advanced tooling with dmls - asiannet dmls... · composite tooling • previously made by cnc cut...

Advanced Tooling with DMLS

Joseph Weilhammer EOS GmbH, D-Krailling / München

Asia User Meeting, 18.01.2008

EOS 2008 · AUM_2008-01-18_Weilhammer

EOSINT M Technology


EOS offers two different EOSINT M systems for tooling applications

— EOSINT M 270•top-end system for all DMLS materials in best quality

•build volume 250 x 250 x 215 mm*•solid state Yb-fibre laser, 200 Watt•dual focus

* = including thickness of building platform

Source: EOS

— EOSINT M 250 Xtended•all-round system for DirectMetal and DirectSteel materials

•build volume 250 x 250 x 200 mm*•CO2 laser, 200 Watt


EOSINT M 270 can now be installed in two versions: "Standard" and "Titanium"

— EOSINT M 270 Standard Version•nitrogen atmosphere from integrated nitrogen generator

•nozzle for radial gas flow over powder bed

•recirculating filter unit•accessory: industrial vacuum cleaner

Source: EOS

— EOSINT M 270 Titanium Version•argon atmosphere from external argon supply (e.g. bottles)

•fan-nozzle for radial gas flow over powder bed

•gas exhaust via liquid bath•gas flow modes "fill" and "hold"•additional oxygen sensors•additional safety features (anti- static etc.)

•accessory: liquid-filled vacuum cleaner (wet separator)


EOSINT M 270 can be changed between "Standard" and "Titanium" versions

— EOSINT M270 systems can be ordered and installed in either Standard or Titanium Version

•EOS Titanium materials may only be processed in Titanium Version•all other EOS materials can be processed in Standard Version•processability of other materials in Titanium Version not yet tested

— Existing EOSINT M270 systems can be upgraded to Titanium Version

— Titanium Version systems can be converted to Standard, and vice versa•for safety and liability reasons, conversion must involve hardware changes and be done correctly

•requires service visit

Details

SOURCE EOS


Source: EOS

Injection moulding tooling; functional prototypes

Bronze-based mixtureDirectMetal 20

Typical applicationsMaterial typeMaterial name

EOS offers a wide range of application-optimized metal powder materials for EOSINT M systems

Injection moulding series tooling; engineering parts

18 Mar 300 / 1.2709EOS MaragingSteel MS1

Functional prototypes and series parts; engineering and medical

Stainless steel 17-4 / 1.4542

EOS StainlessSteel 17-4

CoCrMo superalloyEOS CobaltChrome SP1,2

Ti6Al4V light alloyEOS Titanium Ti64

Pure titaniumEOS Titanium TiCP

Dental restorations (series production)

Functional prototypes and series parts; aerospace, motor sport etc.Functional prototypes and series

parts; medical, dental

Functional prototypes and series parts; engineering and medical

Hardenable stainless steel

EOS StainlessSteel PH1

CoCrMo superalloyEOS CobaltChrome MP1 Functional prototypes and series parts; engineering, medical, dental


EOSINT M Tooling


Joystick in PA6.6 GF; series of 5,000 parts moulded in DirectMetal 20 tooling

Source: EOS, FIT GmbH and EGi

project partners: FIT GmbH and EGi

Injection mould in DirectMetal 20 for a light guide in polycarbonate. Planned production quantity: some thousands.

DirectTool® for small series injection moulding

EOSINT M is ideal for the cost-effective low-volume production of injection moulded parts

Vorführender

Präsentationsnotizen

Additional Information (not intended for direct publication) See case studies CS_M_Modem-cover_e.ppt and CS_M_Dresden-Frauenkirche_e.ppt for more details.


— Key characteristics•18 Maraging 300 type steel (1.2709, X3NiCoMoTi18-9-5)

•fully melted to full density for high strength•easily machinable as-built•age hardenable up to approx. 54 HRC•good thermal conductivity and polishability

— Typical applications•series injection moulding (high volume) •other tooling applications, e.g. die casting•high performance parts, e.g. in aerospace

Source: EOS, Oase

EOS MaragingSteel MS1 - high performance steel for series tooling and other applications

Injection mould insert with conformal cooling, built in EOS MaragingSteel MS1

Characteristics and applications


— Mechanical properties as built•UTS: 1100 MPa•yield strength: 1000 MPa•hardness: 33 - 37 HRC

— Mechanical properties after age hardening (6 hours at 490°C)

•UTS: > 1950 MPa•yield strength: > 1900 MPa•hardness: 50 - 54 HRC

— Physical properties•relative density as built: approx. 100 % 200 internally cooled pin inserts for

injection moulding, built in EOS MaragingSteel MS1. Source: LBC GmbH

Source: EOS, LBC

EOS MaragingSteel MS1 is a high performance steel for series tooling and other applications

Key properties


Advanced and Rapid Tooling with EOSINT M

Hybrid tooling


Composite tooling

Source: Linear Mold & Engineering

This large injection mould uses DirectMetal 20 lifters in a cast epoxy tool base

Top: Lifters in DirectMetal 20, built on EOSINT M 270 in 30 hours. Bottom: moulded part with lifters


EOSINT M can be effectively combined with machined tooling, e.g. lifters and removable inserts

Example: large aluminum tool with DMLS inserts for details

Source: General Pattern Inc.

Molded package tray with one half of machined aluminum tool and laser-sintered inserts (EOSINT M 270, DirectMetal 20)

Other half of aluminum tool with DMLS inserts assembled


Project summary


Linear often builds large injection moulds efficiently by using DMLS to build various tool elements

— Requirements:•efficient production of inserts for composite tooling

•previously made by CNC cut aluminium, hand fabrication or cast epoxy

— Solution:•DMLS with EOSINT M 270

— Result:•reduced time and effort, less CNC and EDM work needed

•DMLS now used to build mould inserts, sliders, lifters, guides etc.



This tool was built in just 6 days by integrating DMLS inserts into a CNC cut aluminium insert

Project summary

— All DMLS components were grown while the aluminium blocks were being CNC cut

— Cavity side also included 4 heel block inserts in EOS StainlessSteel 17-4

— Different materials (DM20 and 17-4) were used to prevent galling

•occurs when materials of same hardness continually slide over each other

— This tool has run about 30,000 parts in PC-ABS so far without any mould deterioration

Core side including 4 wear plates (A) and 8 slide gibs (B) in EOS StainlessSteel 17-4 and 4 slide details (C) in DirectMetal 20, fitted into aluminium MUD insert (D)

A B

C

D


Project summary

Production mould with inserts in EOS MaragingSteel MS1, built on EOSINT M 270

Source: Fruth Innovative Technologies GmbH

Production tooling can be realised very rapidly by integrating DMLS inserts into a machined tool base

— Requirements:•series production tool for injection moulded plugs in PBT GF10%

•tool availability as quickly as possible

— Solution:•3-cavity mould in hybrid concept•machined aluminium tool base with inserts in EOS MaragingSteel MS1 (1.2709)

— Result:•tool available in just 6 working days•tooling cost just €15,000•due to rapid delivery of production mould, pre-series tooling was not needed



Conformal cooling


Project summary

Left: Example of an optimized cooling.Right: 200 pins with integrated cooling channels, built on EOSINT M 270 in 1.2709 in just 30 hours.EOS / LaserBearbeitungsCenter GmbH

Source: EOS, LaserBearbeitungsCenter GmbH

EOSINT M tempering inserts improve the quality and economics in tooling

— Requirements:•mould elements for specific cooling or tempering of injection moulding tools

•long pins with thin cooling channels, cannot be manufactured conventionally

•high hardness, wear resistance and thermal conductivity

— Solution:•production on EOSINT M 270 in EOS MaragingSteel MS1 (1.2709)

— Result:•improved cooling, especially in critical areas•shortened cycle time (productivity)•less distortion of moulded parts (quality)•optimal process control possibilities


Left: Standardized tempering pins in various designs.Above: Special insert for cooling the injection point of an injection mould for producing sealing caps. EOS / LaserBearbeitungsCenter

Quelle: EOS, LaserBearbeitungsCenter GmbH

EOSINT M can produce tempering inserts as standardized or project-specific elements

Cooling water flows up through outer channels and back down through

the central channel


Source: EOS, PEP, Legrand

Mould inserts for an electrical box. Left: conventional drilled cooling channels. Right: conformal cooling via EOSINT M

Conformal Cooling

EOSINT M offers new technical possibilities such as optimized, three-dimensional cooling channels

— 3D cooling or tempering channels ("conformal cooling")

— Optimized tooling•less thermal stress•precise cooling/tempering of critical tool regions

•longer tool life

⎯

Improved moulding•lower stress and warpage•more accurate parts•shorter cycle times

project partners: PEP, Legrand

Vorführender


Additional Information (not intended for direct publication) Sales argument: DirectTool not only offers time and cost savings, but also completely new design possibilities for quality improvement. "Conformal cooling" means cooling channels which are adapted to the shape of the tooling. The picture shows DMLS injection moulding insert, cut open to show the conformal cooling channel. The ability to build conformal cooling channels is one example of how EOSINT M opens up new design possibilities. Other possibilities are for example: building parts with a defined level and type of porosity, e.g. for venting gases from vulcanization moulds, for metallic filters, or for pumping lubricant to bearing surfaces. building parts with defined variation of mechanical and thermal properties within the part, e.g. hard surface with tough interior, or maximized thermal conductivity between forming surface and cooling channels. Note that these abilities may only be fully relevant if EOSINT M is being used to produce the series tooling or the final part, as otherwise they may not be transferable from the prototype to the later production. However these advantages can already be used fully for niche (small-volume) production and can also help prevent part distortion with prototype tooling, which is usually quite different to the series tooling anyway (e.g. different injection and ejection systems, not automated). See case studies CS_M_Golfball_e.ppt and CS_M_Blow-moulding_e.ppt


Temperature of mould, cycle no. 10 @ t= 15 s

Source: PEP and Antiope project

Conformal cooling can greatly reduce hot spots, temperature gradients and/or moulding cycle time

Hot spot: 52.6 °C Hot spot: 75.5 °C

DirectTool, conformal cooling Traditional machining


Temperature of plastic part, cycle no. 10 @ t= 15 s

Source: PEP and Antiope project

Conformal cooling can greatly reduce hot spots, temperature gradients and/or moulding cycle time

Hot spot: 94.5 °C Hot spot: 111.5 °C

DirectTool, conformal cooling Traditional machining



conformal cooling, preforms and clamping systems


Source: EOS, LBC

project partner: LBC

Application examples

EOSINT M can build tool inserts on preforms or mounted on a clamping system

Hybrid insert produced in EOSINT M270 by building on top of a machined preform

Erowa Powerchuck 150 clamping system mounted in EOSINT M system

Vorführender


Additional Information (not intended for direct publication) Although DirectTool can save a lot of time and cost simply by producing standard tooling inserts by DMLS instead of machining and EDM, a much higher benefit can be achieved by redesigning the tooling or using completely new tooling concepts which make use of the unique characteristics of DirectTool. Two examples are shown here. Be careful about presenting this slide to more conservative toolmakers, or to prospects who probably will not have the possibility to use such methods, in case they get the wrong impression. For more details see case studies CS_M_Golf-putter_en.ppt and CS_M_Minute_Mould_en.ppt


Alignment methods for post-processing parts built on EOSINT M


1. Mount platform with known, visible reference (e.g. preform or corner of platform) onto platform carrier

2. Blacken reference geometry and exposure contour with "alignment exposure"

3. Compare position of alignment exposure with reference geometry, e.g. using measuring magnifying glass

4. Shift and rotate optical coordinate system in PSW to compensate for misalignment

Build platform

Position reference, e.g. pins or clamping system

Source: EOS

If a referenced positioning system is used then parts can be aligned for post-processing

Method 1: Align optical coordinate system in EOSINT M270

δx δy δθ

5. Repeat until alignment exposure aligns with reference geometry and save settings

Reference geometry

All parts are then built in fixed, known position (within accuracy of alignment)


PSW 3.3 includes a feature for aligning the optical coordinate system to the hardware

Example of alignment using reference geometry and PSW

Source: EOS

2. Define corresponding file for aligment exposures (example here cylinders positioned over reference holes)

3. Expose reference cont- ours and use PSW alignment feature to translate and rotate exposure to match reference features

1. Define and produce visible reference features on a build platform with fixed position (example here 9 circular holes)

This is an example; also other geometries can be used


Example of using positioning pins to locate build platform on carrier


LBC uses positioning pins integrated into EOSINT M270 to easily and accurately build hybrid tooling

Building a hybrid core in EOSINT M270 (1)


1. Core designed as machined preform (grey, including positioning holes) and laser-sintered addition (blue, including complex cooling channels)

2. Platform carrier in M270 prepared with locating holes and positioning pins

3. Bottom of build platform prepared with locating holes to match platform carrier (precise tolerances)


Reference position pins and PSW alignment feature enable accurate exposure on preforms



4. Machined preform mounted onto prepared build platform (screwed from behind, including positioning pins) and loaded into EOSINT M270

5. Top surface of preform positioned at building plane (Z=0) in powder bed

6. Building starts with first layer exposed onto top of preform, creating a metallurgical bonding


Reference position pins enable coordinate system to be transferred to post-machining systems



7. Remaining layers including cooling channels are built fully automatically by EOSINT M270

8. At job end the complete hybrid insert is ready for removal from the EOSINT M270

9. The insert can be aligned for post-machining (e.g. wire EDM) using the same positioning holes in the platform base


Summary

Left: Tool insert designed for hybrid production.Right: Hybrid insert produced in EOSINT M270 by building on top of a machined preform


EOSINT M can build on top of pre-machined preforms for highly efficiently hybrid tooling

— Requirements:•injection moulding tool inserts with optimzed cooling to greatly improve performance in series production

•rapid and cost-effective production•high performance tool steel

— Solution:•hybrid tooling: CNC machining + EOSINT M 270 with EOS MaragingSteel MS1 (1.2709)

— Result:•EOSINT M 270 with positioning pins enables building on preforms and easy alignment for post/machining

•an efficient solution for advanced tooling


Example of use of Erowa clamping system


EOSINT M offers an optional Erowa clamping system to interface to other machines with Erowa interface

Use of the Erowa clamping system in EOSINT M270 (1)

Source: EOS

1. Erowa Powerchuck 150 unit fits onto platform carrier in M270 process chamber

2. Erowa Powerchuck 150 unit in M270 with spacer blocks (only rear block shown)

3. Palette (prepared build platform) with mating element for Powerchuck


1. Build reference part on platform with reference position, e.g. palette on clamping system

2. Transfer platform/palette with reference part to post-processing system, e.g. CNC milling machine.

3. Align milling machine coordinate system to reference part, e.g. using touch probe

4. Build tool insert etc. using same reference system in EOSINT M, e.g. clamping system

Source: EOS

If a referenced positioning system is used then parts can be aligned for post-processing

Method 2: Align post-processing machine to build platform

Palette

Position reference, e.g. Erowa Powerchuck

Ref. part

5. Transfer platform/palette to post- processing system for post- machining

Note: needs to be done for each post/processing system


EOSINT M offers an optional Erowa clamping system to interface to other machines with Erowa interface

Use of the Erowa clamping system in EOSINT M270 (2)

Source: EOS

5. Completed job after removing powder and front spacer block

6. Laser-sintered part on palette, ready to be transferred to e.g. CNC mill or EDM machine

4. Completed job after raising the build platform


Summary


Building on preforms or pre-machined platforms can offer various advantages

— EOSINT M 270 can be integrated into tooling process chains in many different ways, depending on the requirements and preferences of the user

— Absolute positioning systems and clamping systems can be integrated into EOSINT M270

•Erowa Powerchuck 150 clamping system is available as commercial option•solution with positioning pins (similar to the demonstrated LBC solution) is planned as option

•customers can also implement other solutions via a build platform, if desired

— Using such solutions can save significant, time, effort and cost

Summary

SOURCE EOS


Future


Statement of direction / mid-term perspectives EOSINT M


EOSINT M materials development perspectives


EOSINT M materials perspective (possible scenario)

SOURCE EOS

DM100

Precious metals

Specials, e.g. shape memory alloys

Cermets, MMCs etc.

Hard metals, refractory metals

New alloys and composites

Other non-ferrous

Steels

Light alloys

Superalloys

DM50 DM20

DS50 DS20DSH20

DMLS special 1, 2, 3 ...

DM??????

Brass 1, Pb 1? ...Silver 1, Pt ...

Electrical goldDental gold

Jewellery gold

Al alloy 2, Mg alloy...Al alloy 1

Ti CPTi6Al4V

StainlessSteel 2 (PH1)

StainlessSteel 1 (17-4, 1.4542)

Tool steel 2

CoCr SP1CoCr MP1

Inconel, Waspalloy ...W, Mo, ...

???

Jan.

2008

FuturePast

Tool steel 1 (Maraging, 1.2709)

CoCr SP2


Different versions are possible within material groups

— In addition to adding more and more material groups, different versions of the same material can be developed, e.g.

•special purpose version (specially tuned for specific application requirements, e.g. CoCr SP1) vs. general purpose version (e.g. CoCr MP1)

•fast and economical version (coarse powder) vs. high-resolution version (fine grain size)

•high material specification version (higher purity or more extensive QA documentation) vs. "standard" version (sufficient quality but cheaper)

Examples

SOURCE EOS


Examples of other possible future materials

Source: EOS, 3D Micromac

AlSi10Mg Inconel 718 Hastalloy X

Gold (18 karat) Al2O3 and SiO Cu-W mixture


Quality in the supply chain


Quality procedures need to consider the entire production chain

SOURCE EOS

applicationapplicationdata preparation

data preparation

laser- sintering process


post- processing

post- processing

data generation

data generation

Quality assurance process


HWHW

applicationapplicationdata preparation

data preparation



post- processing

post- processing

data generation

data generation

machine HWmachine HW

peripheralsperipherals

PSWincl. interfaces

PSWincl. interfaces

powder materials powder

materials

Quality procedures need to consider the entire production chain

• correct function of machine

• production of powder constituents

• mixing of powder• powder packaging,

storage, delivery, shelf-life etc.

• powder recycling

• use of correct parameters

• modification of geometry• surface contamination

• delivery to end-user

• modification of data

• correct data capture

SOURCE EOS

Vorführender


Additional Information (not intended for direct publication) This is the most general process chain, applicable to all applications of EOSINT M. Details of the process chain steps depend on the particular application, e.g. post-processing can vary from as little as simply removing the part from the machine as builoding platform, to machining, hardening, coating etc. application is for example injection moulding, direct metal parts etc., as shown in the slide "Applications" For slides relating to data preparation, please see EOS „Company“ presentation.


Statement of direction / mid-term perspectives EOSINT M


Systems: Statement of direction

Continuous development according to the needs of e-Manufacturing

— Examples/potentials

•improved temperature management targeting further improved part quality/accuracy

•improved process control e.g. Online Laser Power Control

•external cool down station for fast turnaround times

•adaption/extension/integration of EOS Software at/for/in e-Manufacturing needs

data/job preparation

SOURCE EOS

tele service

Central database server

EOSTATE

ERP System


Questions and discussion


www.eos.info

advanced tooling with dmls - asiannet dmls... · composite tooling • previously made by cnc cut...

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