institute for Laser ... · Dr.-Ing. Wilhelm Meiners Fraunhofer Institute for Laser Technology Aachen, Germany Additive Manufacturing with laser