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增材制造技术在工业中的应用 Industrial Applications of
Additive Manufacturing Technology
张立强 Kevin Zhang
EOS 大中华区销售总监 +86 181 1622 5969
2015中国国际金属加工高峰论坛
EOS 2014 | EOS | 2
Cellular structure
EOS 2014 | EOS | 3
Additive Manufacturing
EOS 2014 | EOS | 4
Agenda
• About EOS and the Technology
• EOS Industrial Applications
EOS 2014 | EOS | 5
EOS: Technology and Market Leader for Design-Driven, Integrated e-Manufacturing Solutions
EOS Headquarters in Krailling, Germany
EOS Management
Christian Kirner Dr. Tobias Abeln Dr. Hans J. Langer Dr. Adrian Keppler
Privately-owned, founded in 1989,
Headquartered in Krailling near Munich, Germany
Integrated solution provider for Additive Manufacturing
Solution portfolio: Additive Manufacturing (AM) systems, materials (plastics and metals), software and services
Complete end-to-end solutions: from part design and data generation to part building and post-processing
EOS enables competitive advantages for a variety of industries, such as medical, aerospace, tooling, industry, lifestyle products and automotive
EOS is committed to: Innovation – Quality – Sustainability
EOS 2014 | EOS | 6
EOS Additive Manufacturing: Functional Principle
Functional principle for polymer and metal materials. Source: EOS
From a 3D CAD model…
… to complete parts
Application of powder
Exposure by Laser
Lowering of platform
Re-application of powder
Exposure by laser
EOS 2014 | EOS | 7
North America
15% of global client base
Europe & Rest of World
67% of global client base
Asia- Pacific
18% of global client base
EOS: Global Presence
EOS worldwide installed base EOS global footprint
~1,500 Systems ⅓ Metal systems
⅔ Polymer systems
266 customers with more than 1 system
Customers in 51 countries
EOS Sales & Service offices in 11 countries, distribution partners in 22 countries
More than 500 employees worldwide (74% Germany, 26% International)
Strong patent portfolio: More than 700 active patents in nearly 100 patent families
R&D Spendings of approx. 15% of Sales
Source: EOS. Installed base (includes purchased and rented systems) as per 12/2013. Staff figures as per 09/2013.
EOS 2014 | EOS | 8
Customers from Numerous Industries Rely on EOS Technology
Sample customers.
OEMs Service Providers
EOS 2014 | EOS | 9
EOS Direct Metal Laser Sintering (DMLS) Systems
Build size Width 250 mm Depth 250 mm Height 325 mm Laser Yb-fibre laser 400 W
Technical data Precision optics: F-theta-lens, high-speed
scanner Scan speed: up to 7.0 m/s
EOSINT M 270 Dental: High-performance DMLS for production of dental copings and bridges
EOSINT M 290/280: Leading-edge DMLS system for the Additive Manufacturing of metal parts
Build size Width 250 mm Depth 250 mm Height 215 mm Laser Yb-fibre laser 200 W
Technical data Precision optics: F-theta-lens, high-speed
scanner Scan speed: up to 7.0 m/s
Build size Width 400 mm Depth 400 mm Height 400 mm Laser Yb-fibre laser 1,000 W
Technical data Precision optics: F-theta-lens Scan speed: up to 7.0 m/s
EOS M 400: System for the Industrial Production of High-Quality Large Metal Parts
System
animation
building
EOS 2014 | EOS | 10
EOS Metal Materials
Material Group Trade name Material type Typical applications
Maraging Steel EOS MaragingSteel MS1 18 Mar 300 / 1.2709 Injection moulding series tooling; engineering parts
Stainless Steel
EOS StainlessSteel GP1 Stainless steel 17-4 / 1.4542
Functional prototypes and series parts; engineering and medical
EOS StainlessSteel PH1 Hardenable stainless 15-5 / 1.4540
Functional prototypes and series parts; engineering and medical
Nickel Alloy
EOS NickelAlloy IN718 Inconel™ 718, UNS N07718, AMS 5662, W.Nr 2.4668 etc.
Functional prototypes and series parts; high temperature turbine parts etc.
EOS NickelAlloy IN625 Inconel™ 625, UNS N06625, AMS 5666F, W.Nr 2.4856 etc.
Functional prototypes and series parts; high temperature turbine parts etc.
EOS NickelAlloy HX UNS N06002
Parts with severe thermal conditions and high risk of oxidation, e.g. combustion chambers, burner components, fans, roller hearths and support members in industrial furnaces
Cobalt Chrome
EOS CobaltChrome MP1 CoCrMo superalloy, UNS R31538, ASTM F75 etc.
Functional prototypes and series parts; engineering, medical, dental
EOS CobaltChrome SP2 CoCrMo superalloy Dental restorations (series production)
Titanium EOS Titanium Ti64 Ti6Al4V light alloy Functional prototypes and series parts; aerospace, motor sport etc.
Aluminium EOS Aluminium AlSi10Mg AlSi10Mg light alloy Functional prototypes and series parts; engineering, automotive etc.
Materials
EOS 2014 | EOS | 11
Agenda
• About EOS and the Technology
• EOS Industrial Applications
EOS 2014 | EOS | 12
Automotive
Industrial Applications
Tooling
Lifestyle Industry
Sources (upper, left to right): Morris Technologies; M. Kandler, Frauenhofer IPA; Festo; (bottom l. to r.): WITHIN Labs/EOS; EOS; BKL
Medical Aerospace
EOS 2014 | EOS | 13
Additive Manufacturing (AM) Offers Various Advantages
AM technology key differentiators compared to conventional manufacturing processes
Freedom of design Cost advantages Customization Organization
Time to market
Lightweight
Static: weight of parts
Dynamic: moving, accelerated parts
Complex components
E.g. alternative structures of heat exchangers (see below)
Integrated functionality
Embedded functionality without assembly
Complex Parts
Direct Manufacturing
No tooling
No inventory
Individualized parts
Customer specific adaptations
Cost efficient small series up to "lot size one"
Rapid prototyping and serial applications
Fast feasibility feedback of virtual models
Haptic feedback
Image sources: WITHIN Labs, EOS, Hettich
Laser adjustment unit Finger implants Heat exchanger Washing rotor
EOS 2014 | EOS | 14
Aerospace
EOS 2014 | EOS | 15
Aerospace – Jet Engine
GE
Pratt & Whitney
Rolls Royce
AVIO
Snecma
Turbomeca
Klimov
MTU
Engine Alliance
SOURCE: EOS
EOS 2014 | EOS | 16
Aerospace - Fuel Nozzles
DMLS fuel nozzle demonstrates:
Highly complex design built as ‘one piece’
Dramatic reduction in time to create
25,000 annual production
5x more durable
25% less weight
20 pieces to 1
EOS 2014 | EOS | 17
Aerospace applications
EOSINT M enables product optimization
for aerospace devices
new design concepts
Aerospace part design
high complexity
thin walled
Large size (max Ø 248mm ~10 inches)
New materials
EOS Nickel Alloy IN718
EOS Nickel Alloy IN 625
Hastalloy X
Thin walled turbine combustion chamber, produced on
EOSINT M 270, material EOS Nickel Alloy IN 718.
Source: Materials Solutions
EOS_Company-Presentation.pptx | EOS | 19
DMLS Door bracket demonstrates:
Source: Evo Maganize and EADS IW Filton, from: http://www.evo.co.uk/features/features/261526/3d_printing_is_this_the_future.html
Aerospace – Weight Reduction
Door bracket for A380 – DML and Conventional
EOS Ti64 produced on EOSINT M 270Xt at EADS IW.
Highly complex design built as ‘one piece’
function integration
Significant cost reduction
EOS 2014 | EOS | 20
Medical
EOS_Company-Presentation.pptx | EOS | 21
Medical – Dental Copings & Bridge
Source: EOS
EOS 2014 | EOS | 22
EOS_Company-Presentation.pptx | EOS | 23 Page 23
Medical – Orthopedic Implants
Replacement knee joint in
EOS CobaltChrome MP1
Source: EOS, Stryker Orthopaedics and Protocast
project partners: Stryker Orthopaedics and Protocast
Spinal implants in
EOS Titanium Ti64
Batch of finger implants in
EOS CobaltChrome MP1
EOS 2013 - Tooling applications | EOS | 24
Acetabular cup with a trabecular lattice for improved osseointegration
Case study: Acetabular cup
Defined trabecular structure to aid osseointegration
Specific design software allows to vary pore size, porosity throughout the implant and surface roughness
Structural continuity between solid and porous sections due to manufacturing in a single phase
Material: Ti6Al4V alloy
510(k) approval
EOS 2014 | EOS | 25
Unique random structure
Pore size fully
tuneable
EOS 2014 | EOS | 28
Tooling
EOS 2014 | EOS | 29
Additive Manufacturing (AM) applications for tooling
Sources images (left to right): LBC, Ecoparts, LBC, PEP
Smarter design of conformal cooling channels: cost savings, cycle time reduction, increased performance, scrap rate reduction
Injection molding Special application areas Die casting, MIM Rapid Tooling
For duroplasts, thermo-plasts, elastomers
DMLS enables built-in, conformal cooling chan-nels that can be optimized to draw off heat more rapidly and evenly
Result: dramatic cycle time reduction, increased part quality
Ideally suited for the reparation of e.g. tooling inserts, blow molding
DMLS enables partial instead of a complete replacement of a partially damaged
insert
DMLS saves costs and reduces lead times (for repair process)
Aluminum, zinc
DMLS enables cooling system and cooling channels optimization, consequently reducing cycle time reduction and enabling serial production
0 series, prototypes
DMLS can reduce lead times compared to conventionally manufac-tured inserts
DMLS also enables costs
reduction for tool production due to shorter working time, increased mould and better thermal management of mould
Tool insert for injection moulding Tool insert for die casting Tool insert Tool insert
EOS 2014 | EOS | 31
Particularities of the DMLS tool insert
Source: BKS; Polymold; EOS
Hardness tool insert: 52-54 HRC
High glossy polish finishing
Tool insert for the manufacturing of child cup, material EOS Maraging Steel
MS1 (1.2709)
Hybrid design
DMLS manufacturing
Conventional manufacturing
EOS 2014 | EOS | 34
DMLS addresses major plastic applications
Conformal cooling in strategic markets
Quality Productivity Cycle time Delivery time (TTM)
Quality Productivity Complexity
Better quality Complex geometry
Electrical/household Appliances
Packaging
Customer care and healthcare
Automotive
Medical & pharmacy tooling
Toy industry
Life time of inserts Innovation in design Cycle time
Life time of inserts Uniformity of
performance
Cycle time Cost per part
EOS 2014 | EOS | 35
Automotive
EOS_Company-Presentation.pptx | EOS | 36
General material data
Average grain size: 60 µm
Bulk density: 0.59 - 0.62 g/cm3
Density of laser sintered part*: 1.23 - 1.28 g/cm3
Mechanical properties
Tensile modulus: 3200 ± 200 N/mm2
Tensile strength: 48 ± 3 N/mm2
Elongation at break: 6 ± 3 %
Ball indent. hardness: 98 N/mm2
Thermal properties
Melting point: 172 - 180 °C
Source: EOS
Automotive
Essential material properties
* EOS-method
Air intake unit
Fully functional prototype for development
purposes
Project partner: Mann + Hummel
EOS_Company-Presentation.pptx | EOS | 37
Source: Pro2
Automotive Weight Reduction
Laser-sintered piston with
integrated conformal oil/water
cooling channels
27% weight saving
EOS_Company-Presentation.pptx | EOS | 38
Automotive Heat Exchanger
Bicycle Parts
EOS 2014 | EOS | 39
Industry
EOS 2014 | EOS | 40
Festo Bionic Handling Assistant
EOS 2013 - Tooling applications | EOS | 41
A conventional handling device was redesigned leveraging the possibilities of laser sintering
OLD design
Weight reduction 86%
Cost reduction 50%
Lead time reduced from 21 days to 4 days
NEW design
Source: Wittmann, Kuhn-Stoff, EOS
EOS 2014 | EOS | 42
Lifestyle
EOS_Company-Presentation.pptx | EOS | 43
Lifestyle
Source: Future Factories, Freedom of Creation
EOS 2014 | EOS | 44
Precious Metal 3D Printing: Au and Ag
EOS 2014 | EOS | 45
Last but not least
• 2015年3月20日，中国国务院副总理马凯一行访问了EOS在德国慕尼黑Krailling的公司总部，并受到了EOS创始人兼首席执行官Hans J. Langer博士的热烈欢迎。
This presentation may contain confidential and/or privileged information. Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
Thank you!
