05/06/2018
Slide 1
Steve Fisher
District Solutions Manager
Renishaw Incorporated
Transitioning from Development
to Production:
Addressing the Next Steps in
Metal Additive Manufacturing
Image courtesy TCT Magazine
About Renishaw
05/06/2018
Slide 2
World leading metrology & engineering company
Metrology Research Healthcare Additive
• FTSE 250 public company, UK headquarters
• Independent
• 4,500 staff in 35 countries
05/06/2018
Slide 3
• From research lab onto the factory floor
• From prototypes & tooling to series production
• From time compression to higher product performance
• From shapes to consistent, qualified parts
• From plastics to high performance alloys
• From 3D printing to an integrated production process
Additive manufacturing3D printing
05/06/2018
Slide 4
Productive machining – the benchmark for industrial AM
• 140 productive hours per week
• 24 hour unattended operation
• > 99.5% process yield
05/06/2018
Slide 5
Metrology underpins modern manufacturing
• Characterisation of processes
• Feedback for process control
• Verification of process outcomes
05/06/2018
Slide 6
The Productive Process Pyramid™
Process control in
manufacturing
Metal AM in production
05/06/2018
Slide 7
Design for AM AM build Gauging Machining Inspection
Pro
cesses
To
ols
Higher production rates with higher precision
05/06/2018
Slide 8
Additive Metal Manufacturing – “Digital Castings”
Design AM parts with final machining in mind• D4AM – design in fixtures
and machining datums!
Additive work-holding considerations
05/06/2018
Slide 11
Additive work-holding considerations
Maximised
encapsulation
reduces
deflection and
chatter
• Probing for machine reference.
• Multiple angular positions.
• Define rotary axis center.
• Used for multi axis machining.
• Reference ‘pad’ delta from
rotary center or pivot point.
• Used for subsequent thermal
tracking.
Automated processing– initial set up
• Zero point fixture system
• Part measurement on Equator
• Complex measurements of
surfaces
• Automatic transfer to CNC
• Writing to chip / tag possible
• Adaptive machining possible
Automated processing - part set up
• Set ‘ballpark’ tool offsets
• Confirm correct tool & build
• Drills, taps, reamers etc. accurately set to each other
• Reduces inspection for set up & adjustment
• Reduces potential of tool breakages
• No dynamic effects on tool or part are compensated.
Automated processing – tool setting
Accurate machining
• Recording process output from
machined features.
• Analysis of recent parts.
• Automatic tool offset update.
• Adjusting process mean to
nominal dimension.
• Reduces measurement /
manual update time delay.
• Eliminates manual errors.
Automated processing – process control
• Verify feature size to design
intent.
• Check for distortion against
pre-machined condition.
• Analysis of surfaces against
CAD nominal.
Final Certification
Build your AM experience and knowledge
05/06/2018
Slide 18
• Try before you buy: develop your product
and process, acquire knowledge, build
your business case
• Global network of centers providing
facilities, machines, post-processing and
engineering support
Thank you
Your product
design
Renishaw
expertise
Your AM
process
Global support
THANK YOU