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Sustainability approach by Design Optimization for Advanced Layer Manufacturing
Udo BehrendtBusiness Development
Manager Aerospace
E-Manufacturing_May2012_UB.pptx | EOS | 2
~ 1200 systems thereof ~ 450 M-systems
EOS is a ''global organization'' with a significant installed machine base
EOS installed base
Customers in more than 50 countries
EOS sales/service/application in
11 countries
Revenue 108 Mio € (FY 2011/2012)
Worldwide ~ 450 HC
Strong patent portfolio
EOS global footprint
EOS sales/services offices EOS technicalcenter R&D/application office Distributors
AMS RMS EM-PI-ES PROTEC 3D DESIGN LRPS PROMECH ALPHA
DETEKT
DIGITAL-
CAN
NDES
FREEFORM
BIBUS-MENOS
TEMACONSULT
AB-UNIVERSAL YING FENG
SNC
DOYANG
ROLAND-SINGER
Europe:
~750
Asia: ~200
ROW: ~120
NA: ~150
E-Manufacturing_May2012_UB.pptx | EOS | 3
Focus industries
� Lightweight
components
� Substitution metal
by plastic
� Footwear
� Web platforms
� Jewelry / Interior
� Micro electronics
� Micro tooling
EOS is focusing on selected industries
MedicalAerospace /
Turbines
Tooling
Automotive /
Industrial Applications
Consumer
Goods & Lifestyle
Micro
Laser Sintering
� Dental applications
� Implants
� Medical devices
� Aero engine parts
� MRO applications
� Airplane
components
� Injection
molding tools
� Packaging
components
E-Manufacturing_May2012_UB.pptx | EOS | 4
Strong focus on engine and interior market
Focus markets M – Aerospace
Selective growthInvest & Growth Further investigation
� AM is established at jet engines
� High temperature super alloys
� Different applications
� Already used in several aircrafts
� Low weight solutions
� Cost reduction
� Customizing/VIP
� High value through AM
� Most UAV's already containing AM parts
� Fast growing market
� Test bench for new technology
Jet Engine Interior UAV
Focus markets M – Aerospace
E-Manufacturing_May2012_UB.pptx | EOS | 5
Industry view
Source: Press
Citation´s
� “….in our lifetime, at least 50% of the engine will be made with additive
technologies…” - Robert McEwan, General Manager, Airfoils and Manufacturing, GE Aviation, 2011
� “On a 6,000-pound engine, we expect to
save 1,000 pounds….” Todd Rockstroh, GE Aviation in Modern Machine Shop, March 2012
� “I truly believe that additive manufacturing will develop to become the most important, the most strategic and most useful manufacturing technology ever…” – T. Wholers, Wholers
Associates Inc., August 2012
E-Manufacturing_May2012_UB.pptx | EOS | 6
� No Tooling
� Long product life cycle
� Low quantities / Modifications / Upgrades
� Spare parts on demand
� Higher flexibility
� Lose Weight
� Light weight structures
� High integrated subsystems
� Improved functionality
� Reduced Cost
� Investing in parts not tools (Just in time investment)
� Less part counts
� Reduced assembly and quality control
� Novel Materials
� Higher melting points
SOURCE: EOS
ALM – Benefit´s for the aviation industry
Source: 4dsysco.com
Source: medicom.de
Source: ewstvlowcost.com
E-Manufacturing_May2012_UB.pptx | EOS | 7
Hydraulic Manifold(Oil block with lattice structure)
Source: 3T RPD, Within
Design study for a medical instrument
� Special surface structure with grooves or cavities for defined positioning
� Hollow and thin-walled design
� EOS StainlessSteel PH1
� Building time: 25 h
Project: 3T RPD, Within
E-Manufacturing_May2012_UB.pptx | EOS | 8
From block to advanced solution…
E-Manufacturing_May2012_UB.pptx | EOS | 9
From nature to product….
Source: IPA, Messe München
Project partner:
� The gripper is able to withstand 2 bar permanently (>15.000.000 cycles in fatigue testing)
� End stops for angle limitation are realised
� High gripping power
� Extremely low weight
� Walter Reis Innovation Award for Robotics 2006
E-Manufacturing_May2012_UB.pptx | EOS | 10
Integrated functionality
Source: HP
Complex plastic parts in small quantity for EOSINT Systems
E-Manufacturing_May2012_UB.pptx | EOS | 11
Production Applications – Multi-Functional Designs reduce cost and weight
Attach Straps Eliminated
� Part Count Reduction
� Quick & Easy Installation
Multiple Ducts Combined
to Single-Piece Duct
PA 2210 FR / PA 2241 FR
� UL 94 V0 confirmed
� FAR/JAR qualification
� Tested on:
� Flammability
� Smoke Density
� Smoke Toxicity
� Heat Release
Conformal Shapes Achieved and Internal Flow Features Added
Previous (Kevlar/Rotomold) Configuration New (SLS) Configuration
E-Manufacturing_May2012_UB.pptx | EOS | 12
Southampton University Laser Sintered Aircraft
SULSA - UAV
− Project created in about one month
− Built in five parts with ~ 3 kg weight
− Wingspan ~ 2 meters
− Flaps with hinges integrated (no fasteners or screws used)
− Snap fit techniques for easy and quick assembly
− Geodetic structures and ell iptical wings
The world first printed Aircraft with historical Design´s
Source: 3 T RPD
E-Manufacturing_May2012_UB.pptx | EOS | 13
Complex Metal Parts
Source: EOS GmbH
E-Manufacturing_May2012_UB.pptx | EOS | 14
CobaltChrome MP1 superalloy for fully-functional aircraft engine parts
Source: PEP/Turbomeca/Best in Class
Prototypes for Test Rigs
Requirement
� Functional prototypes for developing helicopter gas-turbine engine components
� Capable of running in test-bed conditions, e.g. high strength at high temperature
Solution
� EOSINT M 270 with EOS CobaltChrome MP1 superalloy
Result
� Can be built fully dense in 82 hours
� Can be automatically polished
� Properties fulfill requirements for running on test-bed
Straightener for an helicopter gas-turbine engine. PEP/Turbomeca/Best in Class
E-Manufacturing_May2012_UB.pptx | EOS | 15Source: Materials Solutions
Aerospace applications
Demonstration part
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
E-Manufacturing_May2012_UB.pptx | EOS | 16
With the design freedom of EOSINT M you can integrate all sorts of functionality into products
Source: 3T RPD, Assystem
Integral instrumentation with curved pathways
Cooled aerofoils
Flange design for weight saving and load distribution
Enclosed and perforated honeycomb structure
Weight saving internal cavities oil ways and service channels Complex bosses
E-Manufacturing_May2012_UB.pptx | EOS | 17
Door hinge build with DMLS
Source: Evo Maganize and EADS IW Filton, from:
http://www.evo.co.uk/features/features/261526/3d_printing_is_this_the_future.html
Challenge
� Create a "light weight" nacelle hinge
Solution
� Stress and load path proved design by EADS engineers
� Highly complex design built as "one piece" with integrated function
� Built on M270 Xt
� Material: Ti64
Benefits
� A 60% weight saving was achieved through topology optimization
� Significant cost reduction
Optimized A320 Nacelle Hinge – DMLS and ConventionalEOS Ti64 produced on EOSINT M 270Xt at EADS IW
E-Manufacturing_May2012_UB.pptx | EOS | 18
P3 used EOSINT M 270 to produce a bionic bracket that is 40% lighter than the original
Source: EOS GmbH, P3
Project summary
Requirements
� Reduce weight by keeping product requirements for use in aerospace industry
Solution
� Innovative designed bionic bracket
� Manufactured on EOSINT M 270 using aluminum material
Result
� Weight reduction by 40% (23g)
� Concave bionic bracket weights only 33g(original bracket weights 56g)
� Built full automatically in one piece
� Integrated thread and thus reduction ofassembly parts
Original milled and new designed bracket manufactured on EOSINT M 270
Project partner
E-Manufacturing_May2012_UB.pptx | EOS | 19
Fuel Injection & Swirlers
Challenge
� Improve fuel efficiency of jet engines
� Optimize airflow and fuel swirling
� Cooling with integrated fuel channels
Solution
� Laser sintered on M 270
� Material: EOS CobaltChrome MP1
Benefits
� Highly complex design built as "one piece"
� Cost - < 50%
� Weight reduction - < 40%
� Increased robustness – no joining sections
E-Manufacturing_May2012_UB.pptx | EOS | 20
Gas – Turbine development with EOSINT M 270
Source: Sturzkopf
Project: R. Sturzkopf, Munich
� Gas Turbine TJ 42
� Turbine wheels in IN 718
� Maximum RPM: 100,000
� Maximum EGT: 750°C
� Turbine weight: 3kg
� Thrust @ max. rpm: 420N
� Thrust-weight-ratio: 14(note: Typical values are about 8 for standard aircraft engines)
� So far 5 test cycles completed, no creep, …
� Application: UAV, auxiliary engine for glider
Gas turbine TJ 42 on a engine test rig
Gas turbine TJ 42 EOS NickelAlloy IN718 turbine wheel
E-Manufacturing_May2012_UB.pptx | EOS | 21
Tel:
Fax:
eMail:
web:
+49 89 89 336 2220
+49 89 89 336 2288
www.eos.info
Contact
EOS®, EOSINT®, DMLS®, DirectPart®, DirectTool®, DirectPattern®, DirectCast® and Alumide® are registered trademarks of EOS
Udo Behrendt
(Business-Development-Manager Aerospace)
EOS GmbH
Electro Optical SystemsRobert-Stirling-Ring 1D-82152 Krailling (Munich) Germany