Transformational Use of

Additive Manufacturing

Jason Barkla GDip(CAD/CAM) BTech(IndDes) MMmDes Dip(CompetitiveManufacturing)

Business Development Manager

A.W.Bell Pty Ltd

Introduction

• A.W.Bell and the Need for Transformation

• A.W.Bell and Additive Manufacturing

• The Transformational Journey Begins

• Additive Manufacturing + ABE Casting Process

• Leveraging the power of Additive Manufacturing

• A.W.Bell Now, the Journey Continues

A.W.Bell and the Need for Transformation

• Founded in 1952 as pattern-maker

• Transformed into an investment casting foundry

• Added tooling, post-machining and sandcasting

• Additive Manufacturing established in 2000

• ISO9001 and ISO14001 accredited

• Automotive, medical, general castings, some defence

A.W.Bell and the Need for Transformation

• From 2005 declining demand for tooling and product

for automotive and other commodity industries

• One of several investment casting foundries in the

region

• GFC in 2007-2008 saw the business contract

• Generally uncertain future in the face of imports

• Time to embark on a transformative journey

• Established in 2000

• Over 1000 projects and many 1000s of parts

• Specialising in complex metal products and

prototypes

• Additive Manufacturing with investment casting

• Many parts in heavy-duty end-use applications

A.W.Bell and Additive Manufacturing

• Proof of concept in the end material

• Complex parts with many features and undercuts

• Enormous range of alloys ferrous and non-ferrous

– A356/A357 aerospace grade aluminium

– Super Duplex and other stainless steels

– High tensile steels

– Alloy Bronze for naval applications

– Other air-melt high-performance metals

A.W.Bell and Additive Manufacturing

A.W.Bell Rapid Parts

3D Systems Thermojets

• First 3D Systems Thermojet commisioned in 2000

• Within 2 years running 3 Thermojets

• Very successful allowing parallel testing of parts

while developing soft tooling concurrent with hard

tooling

• Also became manufacturing process in it own right

• Pros

– Slotted straight into investment casting process

– Reasonably fast at about 1.5hrs per 10mm

– Good surface finish on upward facing surfaces

• Cons

– Poor surface finish on downward or overshadowed surfaces

due to supports

– Fragile

– High maintenance machines

– Envelope size

A.W.Bell Rapid Parts

3D Systems Thermojets

A.W.Bell Rapid Parts

Stratasys Vantage S FDM

• Stratasys Vantage S purchased in 2005 a response

to growing need for complex pattern and tooling

manufacture

• Used in conjunction with zinc spray for tooling

• Used as sandcasting patterns directly or as masters

• Other uses on as need basis

• Pros

– Accurate

– Strong

– Stable

– Robust technology

– Real thermoplastic

• Cons

– Slow

– Expensive materials

A.W.Bell Rapid Parts

Stratasys Vantage S FDM

A.W.Bell Rapid Parts

3D Systems SLA 500

• 3D Systems SLA 500 commissioned at start of 2010

• Replaced ageing Thermojets

• Used mainly for investment casting patterns

• Other uses on as need basis

• Pros

– Accurate

– Strong

– Fast

– Large envelope

• Cons

– Large inventory of resin sitting in vat

– Failed builds can be very messy

A.W.Bell Rapid Parts

3D Systems SLA 500

• Stereolithography process using special algorithm

• Produces hollow resin patterns for investment casting

• Excellent surface finish, robust yet light-weight

• Patterns up to 500x500x580mm, can be joined

• Very accurate and stable, do not warp, grow or shrink

3D Systems SLA Quickcast for Investment Casting

3D Systems SLA Quickcast for Investment Casting

• Good surface finish

• Dimensionally accurate castings

• Large castings from single pattern

• Castings can be welded to create much larger parts

• Incredible choice of metals and properties

The Transformational Journey Begins

• Redefining the vision

• Lean training from top to bottom

• Building and strengthening networks and reputation

• ABE casting process

• Lifting quality standards

• Transform A.W.Bell into a supplier of complex metal

components with high mechanical properties, into the

defence and aerospace sectors.

The Transformational Journey Begins -

Redefining the Vision

• All employees were trained in lean and awarded

certificates and diplomas in competitive

manufacturing.

The Transformational Journey Begins -

Lean training

• A.W.Bell is active in regional organisations and well

engaged with governments

• Inducted into the Victorian Manufacturing Hall of

Fame and winner 2013 Medium Manufacturer of the

Year

The Transformational Journey Begins -

Networks and Reputation

• Advanced investment casting process

• High strength, high quality

The Transformational Journey Begins -

Aluminium Billet Equivalent (ABE) Casting Process

• Pursued and gained AS9100C accreditation

• Cultural shift required throughout organisation

The Transformational Journey Begins -

Lifting Quality Standards

• A.W.Bell has developed a world leading casting

process called ABE (Aluminium Billet Equivalent)

• Developed for Aerospace application

• High strength and high density parts

• Allows sophisticated geometries that cannot be

machined from billet

Additive Manufacturing + ABE Casting Process

• Additive Manufacturing supports complex shapes

• Quick turnaround of patterns, perfect for R&D

• Dimensional accuracy and stability

• Removes the need for very expensive and complex

CNC cut aluminium tooling

• Proof of concept for conservative sectors

Additive Manufacturing + ABE Casting Process

Additive Manufacturing + ABE Casting Process

• Advanced shape with challenges for castability

• No funds available for tooling

• Additive Manufacturing + ABE used to attempt FAI

• Results in order for tooling and proper FAI

• Project has now moved to production order

Leveraging the Power of Additive Manufacturing -

Aerospace Component 1

• Complex shape requiring high mechanical properties

• Additive Manufacturing + ABE used to make samples

• Results in order for tooling and FAI components

• FAI now in progress

• Significant export work to be won

Leveraging the Power of Additive Manufacturing -

Aerospace Component 2

• Cylinder head with complex water jacket

• Additive Manufacturing used to make plastic cores for

understanding manufacturing and assembly

• AM sand cores being tested to accelerate FAI

• Potential for AM sand cores to be used in production

• Supports leadtime critical project

Leveraging the Power of Additive Manufacturing -

Engine Component

• Significant progress made in the last 4 years

• Accredited as an aerospace supplier

• Continuing drop-off in traditional product and markets

• Numerous foundries closed throughout the region

• Growing order base and interest from local and

export customers

A.W.Bell Now, the Journey Continues

Thank You for your time

Jason Barkla GDip(CAD/CAM) BTech(IndDes) MMmDes Dip(CompetitiveManufacturing)

Business Development Manager

A.W.Bell Pty Ltd