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LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen 1
Importance of Manufacturing and Research for society needs - sustainable, global and local
Prof. Dr.-Ing. habil. Dr.-Ing. E.h. E. Brinksmeier
University of Bremen, Germany
IWT – Stiftung Institut für Werkstofftechnik
Leuven, 4th December 2015
Lecture on the occasion of a ceremony for Prof. J.-P. Kruth having received the 2015 Bower Science Award
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Typical BremenUniversity, Companies and Sights
IWT
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Legal form
Founders
Personnel
Funding
Building/Labs
3
Foundation Institute ofMaterials Science, IWT
Foundation under Private Law (independent institute)
1. AWT-Association for Heat Treatment and Materials Science (about 250 companies as members)
2. Federal State of Bremen
Overall 163 employees (85 scientists and 73 technicians
Approx 20 % primary funding
approx 80 % third party funding (DFG, AiF, BMBF, EU,…)
Approx. 6.700 m²
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Process & Chemical Engineering
Manufacturing Technologies
Materials Science
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Prof. Dr.-Ing.H.-W. Zoch
Prof. Dr.-Ing. habil.L. Mädler
Prof. Dr.-Ing. habil. Dr.-Ing. E.h.E. Brinksmeier
Heat TreatmentSurface EngineeringMechanical PropertiesPhysical AnalysisLightweight MaterialsMetallographic AnalysisTechnology Broker
Reactive SprayingPowder & ParticleMeasurementsMultiphase Flow,Heat & Mass TransferMelt AtomizationSpray Forming
ECO Center for sustainablemanufacturingMaterial Oriented ManufacturingLaboratory forPrecision Machining
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Process & Chemical Engineering
Manufacturing Technologies
University of Bremen – Department 04 Production Engineering
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18 lectures2 labs and exercises12 degree theses23 doctoral candidates20 Post-Docs
18 lectures6 labs and exercises14 degree theses21 doctoral candidates10 Post-Docs
23 lectures4 labs and exercises30 degree theses26 doctoral candidates9 Post-Docs
Materials Science
Founded in 1982Approx 1800 studentsApprox 180 scientists
Scientific education (2015) Scientific education (2015) Scientific education (2015)
Currently 29 professors9 affiliated institutes
Prof. Dr.-Ing.H.-W. Zoch
Prof. Dr.-Ing. habil.L. Mädler
Prof. Dr.-Ing. habil. Dr.-Ing. E.h. E. Brinksmeier
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IWTStiftung Institutfür WerkstofftechnikBremen 6
Manufacturing TechnologiesOur groups
High Precision MachiningCutting and Forming
forinnovative
manufacturing technologies
Processes and Surface Integrity
Material orientedManufacturing
7
The International Academy for Production Engineering
Collège International pour la Recherche en Productique
Internationale Akademie für Produktionstechnik
Leuven, December 4th, 2015
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The International Academy for Production Engineering
Members– 450 distinguished researchers (Fellows and Members)
from science and industry– 120 young researchers (Research Affiliates)– Membership is limited to invited and active persons who were
recognized by the academy due to their work
Headquaters– Paris, France
Meetings– CIRP Winter Meetings (February, every year in Paris)– CIRP General Assemblies (August, every year in alternating regions and
countries)– CIRP Conferences (several conferences per year)
Leuven, December 4th, 2015
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Motivation– French Engineer General Pierre Nicolau:
„To promote the scientific understanding of production engineeringtechnologies in order to increase productivity of manufacturingindustries.”
Founded in 1951 by– E. Bickel (Switzerland),– D.F. Galloway (UK),– P. Nicolau (France), and– O. Peters (Belgium)
Current vision– To promote research and development among its members from
academia and industry to contribute to the global economic growth andwell being of society.
CIRP – Past and Present
Leuven, December 4th, 2015
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Prof. K. Ueda, JapanCIRP President 2014-2015
Prof. E. Brinksmeier, GermanyCIRP President 2015-2016
CIRP Presidents and General Assemblies
Leuven, December 4th, 2015
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Outline
1. Short Introduction of IWT/Univ. of Bremen, and CIRP
2. Basic views on manufacturing engineering
3. Manufacturing engineering for needs of society and future markets
3.1 Health3.2 Renewable energy supply3.3 Efficient and sustainable mobility
4. Dimensions of manufacturing – sustainable, global and local
5. Conclusion & OutlookSource: KU Leuven – Rob Stevens
Source: IWT Bremen
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Pioneers of Industrial ProductionRemarkable quotes
“Scientists study the world as it is; engineers create the world that has never been.”
Theodore von Kármán, year is unknown
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Industrial ProductionSpectrum of products
Industrial Production
Services
Immaterial Products
Chemical engineeredmaterial goods
Materialized Products
Manufacturedmaterial goods Intellectual creations
sources: Institution of chemical engineers, ZF, fotolia.com, inventors.com
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Industrial ProductionSpectrum of products
Industrial Production
Services
Immaterial Products
Chemical engineeredmaterial goods
Materialized Products
Manufacturedmaterial goods Intellectual creations
sources: Institution of chemical engineers, ZF, fotolia.com, inventors.com
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Core technologies in industrial productionPrinciples of form generation
Tool
Tool movement
Rotation
Work piece
Controlled Shaping(material removal)
Work piece
Tool movement
Lower die
Upper die
Replication
source: after „Werkzeugmaschinen, Grundlagen”, H.K: Tönshoff; Brinksmeier
Work piece
Tool
Tool movement
Work piece
Controlled Additive Manufacturing
- Casting- Metalforming- Molding
- Turning- Milling Metal Cutting- Drilling
- Rapid prototyping- Selective laser melting/sintering- 3D-Printing
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CNC controlCNC control
Turning machinewith crank handle (Ch. Plumier, 1700)
Turning machinewith crank handle (Ch. Plumier, 1700)
Microtome knivesMicrotome knives
1700 1750 18001900
1950
2015
Manufacturing MilestonesHistorical Development of Production Technology
High-speed steel(F. W. Taylor)
High-speed steel(F. W. Taylor)
1990
Assembly Line Production (Henry Ford)Assembly Line Production (Henry Ford)
Steam Engine (J. Watt)Steam Engine (J. Watt)
1850
First lathe (H. Maudslay)First lathe (H. Maudslay)
Industrial robotUNIMATE (George Devol )
Industrial robotUNIMATE (George Devol )
Additive ManufacturingAdditive Manufacturing
1970
Electric motorElectric motor
CAD/CAM tool path generationCAD/CAM tool path generation
Geometry andmaterial properties(Field, Kahles, Peters et al.)
Geometry andmaterial properties(Field, Kahles, Peters et al.)
Industry 4.0Industry 4.0
19601980……
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Manufacturing engineering for needs of society and future markets
sources: after FHG, pictures: melumat.de, Solar Energy World, IWT Bremen
Health Efficient and sustainable mobility
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Renewable energy supply
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Needs of society and future marketsPrecision components for health
source: melumat.de
Health
Society: - health care for extending and improving the quality of life
Example: - eyeglasses
Requirements: - individual lenses- low costs- high quality
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Ophthalmic lenses for eyeglassesManufacturing processes
sources: ADC, Satisloh
Ophthalmic lenses for eyeglasses are generated by precision turning, milling and grinding
Surface finish is performed by different polishing processes
turningmilling polishing Beveling/grinding
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Progressive lens glassesIndividually optimized / customized
sources: Fraunhofer IPT, Aachen
Production of extreme freeform
Reduction of production time < 1 min. per glass
Production without iteration loops
Approx 14 Mio. Freeform progressive lens glasses per year in Germany (2014)
Currently up to 50% growth per year
Over 50% individual progressive lens glasses in the future (90 Mio. pairs per year)
View with individual adapted progressive lens
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Hard Contact lensesManufactured by diamond turning and polishing
sources: Techno-Lens, Menicon, eyenirvaan.com
Contact lenses are manufactured by:
turning and polishing of polymethyl methacrylate (hard)
10% of contact lenses worldwide are hard lenses custom made!
turning polishing Workpiece holder
Contact lens
Polishing tool(covered with slurry)
Slurry
Fixation (with pitch)
Contact lens
Tool
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Soft Contact lensesManufactured by injection molding
sources: Techno-Lens, Menicon, eyenirvaan.com
Liquid monomer is injected into anterior mold
Posterior mold is capped withanterior mold
Liquid monomer hardened throughultra-violet light
90% of contact lenses worldwideare soft lenses mass production!
value of the worldwide contact lens market at approximately $7.6 billion
Upper mold, forms basecurve of lens
Counter mold, forms front curve of lens
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Optical qualityContact lenses and eyeglasses
sources: Zeiss, Issaquah Vision, Reddit, values: Precitech, X-Ram Vision
Hard and soft contact lenses:
Roughness Ra: 8-10 nm
Form accuracy P-V: < 3 µm
Ophthalmic lenses for eyeglasses:
Roughness rms = < 5 nm
Form accuracy P-V = < 5 µm
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Customized manufacturing of hearing devices
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Silicone imprint
Scanning Modeling, generationof CAD/CAM data
3D printing(selective lasersintering, Stereolithography)
Installation ofelectronics
source: PHONAK Hüs
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LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
ConclusionImportance of customized manufacturing for health care
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Source: dpa
Customized manufacturing is a big driving force for growing public health: New manufacturing technologies enable
progress in producing medical devices for a longer and more comfortable life, such as
• Ophthalmic lenses• Hearing devices• Prostheses• Implants• Medical instruments• …
Source: Ceramtec
Source: bestezahnimplantate.de
source: melumat.desource: akustikum.de
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Manufacturing engineering for needs of society and future markets
sources: after FHG, pictures: melumat.de, Solar Energy World, IWT Bremen
Health Efficient and sustainable mobility
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Renewable energy supply
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Space research
Needs of society and future marketsNew manufacturing technologies for renewable energy supply
sources: Solar Energy World
Renewable energy supply
Society: - using of renewable energies, getting rid of oil-based energies
Example: - wind power plants, solar technique
Requirements: - Research to increase efficiency and lifetime
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Needs of society and future marketsNew manufacturing technologies for renewable energy supplyEuropean Commission – 2030 Energy Strategy:
• At least a 27% share of renewable energy consumption• At least 27% improvement in energy efficiency compared to 1990 levels• A 40% cut in greenhouse gas emissions compared to 1990 levels
Source: European Commission
a. Wind power plants
Requirement: Reliable power train (40% share of failure isrelated to gearboxes)
Need for research in gear failure analysis and manufacturing ofenhanced gears
b. Solar technique
Requirements: High efficiency, low cost
Research needs for solar cells and high precision optics
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sources: Solar Energy World, MDA
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Fresnel lenses concentratesunlight 500 times
Focuses sunlight onto small, highly efficient multi-junctionsolar cells
In 2014, a new world recordhas been established:
The newest solar cellsconvert 46% of solar light into electricity
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Fresnel lenses for solar energyConcentrator photovoltaic (CPV) modules
source: Soitec
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Fresnel lensesManufacturing and functional principle
source: lighthouselens.com
Fresnel lense in lighthouse (Fresnel, 1822)
Functional principle of a fresnel lense
Light focusing by a fresnel lense
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Fresnel lenses for solar energyFunctionality of concentrator photovoltaic (CPV) modules
source: Soitec
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230e
Concentrator module of a photovoltaic systemTIR facets
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Solar concentrator with hybrid PMMA lens
Solar cellHeat sink Aspheric lense
Hybrid lenseHybrid lens with total internal reflectionSize: 40 mm x 40 mm625 elements per m2
Mold insert:Diamond turned; material:Nickel on steel substrate
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Conclusion
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Manufacturing engineering makes a significant contribution to renewable energies, e.g. within the fields
• Solar technology• Wind power plants
Another challenging field for further research:
• Energy storage
Importance of manufacturing for renewable energy supply
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source: Fotolia.com
source: IWT Bremen
sources: wikimedia, Solar Energy World
source: MDA
Source: Solar Energy World
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Manufacturing engineering for needs of society and future markets
sources: after FHG, pictures: melumat.de, Solar Energy World, IWT Bremen
Health Efficient and sustainable mobility
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Renewable energy supply
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Needs of society and future marketsNew manufacturing technologies for efficient and sustainable mobility
sources: IWT Bremen
Efficient and sustainable mobility
Society: - Efficient and sustainable mobility
Examples: - Fine finishing of gears
Requirements: - Research to increase efficiency and lifetime of gearboxes
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Pioneers of Industrial ProductionRemarkable quotes
“There will be built not more than 5000 vehicles in total. The reason is that there are not enough chauffeurs to steer it.”
Gottlieb Daimler, year is unknown
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Challenges for power trains:• Reduction of the design space and weight
of gearboxes without lost of transmissible power Resource efficiency
• Reducing the gear noise• Increase energy efficiency and reduce CO2
emissions by reducing the power loss in gearboxes Energy efficiency
Sustainability
Source: Porsche AG
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Gear ProductionNew manufacturing technologies for efficient and sustainable mobility
Global developments of CO2 - Limits :
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Gear Production – Some Figures:
• Sales worldwide: approx. 200 – 250 billion € per year• Produced cars: approx. 70 million per year
• Average: 15 gears per car gearbox• > 1 billion gears per year for car gearboxes
Source: IPPCSource: Hansen Industrial Gearboxes, Antwerpen
Source: ZF
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Research in Gear ManufacturingNew manufacturing technologies for efficient and sustainable mobility
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Surface roughness: Shape accuracy: Surface integrity:
Fields of research:
Technology transfer:
Fine finishingof gears withhigh shapeaccuracy:
Sources: IWT Bremen
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Research in Gear ManufacturingFine finishing of gears with high shape accuracy
time
tem
pera
ture
geargrinding
heattreatment
deburring, cleaning
softturning
gearhobbing
Standard process chain of gear production:
Demands on gears: reduction of:
• noise emission• weight• Volume
increase of:• torque/power• lifetime
Tasks of gear grinding:• reduction of:
• surface roughness
• increase of: • gear tooth quality
IWT
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Research in Gear ManufacturingFine finishing of gears with high shape accuracy
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vibratory finishing(var.)
surf
ace
roug
hnes
s
shape deviation
skive hobbing(IT 6 – 8)
continuous gear grinding(IT 3 – 6)
gear profile grinding(IT 2 – 6)
state after heat treatment
low
high
highlow
fine finishing- down to “near optical”
surface quality
honing(IT 5 – 7)
source: Gleason-Pfauter
Surface roughness and shape deviationdepending on different finishing processes
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Research in Gear ManufacturingFine finishing of gears with high shape accuracy
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Sa = 0.61 µmSz = 3.92 µm
Sa = 0.012 µmSz = 0.081 µm
Fine finishing of gears – Research achievements:
• New 2-step-approach with elastic wheel (2nd Step) leads to highest surface quality:• Sa = 0.012 µm• Sz = 0.081 µm
• Gear tooth quality of preceding finishing can be kept• Low risk of thermal damage• Positive influence on surface integrity (compressive residual stresses)• Applicable on conventional gear grinding machines• Subsequent processes (vibratory finishing, lapping, honing, polishing) can be omitted
a) pre-ground b) fine-finished
Surface roughness before (a) and after (b) fine finishing (WLI measurements):
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IWTStiftung Institutfür WerkstofftechnikBremen
Conclusion
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Manufacturing engineering provides the technologies to meet future requirements of resource and energy efficiency.
Example:
Gear manufacturing
Very high number of units
Big impact of gears on
• Resource efficiency• Energy efficiency
in mobility
Importance of manufacturing for efficient and sustainable mobility
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Source: IWT Bremen
Source: IWT Bremen
Source: Hansen Industrial Gearboxes, Antwerpen
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Importance of Manufacturing
Manufacturing is still the driving force of the European economy and it provides:
• Creates about 20% of all jobs (more than 30 million)• Largely in SMEs in 25 different industrial sectors
• About 75% of EU exports are related to manufacturing• In manufacturing: over 80% of EU private sector R&D expenditure
Andrea Gentili, “Manufuture”, 2012
European Perspective:
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Categories of Manufactured GoodsLocal Manufacturing matters
About half of all manufacturing occurs
near the customer:
Source: McKinsey, Manufacturing the Future, based on data from IHS Global insight, OECD, ASM 2010
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Manufacturing employment by groupLocal Manufacturing matters
The importance of localmanufacturing continues
to grow:
Source: EU KLEMS; OECD; McKinsey Global Institute analysis
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Competitive Sustainable Local ManufacturingParadigm by Jovane and Seliger
Competitive Sustainable Global Manufacturing paradigm:„Global manufacturing industries constitute factories located in countries with
competitive advantage (tax, labor cost, etc.)”
Competitive Sustainable Local Manufacturing paradigm:„Establishing local manufacturing industries for local customers.”
Motivation: The proximity of the manufacturer to the final customer is critical to product delivery, fit and service.
Local Perspective:
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Competitive Sustainable Local ManufacturingParadigm by Jovane and SeligerCompetitive Sustainable Local Manufacturing paradigm:
„Establishing local manufacturing industries for local customers.”
Consequences:
• Creates local jobs in product design, in the manufacturing of these products and in their service
• Liberated local capability creates new economic momentum based on manufacturing new products, characterized by:
• their need to be tailored to individual buyers• be modified during their lifetime to re-adapt to
changing needs of customers• Requires new manufacturing technologies and a new
generation of manufacturing professionals• “Local manufacturers are more likely to innovate
because of their close proximity to their customers.”
Eyeglasses
Additive Manufacturing
Source: KU Leuven –Rob Stevens
All –in-onedigital surfacingcenter
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Additive Manufacturing- a local and sustainable technology
Sustainable Manufacturing“meets the needs of the present without compromising the ability of future generations
to meet their own needs.“
„Manufuture“ Conference 2007
Additive Manufacturing – Potentials:
• Reduced raw material usage and energy consumption, which is a key contribution to environmental sustainability.
• Healthcare products customized to the needs of individual consumers, which is expected to significantly improve population wellbeing.
• On-demand manufacturing, which presents an opportunity to reconfigure the manufacturing supply chain to bring cheaper products to consumers faster while utilizing fewerresources.
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Source: Huang, Liu, Mokasdar, Hou: Additive manufacturing and its societal impact::a literature review, Adv. Manufacturing Technology 67, 2013
Source: KU Leuven – Rob Stevens
Source: Lincoln Electric
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
… Additive Manufacturing
Manufacturing Engineering provides the basis to be able to cover needs of society in areas such as:
• Health• Renewable energy supply• Efficient and sustainable mobility
The importance of local manufacturing continues to grow:
A competitive sustainable local manufacturing
requires new manufacturing technologies like…
50
Conclusion
Health Efficient and sustainable mobility
Renewable energy supply
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Additive ManufacturingAdditive Manufacturing
Source: K
U Leuven –
Rob S
tevens
LFMLabor für Mikrozerspanung
IWTStiftung Institutfür WerkstofftechnikBremen
Thank You Audience, and Congratulations toProf. Jean‐Pierre Kruth!
Thank You Audience, and Congratulations toProf. Jean‐Pierre Kruth!
DÖ
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