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This presentation may contain confidential and/or privileged information.Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
Performance Trends in Additive Manufacturing Technology
Anand Prakasam
EOS GmbH
EOS Corporate Presentation | 2
Today’s Presentation format
- AM OVERVIEW
- Key contributors for successful production- validated process
- Comparing the hardware productivity
- Improvements in software, Quality Monitoring , raw materials
- Overview on Additive minds
- Summary
EOS Corporate Presentation | 3Source: McKinsey Global Institute Analysis
3D Printing is seen as one of the twelve economically disruptive technologies
MobileInternet
Automation of Knowledge Work
Internet of Things
CloudTechnology
Advanced robots
AutonomousVehicles
Next-Generation Genomics
EnergyStorage
Advanced Materials
Advanced Oil and
Gas Exploitation
RenewableEnergy
3D Printing
EOS_Company-Presentation.pptx | EOS | 4
“The Manufacturing Technology that will change the World“The Economist, 2011
Media: Additive Manufacturing _ 3D Printing
EOS Corporate Presentation | 5
Yesterday:
Prototyping
Technologicalcapabilities
Until 2020:
Production ramp up
▪ Quality control ▪ Differentiation▪ Total cost of Ownership
(TCO)▪ Automation▪ Technology integration
Today:
Pre-production
▪ Part quality▪ Process robustness▪ Cost per part
Growth of AM Industry
EOS Corporate Presentation | 6
Key elements for Successful Production
Balanced triangle
Process
MaterialSystem
Part qualityProcess robustness
IndustrializationEf
fect
s
EOS_Company-Presentation.pptx | EOS | 7
Additive Subtractive
Manufacturing Processes
EOS_Company-Presentation.pptx | EOS | 8
Laser-sintering process: Key-technology for e-Manufacturing
Material ProductLaser-Sintering
Process of Laser Sintering
▪ video
EOS Corporate Presentation | 9
Key elements of Additive Manufacturing
Balanced triangle
Process
MaterialSystem
Part qualityProcess robustness
IndustrializationEf
fect
s
EOS Corporate Presentation | 10
Productivity improvement
Productivity can be improved by the following
- Hardware upgrade – Process optimisation , multiple lasers etc
- Software enhancement – Segmentation etc
- Smart AM designs
EOS Corporate Presentation | 11
Hardware Productivity Comparism
• Original STL file
• Possible Orientation
• Build Time Estimation in M290, M400 & M400-4
• Conclusions and Remarks
EOS Corporate Presentation | 12
Original STL files – Build 1
EOS Corporate Presentation | 13
Possible Orientation
• Considered this orientation to accommodate as many parts as possible and to have minimum build time
• Supports generated outside are easily accessible for post processing
• The orientation shown in the image is for M290 and for M400-4, this need to be rotated considering the recoating direction
Build 1
EOS Corporate Presentation | 14
Build Time Estimation – Build 1
Can accommodate 2 parts each (2+2)
Approximate Build Hours : 68 Hours
M290 , DirectPart 30 Microns
Can accommodate 4 parts each (4+4)
Approximate Build Hours : 46 Hours
M400-4 , DirectPart 30 Microns
EOS Corporate Presentation | 15
Build-1 M4-SF-1 KW laser
With custom layer thickness
Approximate Build Hours : 39 Hrs
EOS Corporate Presentation | 16
Build Time Estimation
Part Name: 248 & 549
System Total no.of Parts Build Time
M290, 1 x 400w 2+2 68 Hrs
M400, 1 x 1000w 4+4 39 Hrs
M400-4, 4 x 400w 4+4 46 Hrs
EOS Corporate Presentation | 17
Original STL files – Build 3
Axial Fan Centrifugal
EOS Corporate Presentation | 18
Possible Orientation
• Considered this orientation to get the minimum build time
• Supports generated outside are easily accessible for post processing
• Supports are generated in the hollow profiles of Centrifugal part, but it’s accessible for removal
• The orientation shown in the image can be used for both M290 and M400-4
Build 3
EOS Corporate Presentation | 19
Build Time Estimation – Build 3
Can accommodate 2 parts each (2+2)
Approximate Build Hours : 16 Hours
M290 , DirectPart 30 Microns
Can accommodate 5 parts each (5+5)
Approximate Build Hours : 9 Hours
M400-4 , DirectPart 30 Microns
EOS Corporate Presentation | 20
Build-3 M4-SF
With custom layer thickness
Approximate Build Hours : 8:02 Hrs
EOS Corporate Presentation | 21
Build Time Estimation
Part Name: Axial fan & Centrifugal Version
System Total no.of Parts Build Time
M290, 1 x 400w 2+2 16 Hrs
M400, 1 x 1000w 5+5 8:02 Hrs
M400-4, 4 x 400w 5+5 9 Hrs
EOS Corporate Presentation | 22
EOS M 290: the complete solution that meets all customer requirements
EOSPRINT 2.0 with ParameterEditor
▪ Up to 20% productivity increase possible
▪ Workflow-based graphical user interface reflecting the AM CAM process makes it intuitive and quick to learn
▪ New exposure strategies enable production of previously unbuildable parts by avoiding support structures in areas where they cannot be removed
▪ ParameterEditor provides even greater freedom and openness for material development, application-specific parameter optimization and process development
Productivity
Matthias HerkerApplication Engineer Additive Manufacturing at AUDI AG
Thanks to plane segmentation and new exposure
strategies, we are able to produce faster than ever before
without sacrificing quality. In the future, we will significantly
improve our productivity, cost-effectiveness as well as the
general feasibility.
Samuel BlowerDevelopment Engineer at Materials Solutions
New features such as ‘Flow Optimisation’ have allowed us
to build things that were not possible with the previous
software.
EOS Corporate Presentation | 23
EOSTATE
System
EOSTATE
Laser
EOSTATE
Powder-Bed
EOSTATE
MeltPool
EOSTATE Exposure OT
EOS M 290: the complete solution that meets all customer requirements
EOSTATE Monitoring Suite
▪ enables to conduct a real-time quality assurance of all production and quality relevant date
▪ leads to considerable savings in QA efforts and costs
▪ offers the most extensive portfolio in the additive manufacturing market
Elements EOSTATE Monitoring Suite:
Extensive quality control features
Powered
by
Powered by
EOS Corporate Presentation | 24
EOS M 290: the complete solution that meets all customer requirements
▪ Reliable and repeatable quality – day in, day out no matter how complex the build jobs are
▪ Homogeneous part properties – from part-to-part, build job-to-build job and machine-to-machine
▪ Comprehensive statistics that give confidence for production and serve as a complete documentation of a customers Quality Management
DMLS quality fulfils the demanding requirements in production
EOS ensures constant metal material quality
EOS Corporate Presentation | 25
EOS applies thorough quality assurance in materials and process development
Source: EOS
Measurement of density and mechanical properties
EN ISO 3369 "Impermeable sintered metal materials and hardmetals – determination of density"
Zwick/Roell Z050, max. force 50kN, force accuracy according to ISO 7500-1, extensometer accuracy according to ISO 9513
Series1
Series2
Series3
1030
1050
1070
1090
1110
1130
1150
12
3
1128
1123
11431139
1147
1133
1140
y-Richtung
yield strength [MPa]
x-Richtung
View on platform:
Mechanical data depending on positio
Density cubes
Tensile bars
EOS Corporate Presentation | 26
EOS has thorough quality assurance procedures for the production of powder materials
Source: EOS
▪ Production batches of powder are tested on an EOSINT M system with defined setup (QA-machine)
▪ Parts tested for tensile properties and density
▪ Results documented as "Declaration of laser-sintered properties"
QA of powder materials (2)
EOS Corporate Presentation | 27
Customer Voices Aerospace
2
7
We produce parts for one of the world's most advanced engines, the geared turbofan, with one of the world's most advanced 3D printing technology by EOS.
Dr. Karl-Heinz DuselDirector of Rapid Technologies at MTU Aero Engines
The thermal elements produced using the EOS M 290 withstand temperatures of up to 1,000°C and continue to be fully functional at twice the speed of sound.
Katharina KreitzManaging Director at Vectoflow GmbH
Borescope boss made of nickel-based alloy Flow measurement probe made of nickel-chromium alloy
EOS Corporate Presentation | 28
Customer Voices Industry
2
8
This is AM in its most advanced form, using the 3D printing system with four lasers developed by EOS enables a highly efficient industrial series production.
Vladimir NavrotskyHead of Technology and Innovation at Siemens Energy Service O&G
EOS technology gave us the opportunity to offer exactly the right solution for our customers who have a specific challenge.
Sebastian KießlingManaging Partner at Euro-K GmbH
Repaired burner tip Complex burner made of EOS NickelAlloy IN718
EOS Corporate Presentation | 29
Customer Voices Medical
2
9
We are amazed by the application possibilities and the high-quality production that can be achieved using the EOS system.
Christoph ErhardtDirector Additive Manufacturing at Alphaform AG
Together with the knowledge of the doctors it was the high quality of the implant that served as a guarantee for the enduring success of the procedure.
Atif CakorR&D Manager at Instrumentaria Co., J.S.C.
Permeable skull implant made of titanium Lightweight hip implant made of titanium
EOS Corporate Presentation | 30
EOS Additive Manufacturing for Tooling Applications
Smarter design of conformal cooling channels: Cost savings, cycle time reduction, increased performance, scrap rate reduction
Injection Molding Repairing Die Casting Rapid Tooling
Salcomp tool insert and injection-moulding part PEP (Pôle Europeen de Plasturgie) tool insertEcoparts tool insert
▪ Challenge: Enable precision cooling for production of mobile phone plastic parts
▪ Solution: Improved cooling design. Manufacture of core inserts using EOS technology
Result
▪ Production increased by 56,000 units/month
▪ Rejection rate reduced from 2% to 1.4%
▪ Annual cost savings of approx. 20,000 euros
▪ Challenge: Repair a partially damaged tool insert
▪ Solution: Generation of a new reference surface; Positioning of part in EOS machine. On-top construc-tion of missing parts
Result
▪ Save costs of a complete new insert construction
▪ Reduction of lead time: partial construction instead of complete construction
▪ Challenge: Injection moulding tooling for 50,000 electrical component parts
▪ Solution: Redesign of inserts with conformal cooling channels; inserts built in EOS MaragingSteel MS1
Result
▪ Lead time and cost reduction
▪ Higher mould productivity
▪ Better thermal management
▪ Challenge: Build a tool insert for a die casting application
▪ Solution: Cooling system optimisation; insert built via DMLS on EOSINT M 270 in EOS MaragingSteel MS1
Result
▪ Significant cycle time reduction
▪ Improved life time of inserts
Innomia tool insert for die casting
Sources images (left to right): Innomia, Ecoparts, PEP
EOS Corporate Presentation | 31
EOS Corporate Presentation | 32
EOS: Technology and market leader for design-driven, integrated e-Manufacturing Solutions
3
2
Dr. Adrian Keppler, Eric Paffrath, Dr. Hans J. Langer, Dr. Tobias Abeln (from left to right)
▪ Privately-owned, founded in 1989 by Dr. Hans Langer
▪ Focus on end-to-end Solutions for Additive Manufacturing: from part design and data generation to part building and post-processing
▪ Active in a variety of industries, focus on medical, aerospace, industrial applications
▪ EOS is committed to: Innovation – Quality – Sustainability
▪ Revenue FY 17/18: ~ 345 Mio €
▪ Revenue Increase ~ 20%
▪ Invest 14% of revenue in R&D
EOS Headquarters in Krailling, Germany
EOS Corporate Presentation | 33
EOS Shaping the future of Manufacturing
Systems Materials Software Services
An integrated portfolio to provide customer value
Process AMConsulting
EOS Corporate Presentation | 3434
EOS Corporate Presentation | 35
We are Additive Minds!
>250 Successful Customer Projects
in >25 Countries#1 Consultancy in AM Market > 100 of AM Experts: largest team world wide
8 Trainings &12 Consulting Packages5 global Innovation Centres
ADDITIVE MindsBest-in-class Consulting for Industrial 3D-Printing
For further information:EOS GmbH Electro Optical SystemsRobert-Stirling-Ring 1 82152 Krailling/Munich Germanywww.eos.info
EOS Corporate Presentation | 37
Design for AM
Lattice Structure Design
Parameter Editing Workshop
Melt Pool Monitoring
360° Improvement Programme
Cost per part optimisation
Factory Layout
Additive Manufacturing Qualification
Operational Qualification Support
Innovation with 3D Printing
Fundamentals of metal 3D Printing
Part Screening & Selection
AchieveAM
Readiness
DevelopAM
Application
Ramp-upAM
Production
Quality & Scale
Production
Additive Minds Consulting
Certification
ScalingProductio
n
Re-/Designfor AM
Process and Material Optimization
Optimizationof
Production
Fast ProductionImplementation
Introductionto AM
Part Selection
EOS Corporate Presentation | 38
Siemens invested €21.4 m into its AM facility
Image Courtesy of Siemens
EOS Corporate Presentation | 39
N New era of Manufacturing
3
9
EOS Corporate Presentation | 40
Customers have a strong footprint in Aerospace
Source: EOS
EOS – sample customers Aerospace Industry (incomplete)
EOS Corporate Presentation | 41
thank you for your TIME and ATTENTION