additive manufacturing in production engineering: chances ... 14/cirp icme 14_plenary session...

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Additive manufacturing in Production Engineering: Chances and Challenges

Prof. D.Sc. M.Sc. Gideon N. Levy

Additive Manufacturing and

Electro Physical & Chemical Processes

[email protected]

Fraunhofer J_LEAPT Naples

9th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2014,

Capri (Naples), Italy, 23 - 25 July 2014

AM is Hot 0published 13.02.2013

“3D printing that has the potential to revolutionize the way we make almost everything“ President Obama

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World gov. funding 5`561 Mio € Mio €

Singapore 500 Mio SGD 293 Mio € 293

China 2 Billion USD 1466 Mio € 1466

UK 60 Mio GBP 74 Mio € 74

European Union (approx.) 2 Billion EUR 2000 Mio € 2000

Russia 2 Billion USD 1466 Mio € 1466

Australia AMCRC 250 Mio AUD 171 Mio € 171

Australia AM machines 17.5 Mio AUD 12 Mio € 12

US (NAMII) 30 Mio USD 22 Mio € 22

US America Makes 9 Mio USD 7 Mio € 7

New Zeland

Taiwan

South Africa

South America

Mexico

Mio € 5'561

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Additive Manufacturing government funding

WED over 45 years AM-SLS less than 25!

1969

1986

2012

1994

2004

2012

One Technology

Many applications

Many Technologies

Many applications

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Agenda I

� 1. Background

� 2. Scientific Manufacturing Management (Taylorism)

� 3. Systems, Monitoring and Materials

– Performance (productivity, repeatability, accuracy)

– Materials (Plastics, Metals, (Ceramics, Biomaterials))

– Automation

� 4. Application Driven

� 5. Conclusion

More than 128 years ago..

This internal combustion engine was an integral aspect of the patent for the first patented automobile, made by Karl Benz on January 29, 1886

4

More than 25 years ago

08.08.1984 17.10.1986

Patents of SLM and 3DP

12.07.1999 03.05.1999

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5 Senses

Why do have AM a great potential?A

bs

tra

ct

Real

Pe

rce

pti

on Thinking

SpeakingWritingPrintingPaintingCraftingArt, Music

Virtual realitySoftware Film TVSimulation ModellingScience: Rules and equations Physics, Chemistry Mathematics

Everything we have And more0.

AM is an Enabling Multidisciplinary Technology

System / Process

Materials

Applications

Up stream/ Down stream

PolymersMetalsCeramicsCompositeBiologic

Application dedicatedAutomation

Part and powder handlingBatch to continues

00000..

Adaptive controlClosed loopProductivityRepeatability000000

Design for AM3DP design

toolPart finishing

Coating Modifications

0000

IndustryAviationAutomotiveJewelry

Medical devicesScaffolds

Organ printing00..

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Terminology - Process Categories I (2012)

1. Vat Photopolymerization Process

Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon

Liquid Photopolymers,

Ceramic or Metal filled photopolymers

2. Material Jetting Process

Multiple nozzles Single nozzles

Thermoplastics, Wax or Photopolymers, Metals,

Optical materials, Electronic materials

3. Binder Jetting process a liquid bonding agent is selectively deposited

to join powder materials.

Polymer, Metal, Ceramic powders

4. Material Extrusion Process

FDM Polymers, composite

C

C

C

T

T

CChemical

TThermal

TThermal post processing

T

Terminology - Process Categories II (2012)

5. Powder Bed Fusion Process

SLS, SLM, EBM

Polymers, metals & ceramics powder

6. Sheet Lamination Process

Bonding, hot melt, glue, US welding

Paper, Metal, Polymers

7. Directed Energy Deposition Process

focused thermal energy is used to fuse materials by melting as they are being deposited

Metal, polymers, powder, wire

T

T

T

C

CChemical

TThermal

TThermal post processing

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Process / material matrix

For most process some bio-compatibles are available.

https://www.additively.com/en/

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Gartner Hype Cycle of Emerging Technologies, Trends for 2014

The value chain in product creation

CONCEPT MODELING

RAPID PROTOTYPING

Pre-SERIE / BRIDGING

CONFORMAL COOLING / TOOLING

ADDITIVE MANUFACTURINGREVERSE ENGINEERING

The Trend

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US Patents on RP/AM in steady state trend- maturity growth?

Source: www.additive3d.com/home.htm

Agenda I

� 1. Background


� 3. Systems, Monitoring and Materials



– Automation


� 5. Conclusion

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AM Manufacturing and SM (subtractive manufacturing) are comparable tasks with new features

Additive manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. (ASTM standard F 2792 - 09)

Manufacturing is the use of machines, tools and labor to make things for use or sale. The term is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale.

Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".

=

http://sitemaker.umich.edu/ykoren/education

Manufacturing paradigms

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AM is significant in various Manufacturing Paradigms

� Craft production

is “the application of skills and material-

based knowledge to relatively small scale

production”

� Mass Production

is “ the production of large amounts of

standardized products, including and especially

on assembly lines “

� Mass customizationwas defined by Tseng & Jiao (2001) as

“producing goods and services to meet

individual customer's needs with near mass production efficiency “

Its core is a tremendous increase in variety and customization without a corresponding increase in costs. At its limit, it is the mass production of

individually customized goods

� Mass Individualisation

“Gthat is relevant to the individual user “,

based on the user’s implicit behaviour and

preferences, and explicitly given details” – finally, the

most important part. Personalization uses both

implicit and explicit information,


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� Mass customization � Mass Individualisation


� Personalization (Custom-fit)

The custom-fit concept can be understood as the of offering one-of-a-kind

products that, due to their intrinsic characteristics and use, can be totally adapted to geometric

characteristics in order to meet the user requirements


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Manufacturing Implemented Scientific Management (Taylorism)

� Scientific management is a theory of management that analyzes and synthesizes workflows, with the objective of improving labor productivity.

� Total Quality Management (or TQM) is a management concept coined by W. Edwards Deming. The basis of TQM is to reduce the errors produced during the manufacturing or service process, increase customer satisfaction, streamline supply chain management, aim for modernization of equipment and ensure workers have the highest level of training

� Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.

� Management philosophy derived mostly from the Toyota Production System (TPS)

Source: www.strategosinc.com/

Applic

ations

Applic

ations

Applic

ations

Applic

ations

Implement scientific manufacturing management (Tylorism)

� The first level of industrial usability was reached� Numerous applications of AM are success business

cases� Modeling, permanent continuous performance advances

are required

Process, System, Materials

Production integration

Plant integration

� Standards� TQM� Automation � Productivity

� Upstream processes� Downstream processing� business process or business

method

Applic

ations

Applic

ations

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Design Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP AM USE

The bottlenecks in AM are the challenges

Actual operator influence on results - the challenge

Partial advances:� Digitalisation� Protocoling� Laser calibration� Digital scanners� Heaters� Sensors � ---� ----

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Agenda I

� 1. Background


� 3. Systems & Challenges



– Automation

– ..


� 5. Conclusion

Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

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SLM - Machine size categories

Small dedicated <1

Mid range 15-30

Very large > 100

China 2013 $80 million investment in AM

An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China.

Courtesy of Guancha Zhe.

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SME RAPID Detroit 2014

Hybrid Systems in metal and polymers

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

The Additive Manufacturing TQM Model with AC

Plastics

Metals

Ceramics

Composites

Solid Liquid Gases

Powder

Foil

Wire

Material

Thermal Layering

Chemical Layering

postprocessing

traditionalprocessing

coatingfinish

Q1

Q2Q3

Q4 Q5 Q6Q3

Part

Data

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Factors influencing manufacturing process

Laser beam

Process gas

Powder

Melting process

Bechmann F., LANE conference 23th September 2010, Erlangen

Feedback control of Selective Laser Melting

P. Mercelis, J.P. Kruth, J. Van VaerenberghDepartment of Mechanical Engineering, University of Leuven, Celestijnenlaan300B, Leuven, Belgium

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

http://www.grantadesign.com/ and 3DP materials

3DP

3DP

3DP

3DP

3DP

Food

3DP

Bio-mat

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The selection of the right material is never an easy task

Material selection criteria.

The selection of the right material is never an easy task because many parameters need to be considered to obtain the best system at the lowest possible cost. The perfect material does not exists! In most of cases, you will have to compromise between different properties and clearly define the "must have" and the "nice to have" properties

AM material selection is never an easy task as well

AM additionalselectioncriteria

Process + material (one united selection)

Material properties consistent over use time

Process resolution

Part geometry process conformity

Part printing orientation

Anisotropy

Density porosity, delamination

Process provider: quality, time, cost

Post processing finish coating

Long-term duration usability

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SLA and SLA metal coated helical over time

3DP Digital Materials

100% Material A

100% Material B

75%:25%

50%:50%

25%:75%

Source: SFF 2012, Daniel Dikovsky, Ph.D.

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SLS - Thermoplastics polymers (Red= tried for SLS)

PP

Polymer material choice advances

, iRPD

; EOS

So

urc

e:

Ze

ha

vit

Re

isin

SM

E-R

ap

id J

un

e 2

01

4, D

etr

oit

V

P M

ate

ria

ls B

us

ine

ss

Un

it,

Str

ata

sys

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SLM - materials options

Stainless steel CL 20ES ( 1.4404 )

Hot-work steel CL 50WS ( 1.2709 )

CL 60DG ( 1.2709 )

CL 90RW (1.2083 )

Aluminum CL 30AL ( AlSi12 )

CL 31AL ( AlSi10Mg )

Titanium CL 40TI ( TiAl6V4 )

Nickel-based alloy CL 100NB ( Inconel 718 )

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

Part

Laser Beam

Powder

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

Part

Laser Beam

Powder

Some trends and challenges in AM – Materials research

� Filled Materials

� Multi material

� Local alloying

� Digital Materials

� Gradual Materials

� Designed Anisotropy

� Designed local property

� Optimized metallurgical structures

� Ceramics and composite

� Medical and Biomaterials

� Nano Materials

� Micro parts

� Memory shape alloys in AM

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

Multi Physics-CAD (MP-CAD) Tools are in due

– Light weight– Ecological design– Topological optimization

– Flow – Minimal parts(Diffusor)– Static mixer– Aeronautics

– Heat transfer

– Local physical properties

– Digital materials

– Alloyed materials

– Medical

– Biological design

– Engineered surfaces

– Scaffolds

– Life Style

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Light-weight “material“ selection done by geometry

Materials designed with new additive manufacturing techniques exhibit high stiffness and low density, occupying a previously unsettled area of the Ashby material selection chart for Young’s modulus (stiffness) versus density. The octet truss structure recently fabricated by Livermore researchers is a stretch-dominated lattice.

Multi Physics-CAD (MP-CAD) Tools needed

Optimal helmet design� Aerodynamics� Air flow (noise)� Cooling� Security � Aesthetics � Personalized

MP-CAD

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AM made - (no supports) Heat exchanger

Heat exchanger 450x4050x500 mm

Topological Optimizations

Topological optimized design results are:

• Complex geometries

• Conventionally not produce able

• Have to be smoothed

• Highest geometrical freedom

• Agile manufacturing

• New design concepts

Chances for Layer Manufacturing:

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

Supply-chain optimizations potentials

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Logistics and supply chain management flexibility

Production on Demand

DirectSpare: A European Approach for Spare Parts on Demand

Birth andyouth

problems

Aging andwear

problems

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

Applications arrays divide and focus consequently on different quality issues and standards

EntertainmentMovie?

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Main Application areas of AM/ 3DP

DifficultyValue

Added Value: Translate process characterization into specific applications

� Freedom of Design

� Lightweight structures (hollow)

� No-Tool production

� Assemblies, integrated design

� Anatomical personalized

� Ergonometric design

� Customization individualization

� Conformal cooling

� Gradual materials (on the way)

� Medical scaffolds (on the way)

� Bio Materials (on the way)

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Bio inspired AM fabricated systems

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Conformal cooling systems and heat exchanger

A great chance is coming up in moulds!

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Renishaw's additive manufacturing system to boost production capabilities at Directed Manufacturing Inc

Biomedical engineering (BME) advanced complexity

Medical devices

Neural engineering

Implants

Pharmaceutical Eng.

Tissue engineering

Artificial body part

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Medical and Life Science a promising future

MCP

Dr. Anthony Atala (USA) : 3D Printing of Body Parts

Institute for Regenerative Medicine in North Carolina

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Winsun 3D printed house (China)

How a Chinese Company Built 10 Homes in 24 Hours

Winsun’s 3-D printer is 6.6 meters (22 feet) tall, 10 meters wide and 150 meters long, the firm said, and the “ink” it

uses is created from a combination of cement and glass fibers. In a nod to China’s green agenda, Winsun said in the future it plans to use scrap material left over from construction and mining sites to make its 3-D buildings

Suzhou-based construction-materials firm Winsun New Materials says it has built 10 200-square-meter homes using a gigantic 3-D printer that it spent 20 million yuan($3.2 million) and 12 years developing.

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3D Printing: now printing food too

Chocolate portraits made with a 3D scannerand 3D printer. (Photo/Agencies)

3D Printers in 30% of Households

Experts Futures Researchers

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Agenda I

� 1. Background





– Automation

– ..


� 5. Conclusion

We are on the right track

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Conclusions

� The sustainability will be a mayor issue for all of us

� The implementation of Scientific Management (Taylorism) is a must

� Hybrid systems are in due

� Productivity, Automation and quality enhancements are a permanent issue

� New application driven manufacturing tasks coupled with product innovations are just around the corner.

� Interdisciplinary and complexity are increasing

� Additive Manufacturing Processes are a great challenge and chance in manufacturing

� 5 years to go!

� The scientific AM community has to be involved

Personalized

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Construction of a CUBESAT using AdditiveManufacturing

Additive manufacturing

The sky is the limit !

additive manufacturing in production engineering: chances ... 14/cirp icme 14_plenary session...

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