Tom de Bruyne - Layerwise

© LayerWise NV, all rights reserved 6/4/2012

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Themadag Additive Manufacturing Mikrocentrum TNO

Let Additive Manufacturing Inspire You

LayerWise 2012


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Who we are

“What is the manufacturing potential of Selective Laser Melting”

Experiences at LayerWise NV2012


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Content

About LayerWise Technology Drivers for SLM manufacturing Future outlook


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About LayerWise

Increase your added value through advantages of

Metal Additive Manufacturing

Therefore LayerWise offers its technological expertise realized by being technology developer as well as technology user


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About LayerWise

20081989 1991 2007 2009 2010 2011

Start of AM Research

Start of METAL Research

Full Dense Metal Samples

2001

Phd P. Mercelis

Phd J. Van Vaerenbergh

SLMSLSSintering

2012

Thin Wall 0.5MM

Thin Wall 0.3MM

Thin Wall 0.225MM

Thin Wall 0.19MM

Thin Wall 0.18MM

RP 0% Manufacturing

10% Manufacturing

50% Manufacturing

70% Manufacturing

90% Manufacturing


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About LayerWise

dental prosthesescrowns and copings

standard implantscustomized implantsmedical toolsmedical modeling

chemicalpharma

foodpressure & gas

automotiveconsumer

mechatronicsmechanization

solar-lightingelectronicsaerospace

tooling

ISO 9001 & 13485 certified


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Technology


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Technology

Directly from 3D CAD Layer-wise production 3D components by successive

connection of thin 2D layers


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Technology


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Metal Additive Manufacturing

Principle

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Technology



Technology



Technology



Technology



Drivers for SLM manufacturing

Additive manufacturingSame materialSame characteristics

What is the added value?


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Manufacturing Cost Total cost of ownership - performance

Type of Driverpart

Mostly small parts Small, medium and large parts

SLM feature Tool-less manufacturing

• Monolythic construction• Flow-optimized• Miniaturisation• Customisation• Mass reduction




Flow typeLaminarTurbulent

Channel shapeCross section3D traject

Pressure dropVariable sectionsrestriction

HeatexConformalBalanced

CFD analysis SLM Manufacturing




10 mm







200 mm






















Custom made hip implants with porous structure rigidly connected to theimplant for a severe pelvic discontinuity (left) and separate parts in a multicomponent revision (right). Courtesy: Mobelife NV, Leuven, Belgium



Future outlook

“What is the manufacturing potential of Selective Laser Melting”

Experiences at LayerWise NV2012



Future outlook



Future outlook

SLM is here to stay

– Technology development

– Awareness SLM specific design

Standardization is needed

– Material

– Validation

Technology will shift

Purpose-built AM lines

Automation - process control

Cost will decrease

Build rate

material



Future outlook

Materials : Stainless, super alloys, heavy metals (18+ materials)

Cost : 2008 -> 2012 - buildrate x 4

Upscaling : max dimenions x 5 to circa 500 mm

Surface control : Ra 5 -> Ra 0.9 & Ra 0.1

Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)

Pardigm shift: DfM-> design for function



Future outlook

Sustainable PRODUCTION

Material(ex 1/20 BtoF)

Ancilliary consumables(ex tooling)

Re-localized production(ex LayerWise

Sustainable PRODUCTS

Weight(ex 30% payl.)

Plant footprint(ex inj. molding)

Process intensification(ex flow reactor)

Sustainable ECONOMICS

Sustainability is not the incentive...

but value creation comes from

sustainable design



Contact details

LayerWise N.V.Kapeldreef 603001 LeuvenBelgium

tel: +32 16 29 84 20fax: +32 16 29 83 19

[email protected]