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Version 2.1 Confidential © 2018 FIT AG
New product solutions by using WAAM
as a new technology in AM
3DMP® FORUM
June 21, 2018 in Berlin
Philip Emmerling
Development Engineer
Version 2.1 Confidential © 2018 FIT AG
FIT AG – AM Experience since 1995
• Founded in 1995, 330 employees
• >10,000 m² manufacturing space
• Revenue in 2017: € 25.4 million
• CAGR > 25 % during 2013
• Operating the world’s largest aluminum
additive manufacturing facility
August 1995
Founded as a
Rapid Prototyping
service bureau
1997
First research project
with paper lamination
technique
1998
Starting laser sintering
2003
Successful Rapid
Tooling with DMLS
metal tools
2004
Unique FIT ERP system
installed for quicker quoting
and most efficient prototyping
production
2005
First EBM system
running titanium
2006
First-time presentation
of microstructured parts
at Euromold
2008
Sintermask Sweden
acquired
EN ISO 13485 achieved (medical certification)
2009
netfabb founded
2010
Skin Freeze
2012
FDA complianceachieved
2013
First four laser
metal machines
worldwide installed
(SLM 500)
2014
7 SLM machines dedicated
to metal, including 3 large
frame SLM 500
20154 Electron Beam Guns
20 CO2 Laser
40 Fiber Laser
2018
Implementation of
Center for advanced
AM technology
2016
Operation of the first
FAB@FIT factory
2018
Opening FIT Campus
with Boarding House
2017
Opening new
FIT Office Tower
First 5-axis
WAAM system
GDP system
Version 2.1 Confidential © 2018 FIT AG
Motivation: Worldwide Leadership in AM Technologies
AM system forworldwide
high qualitymanufacturing with
FIT certified AM equipment
FIT is theworldwide leading
manufacturer specialized in
Additive Manufacturing
Significantly lower costs and faster execution going into
Additive Manufacturing
for FIT customers
Our mission! For customer success!
Our clients choose FIT as preferred partner due to
proven success.
As a leading AM Company we support our customers
in five strategic fields of business.
Increasing complexityStrategic partnerships for long-term success
Strategic AM
Consulting
Prototyping
Services
Spare Parts
on Demand
ADM
Components
Production
Tools
Version 2.1 Confidential © 2018 FIT AG
Business Units
Prototyping
• Concept models
• Functional prototypes
• Pre-production runs
Additive Design and Manufacturing
• Additive engineering
• Component manufacturing
• Volume manufacturing
Research and Development
• System development
• Process development
• Material development
Version 2.1 Confidential © 2018 FIT AG
Traditional model making, jigs
and tools
Segments & Solutions
Design & mockups
Functional parts & castings
Pre-production runs
Functional prototypes with
individual quality agreement
Solutions @ Prototyping
ADM-Q
Final part produced under individual
Quality agreement
ADM-V
Volume Manufacturing
ADM-CV
Customized Volume Manufacturing
ADM-E
ADM and 3S Engineering
ADM-W
Additive Design & Manufacturing
Workshops
ADM-S
Spare Parts on Demand
Solutions @ Production Solutions @ R&D
Integrated software(MES, workflow, quality control, statistics…)
Hardware development
Material development
Process automation
Version 2.1 Confidential © 2018 FIT AG
Overview: Range of Technologies at FIT
Plastic Metal ADM Measuring Surface Finising
Drop on Powder Investment Casting ADM Workshops CT Scanning Metal Coating
Stereolithography Laser Melting ADM Engineering 3D Scanning Assembling
Fine Layer Technique Electron Beam Melting ADM Quality Optical Profilometry Spray Painting
Full Color Polyjet WAAM ADM Volume Mfg. Metallography Precision Engineering
Gel Dispensing Printing Lathing & Milling ADM Spare Parts Tensile Testing Shot Blasting
Selective Laser Sintering Ceramic ADM Customized
Volume Manufacturing
Optical Microscopy
Fused Deposition ModelingCeramic Printing
3D Coordinate
Measurement
Vacuum Casting / RIM Element Analysis
PA Casting Surface Roughness
Lathing & Milling Powder Analysis
Lamination
Model Building (conv.)
Elastomers
Injection Molding
Version 2.1 Confidential © 2018 FIT AG
Always a Step Ahead – Technology Integration @ FIT
More than 20 years of expertise
• Adoption of new technologies
• Evaluation of new technologies
On-going improvements in all available
technologies and application
development for new products
Version 2.1 Confidential © 2018 FIT AG
Time Schedule
April: Gefertec
machine arrives
August – October:
- FIT sample parts (hollow sphere, propeller)
- Complex parts (brackets, half-shell)
Since January 2018:
- Constantly incoming customer
orders
2018
2 employees integrate technology
into manufacturing work flow in
FIT facility
May – July:
- Parameter evaluation
- Qualification of material
- Maraging steel, aluminum,
stainless steel
Adoption steps of the technology:
November – December:
- Process optimization
- Copper-aluminum, Inconel
- First incoming customer orders
April 2018:
WAAM team expands by a trainee
and a MSc student
2017
Processing of:
- Multimaterials
- Titanium
Further development:
- Simulation of deformation and
temperature
- Internal structures
Version 2.1 Confidential © 2018 FIT AG
Technology and Comparison
RADICLE
Powder bed
WAAM
Laser deposition
Version 2.1 Confidential © 2018 FIT AG
Technologies in Comparison
Cost reduction
Material efficiency
Mechanical properties
Post-production
Part size
Build rate
Accuracy
Complexity
Reproducibility
WAAM Powder Bed / Laser Deposition
Version 2.1 Confidential © 2018 FIT AG
Process Chain @ WAAM
Customer
CAM toolpathing
Shape &
deformation controlQuality check
Simulation
Assigning of
parameters
Finished
part
Finished Part
WAAM
manufacturing
Challenge @ FIT
Customer
CAD model
CNC
finishing
Design adjustment
for WAAM
Version 2.1 Confidential © 2018 FIT AG
Design Adjustment for WAAM
Customer CAD model
FIT offset
Removal of critical
elements, e.g. holes
Adjusting of radii
Removal of undercuts in
building direction
Version 2.1 Confidential © 2018 FIT AG
Process Chain @ WAAM
Customer
CAM toolpathing
Shape &
deformation controlQuality check
Simulation
Finished
part
Finished Part
WAAM
manufacturing
Challenge @ FIT
Design adjustment
for WAAM
Customer
CAD model
CNC
finishing
Assigning of
parameters
Version 2.1 Confidential © 2018 FIT AG
WAAM Buildup Strategies
3-axis buildup
with substrate plateRadial buildup base body 3-axis buildup of flaps
Combination of different buildup strategies within one part
First step: radial buildup of base body
Second step: 3-axis buildup of fittings
Version 2.1 Confidential © 2018 FIT AG
Offset
WAAM CAM Toolpathing and Parameter Assignment
Profile
MeanderCombined strategic planning with
various welding parameters
Welding parameter 1
Welding parameter 2
Welding parameter 1
Welding parameter 2
Different strategies depending on part geometry
Version 2.1 Confidential © 2018 FIT AG
Process Chain @ WAAM
Customer
CAM toolpathing
Shape &
deformation controlQuality check
Assigning of
parameters
Finished
part
Finished Part
WAAM
manufacturing
Challenge @ FIT
Design adjustment
for WAAM
Customer
CAD model
CNC
finishing
Simulation
Version 2.1 Confidential © 2018 FIT AG
Complete manufacture of part Buildup on semimanufactured part Hybrid manufacturing
Internal structures
Selective enforcement of
prefabricated part Massive coating of parts / multimaterials
Application samples
Production Process WAAM (Wire Arc Additive Manufacturing)
Version 2.1 Confidential © 2018 FIT AG
- Testing of tensile strength
- Measurement of hardness
- Measurement of density
- Microstructural analysis
- Computertomography
Qualification of materials & process monitoring
Cross section Microstructural analysis
Process monitoring
Production Process WAAM (Wire Arc Additive Manufacturing)
Version 2.1 Confidential © 2018 FIT AG
Production Process WAAM (Wire Arc Additive Manufacturing)
Material properties & benefits
− Material efficiency by targeted material application
− High build rates of up to 600 cm³/h
− Easy storage
− Lower material cost by use of wire material
− Huge variety of usable materials – nearly all weldable wires
Version 2.1 Confidential © 2018 FIT AG
Process Chain @ WAAM
Customer
CAM toolpathing
Shape &
deformation controlQuality check
Simulation
Assigning of
parameters
Finished
part
Finished Part
WAAM
manufacturing
Challenge @ FIT
Design adjustment
for WAAM
Customer
CAD model
CNC
finishing
Version 2.1 Confidential © 2018 FIT AG
CNC finishing
Version 2.1 Confidential © 2018 FIT AG
Quality Assurance
ComputertomographyOptical scanning Parameter evaluation
Version 2.1 Confidential © 2018 FIT AG
Finished Part: Engine Cover
Preparation time: 10 h
Material: 1.5125 G3Si1
Part size: 442 x 442 x 100 mm
Deposition rate: 350 cm³/h
Welding time: 13 h
Volume of
finished model: 3,080 cm³ (24 kg)
Engine Cover
Version 2.1 Confidential © 2018 FIT AG
More Practical Examples
PropellerBrackets
Preparation time: 4 h
Material: G3Si1 1.5125
Part size: 200 x 240 x 240 mm
Deposition rate: 230 cm³/h
Welding time: 1h
Volume of finished
part: 880 cm³ (7 kg)
Motorsport
Aerospace
Machinery
Preparation time: 6 h
Material: 1.4430 X2CrNiMo19_12
Part size: 480 x 200 x 90 mm
Deposition rate: 300 cm³/h
Welding time: approx. 8 h
Volume of
finished model: 1,500 cm³ (12 kg)
Version 2.1 Confidential © 2018 FIT AG
Why WAAM?
Conclusion
− Technology leader im in the field of Additive Manufacturing
− 25 years of experience in rapid prototyping
Resources @ FIT:
− Total of 10,000 m² manufacturing space at FIT Campus
− More than 300 employees: 25 employees in R&D / Advanced AM
Technology / Application development
Why FIT?
New technologies: High potential for future
− New materials, new product solutions, hybrid solutions
Benefits of the technology:
− Augmented variety of usable materials
− Spare Parts on Demand
− Material efficiency
− High degree of automatization
− Cost optimization (no tooling costs)
Version 2.1 Confidential © 2018 FIT AG
Thank you for your
attention.
Vision Without Execution Is Just Hallucination !
3DMP® FORUM
June 21, 2018 in Berlin
Philip Emmerling
Development Engineer