2012 06-21-inauguration-labo-additive-manufacturing sirris - umberto baraldi

The collective centre of the Belgian technology industry

22/06/2012© sirris 2011 | www.sirris.be | [email protected] | 2

Driving industry by technology

• Mission?

To help companies implement technological innovations

• Why?

Strengthen the competitive position over the long-term

• For whom?

The Belgian technology industry


The collective centre

Federation for the technology industry

Collective centreof the technology industry• Nonprofit organisation• Industry owned

“Increase the competitiveness of companies of the Agoria sectors through technological innovations”

MISSION


of the technology industry

Aerospace Automotive Construction products

Contracting & Maintenance Electrical engineeringIndustrial automation Mechatronical engineering

Information and communication technologies (ICT)Metals & materials Metal processing Mounting & cranes

Plastics & composites Security & defence


Sirris members

2325 SME’s (<250 employees)

2450 companies

125 large companies (>250 employees)


Mission statement in practice

Making the right technological choicesfor sustainable economical growth

Translating new technologies intangible products for a company

Taking into account the business & technology strategy of the company

value innovationthrough

technology


What does Sirris mean to you?

From individual services to common research programs

Large partnernetwerk – Optimized projectfinancing (public&private)Intellectual property stays in company


Domains of competence

•Materials Engineering•Production Technology•Mechatronics

•Additive Manufacturing•Software Engineering & ICT•Technology Coaching


Local presence, near the companies

LeuvenMechatronics

Technology CoachingSirris Leuven Composites Application Lab

HasseltMaterials Engineering

Production TechnologySmart Coating Application Lab

CharleroiAdditive ManufacturingBiomedical applications

BrusselsSoftware Engineering & ICTTechnology Coaching

GhentMaterials Engineering

LiègeAdditive Manufacturing

Materials EngineeringNanomaterials and plasma

Sirris Microfabrication Application Lab

> 120 technology experts distributed over 6 sites in the 3 Regions


Partners network

AuthoritiesAcademics

Industrials

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Facts & figures in 2011

5000 interventions per year (advice, projects, services)

whose 75% for SME’s

within 1840 different companies

2000 payed projects and services for 5.4 mio EUR

2900 free advices subsidized

23M turnover


Group Nanopowders & Plasma

Sirris In Wallonia : 3 competence groups

Rational integration of advanced materials

in Products and processes

• Polymers• Composites / Nanocomposites• Thixo/MIM/PIM• Light metals• Microtechnology

§ Product concept and development§ Thermal Management§ Multifunctional products § Traceability§ Smart products

Additive processes &

specific materials

for tool-less manufacturing

• Rapid prototyping• Rapid tooling• Rapid manufacturing

§ Additive process & post process development § Porous and functionally graded materials § Fast « Time to Market »by direct manufacturing § Medical applications

Nanopowders for demanding applications

§ Nanopowders production by synthesis in a plasma torch§ Nanopowders characterisation

§ Nanopowders production units developments§ Ceramic and metallic nanopowders§ Handling/safety solutions for nanometric materials§nanocomposites

Group Materials Engineering

Group Additive Technologies

the collective centre of the Belgian technological industry

Additive Manufacturing – Layer Manufacturing:à Rapid Prototyping – Rapid Tooling – Rapid Manufacturing

SIRRIS – ADD department

Incubation times

1980-1990

Focus :Main focus on supporting

plastic material processor and plastic material users

Specific issues :Injection moulds cost

reductionNew polymers in productsRecycling

Actions :- Reducing mould costs by beter concept –

- Demonstration of CAD (2D/3D) Capabilities- First applications and demonstration of

mould filling simulation( moldflow / inssight)

- Closed loop control of mould filling- Reduction of mould costs by new

fabrication technology- Polymer casting, low melting point alloy

projection, …-

Recurrent requirement:- Validation of plastic parts before injection mould ready- Availability of model as soon as possible

Starting the activity

1990

Inputs :- Technology watch has put

into light new technologyfor direct part fabrication from CAD files

Stereolithography- Increasing performances of

3D CAD software and related interest in industry

Actions :

- Setting up of consortium with industrialpartners

- FN Browning – Mecasoft – Aspel

- Purchase of SLA machine- 50% cost supported by Sirris

(Crif/Wtcm)- 50% cost prepaid services to the

industrial partners

- Machine installed and running in Septembre 1990

Rapid prototyping years

1990-1996

Activity :- For industrial partners and for

sectors, realisation of demonstration parts

- Stereolithography models are keycommunication tools for the development of plastic parts. It isan unambiguous interface allowing designers, tool makers, molders, users to interact quicklyand efficiently.

- In RD projects (local and EC funded), valorisation of quick model making technology to produce cast or sprayed injection cavities

Conclusions :

- Because of requirements concerning betterpart properties, purchase on own cost of an FDM machine

- Low cost mould production techniques based on SLA models not viable. If the future of Rapid prototyping is RapidTooling then other techniques are required.Recurrent requirements:-Better part properties to provide quick functional validation-More precise processes

Rapid tooling years

1996-2002

Activity :- In 1996 purchase of- - an DMLS machine to produce

metal inserts for injection moulds- - an SLS machine to produce

functional plastic parts in polyamide

- RD projects (local and EC funded), in order to improve the applicatbility of additive technologies in the tooling sector(rapid tooling) (with Materilise)

- Demonstration activity to sensibilise industrial sectors on the potential of thesestechnologies (Dito Materialise)

Conclusions :

- Fairly big success of SLS for the production of parts applied in practice (even smallseries productions !)

- Tooling applications are quite a challenge and widespread applications of additive technologies for this applications is not possible on the short term.

- Nonetheless important potential for solution of critical cooling problems.

Recurrent requirements:-Better part properties, faster production process-Functional metal and ceramic parts

The transition years

2002-2008

Activity :- In 2001 purchase of a

revolutionnary machine allowingproduction of metal and ceramic« green » parts : Optoform

- In 2004 purchase of a 3D printing machine providing multiple foldproductivity increase for small and large metal parts : ProMetal

- RD projects (local and EC funded), in order to develop specificmaterials for aerospace and medical sectors

- Demonstration activity to sensibilise industrial sectors

Conclusions :

- Lots of problems with the equipments !- Beta machines required very important

efforts to get running satisfactorily.- Optpoform out of the market.

- Important interest in the medical and aerospace sectors (customisedbiocompatible applications of short seriescomplex parts)

Recurrent requirements:-Still better part properties, faster production process-Functional metal and ceramic parts still not fully adressed

The Rapid Manufacturing years

2009-…

Activity :- In 2009 purchase of an improved

SLS machine (own costs)- In 2009 purchase of an EBM

machine (medical applications)- In 2010 purchase of an SLM

machine for hi tech metal parts- In 2010 purchase of a 5 axis laser

cladding unit (graded materialsand aerospace applications)

- In 2009 purchase of a multimaterial 3D printer for multimaterial functional parts and medical applications

- Start of dedicated ceramic spinal implants for « real life » use withthe optoform technology

Conclusions :

- In 21 years, the additive manufacturingtechnology qualified from an anecdotic one shot process to an accepted production technique of hig-value technical parts.

- Sirris, always in relation to industrialinterests and inputs, invested a lot to set up a unique competence and capabilitiesteam in this area.

This technology field is moving forward at a constant pace, promising interesting capabilities in micro-manufacturing and mass customisation. These issues interest our sectors, and we will keep up to date.

20

SIRRIS – ADD (1990 – 2012)• 15 engineers and technicians • Two locations: Liège (10 p.) and Gosselies (5 p.)

In-house additive technologies• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (2 Optoform)• 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal)• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser Melting (MTT) SLM 250 HL for metal parts and inserts• EBM Arcam A2 (Titanium & CoCr)• Laser Cladding (Irepa Laser EasyCLAD)• 3D Printing of wax (Thermojet)

• Vacuum Casting of alu, bronze, zamak• 3D scanning & metrology (GOM, Metris, Wenzel)

ADD capacities & competencies

21

Motor vehicles11% Aerospace

22%

Industrial/business machines

3%Consumer products/electronic

s15%

Medical/dental29%

Academic institutions

14%

Military1%

Architectural 3%

Other:2%

ADD application areas


Laser Sintering of polymer powder

23

Post-milling

3D Printing Prometal


Laser Sintering of metal powder

• Direct Metal Laser Sintering

• Mould inserts in Bronze/Nickel alloy and steel• Direct Parts • Layers 20 µm. Accuracy 50 µm.

• EOSINT M250 Xtended

Material properties: 15 years evolution


─ Aerospace: Functional PartsApplications

Heat Reflector

Material: Ti6Al4V ELISize: Ø 140 x 80 mmWeight: 2,5 kgBuild time: 16 hours

Rocket Engine Impeller

Material: Ti6Al4VWeight: 4,5 kgBuild time: 36 hours

Landing Gear Component

Pressure Vessel

With Cooling Channels

Electron Beam Melting - Arcam


Applications

Ti 48Al-2Cr-2Nb

Ti 6-4Interface

Abrupt transition between Ti 6-4 and Ti 48Al-2Cr-2NbClean, well bonded fully dense microstructure.

A-Impact: Conventional Ti alloy(Ti 6-2-4-2)

B-LC fatigue: Orthorhomic Ti alloy(Ti 22-23)

C-Creep: Gamma Ti-Aluminide (Ti 48-2-2)

Denis Gravet

Functionally Graded Materials (FGM)

Functional surface:tool steel 1.2344 (finished)

Basic material:copper alloy (Ampco 940)

15-03-2009

Topology optimization

Free space definition

Efforts repartition

STL file

Smoothing or redesign based on the STL geometry

Flying Cam example (Compolight project)

Stress verification

Weight reduction with the same mechanical result

FLYING-CAMU N M A N N E D A E R I A L S Y S T E M S

Most of the components produced by AM44 parts in PA + C31 parts in PA (white, black, painted or not,…1 part in Connex500

30

Controlled PorosityLightWeight solutions – 3D structures

Quality, Repeatability,

StandardsSustainability

Composites SiC+ alu, Connexdigital materials…

SIRRIS ADD – Actual & Future developments

Titanium, Inconel, aluminium

Nano particles incorporation

Medicalapplications

Functionally Graded materials and

porosity

the collective centre of the Belgian technological industry

Sirris Gosselies

22/06/2012© Sirris | www.sirris.be | [email protected] | 32

Sirris – Gosselies

Historical recap.

• Since1997 : Close collaboration started with Technofutur in the field of micro-manufacturing technologies (plastic injection and µSLA), and composite materials processing.

• Support through Feder and Interreg Funding for development of Advanced manufacturing technologies (PIM, Rapid manufacturing) competences and transfer

• 2008 : Strategic focussing of Gosselies dept in the bio-medical field

• BioManufacturing Platform (Feder project support)Arcam – Titanium & Connex 500 – multimaterial Add process

• Team grows to 5 FTE

2012 i li !


Sirris – Gosselies

• Projet Campus Technologique :• Closer cooperation with Agoria (offices in “Maison de

l’Industrie”) • Sirris Lab in the “ Village Plasturgie & Composite”• Shared workplaces with Technofutur Industrie

(plasturgie) and Cenaero (projet Cilab)


Sirris – Gosselies - Strategic partnerships

Partnership management :

• Continuation and reinforcement of collaboration with Technofutur(equipement sharing, common projects, training support)

• Renforcing partnership with Agoria (win-win industrial impact)

• Renforcing partnership with local key actors (innovatech, Igretec)

• Continuation of Interreg projects and actions (Pristimat, Ecolaserfact) interreg FRED)

• Develop collaboration with other CRA (Cenaero, Cetic)


Sirris Gosselies - Value for Industry

Service development : direct industrial support

• More then 150 industrial projects/year most in the province Hainaut/Namur (65%) (direct service income of +/- 200k€)

• Main industrial sectors Manufacturing, Biomedical and Aeronautic area

• Majority of activities oriented towards product developmentsupport, rapid manufacturing technology applicability

• Applications in MIM and µmoulding ( symbiosis with ING/ SMALL/technofutur)

.


Sirris Gosselies - Value for Industry

Service development : direct industrial support

• Increase industrial impact with 2 guidances based in Gosselies

Guidance SimADD : promote beter use of additive technologies in direct manufacturing of hi-value products by integration of numerical development chain

Guidance Biomediv : in partnership with Centexbel, support companies in innovative projects in the « medical devices » area.


Sirris – Gosselies - Expertise development

Service development : Projets de recherche en partenariat avec l’industrie

• Plateforme de bioManufacturing Biofact W

• Projet Interreg Pristimat (champagne/ardenne – Hainaut Namur)• Domaine médical• Domaine Transport• PIM-MIM

• Prospective projet Hennuyer « ECOPOLE » (mécatronique/nanos/surface)


─ Medical: Implants – Prosthesis - InstrumentsApplications

Material: CoCr ASTM F75Build time: 8 knees in 20 hours Material: Ti6Al4V ELI

Build time: 16 cups in 24 hours

Material: Ti6Al4V

Size: 180 x 130 x 5 mmBuild time: 12 hours

Electron Beam Melting - Arcam

[email protected] / #Sirris / Sirris_be


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