on the way to additive layer manufacturing: chances ... files (norbert)/2... · additive layer...
Post on 19-Jul-2018
216 Views
Preview:
TRANSCRIPT
October 2015 ETCG ALM 3D Printing Overview
Emerging Technologies & Concepts
Peter SANDER
On the way to Additive Layer Manufacturing: Chances & Challenges for the future industrial production
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ETCG ALM 3D Printing Overview
Airbus Emerging Technologies & Concepts
October 2015
Peter Sander, Dipl. Ing. Airbus Hamburg Manager Emerging Technologies & Concepts Germany 34 Years Aviation Industry Indutrial Engineering Tool design and manufacturing Manufaction Engineering Sheet Metal Production CRFP Production Stade A380 Operations Airbus R&T since Oct. 2010
Seite 2
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
On On the way to Additive Layer Manufacturing: Chances & Challenges for the future industrial production Agenda 1 – 3D Printing / ALM – an Overview ALM activities WW (some..) ALM Motivation ALM Materials&Processes 2 - 3D Printing Platform Airbus & linked Universities Demonstartor activities Industrial Needs 3 - Emerging Technologies & Concepts Way of Working
Page 3
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
July 2015
October 2015 ETCG ALM 3D Printing Overview
Page 4
Harvard Business Manager
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
July 17.th 2015
October 2015 ETCG ALM 3D Printing Overview
Page 5
DVZ
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM – AM – 3D Printing Wohlers Report 2015, Market Growth
October 2015 ETCG ALM 3D Printing Overview
Page 6
http://wohlersassociates.com/
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
ETCG ALM 3D Printing Overview
October 2015
Seite 7
Terry Wohlers Report 2015
Wohlers, Airbus & LZN WS March 2015
Prof. C. Emmelmann (LZN), Terry Wohlers, Peter Sander Jens Telgkamp, Airbus Hamburg http://www.wohlersassociates.com/
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM 3D Printing in Space, house printing China
October 2015 ETCG ALM 3D Printing Overview
Page 8
https://www.youtube.com/watch?v=SObzNdyRTBs
https://www.youtube.com/watch?v=XENDSqp-Oss
https://www.youtube.com/watch?v=d8JmuMbAcCE
10 printed houses in 1 day?
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM 3D Printing Pavillion - China
March 2015 ETCG ALM 3D Printing Overview
Page 9
http://www.designboom.com/architecture/vulcan-beijing-design-week-bjdw-largest-3d-printed-architectural-pavilion-parkview-green-10-07-2015/?utm_campaign=monthly&utm_medium=e-mail&utm_source=subscribers
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Jewellery Complete new design freedom – fully customized
October 2015 ETCG ALM 3D Printing Overview
Trend: ALM enables Fully Customized Products
Page 10
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM Werkzeuge/Maschinenteile (Concept customer event 09/14)
October 2015 ETCG ALM 3D Printing Overview
Page 11
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Cars only to show that it could work
October 2015 ETCG ALM 3D Printing Overview
http://www.tctmagazine.com/3D-printing-news/3d-printed-shelby-cobra-marks-50-years-classic-car
http://www.dailymail.co.uk/sciencetech/article-2232252/The-secret-James-Bonds-priceless-Aston-Martin-DB-5-stunts-3D-printed-models-used-Skyfalls-dangerous-scenes.html
Page 12
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Cars New light weight concepts, enabled by ALM
October 2015 ETCG ALM 3D Printing Overview
Page 13
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Yacht - Shipbuilding first demonstrators
March 2015 ETCG ALM 3D Printing Overview
http://www.slate.com/blogs/future_tense/2014/03/26/_3d_printing_a_kayak_jim_smith_kayak_grassroots_engineering_3d_systems_siskiwit.html
Page 14
https://www.youtube.com/watch?v=yzkbgSfPNnk
Topology optimized Clamp > 50% weight reduction
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Maersk On Board spare part cell
October 2015 ETCG ALM 3D Printing Overview
Trend: Production on demand Located at the point of use
http://3dprint.com/9021/maersk-ships-3d-printers/
Page 15
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
US Army In field spare part cell
October 2015 ETCG ALM 3D Printing Overview
Page 16
Production on demand Located at the point of use
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
BIONIC_3d_printing
Web search & Overview 2013/02/06
Matthias Hegenbart
USA NASA ALM In space
October 2015 ETCG ALM 3D Printing Overview
Page 17
Trend: Production on demand Located at the point of use
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Approaches USA, NASA
ETCG ALM 3D Printing Overview
http://www.nasa.gov/exploration/systems/sls/3d-printed-rocket-injector.html
October 2015
Seite 18
115 parts 2 parts Trend Multi functional parts
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
ALM Approaches USA, Space X
ETCG ALM 3D Printing Overview
http://www.spacex.com/news/2014/07/31/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed
October 2015
Seite 19
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM Aircraft APU Engine Activities Australia
ETCG ALM 3D Printing Overview October 2015
Monash University and spin-out company Amaero Engineering on Concept X-Line 1000
http://www.gizmag.com/3d-printed-jet-engine/36273/ http://www.abc.net.au/news/2015-02-26/australian-researchers-create-first-3d-jet-engine/6262462
Page 20
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM Aircraft Engine Activities
ETCG ALM 3D Printing Overview October 2015
http://www.flightglobal.com/news/articles/rolls-royce-to-fly-trent-xwb-with-largest-ever-3d-printed-409207/
Page 21
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Flying Approaches Airbus Group
June 2015 Airbus Emerging Technologies & Concepts ALM Overview
EF2000
Page 23
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Airbus Group Airbus Helicopters, Inox exhaust noozle, 1. Flight April 1st 2014
June 2015 Airbus Emerging Technologies & Concepts ALM Overview
Page 24
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
On the way to Additve Layer Manufacturing: Chances & Challenges for the future industrial production Agenda 1 – 3D Printing / ALM – an Overview ALM activities WW (some..) ALM Motivation ALM Materials&Processes 2 - 3D Printing Platform Airbus & linked Universities Flying Parts & Demonstartor activities 3 - Conclusions
Page 25
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Motivation General statements
October 2015 ETCG ALM 3D Printing Overview
Page 26
Weight saving 30 - 55% NRC reduction up to 90% Lead time reduction up to 75% Cost saving 2016 onwards up to 10% “Green” technology energy red. up to 90%
“Game-Changing” technology Available: 01.01.2016 Powder Bed Laser beam Ti
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Motivation 50% Reduction of process steps conventional ALM
October 2015 ETCG ALM 3D Printing Overview
PAG starts ALM Production in VAR July 2014
Trend: Near End Contour Relevant reduction of production steps
Page 27
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3D Printing “ALM”: Technologies ETCG ALM 3D Printing Overview
(PA) ; (PEK)
Ultem (PEI)
(Ti) ; (Ni/Inconel) ; (Al)
October 2015
- PLASTIC - - METALLIC -
FDM: Fuse Deposition Modelling ; SLS: Selective Laser Sintering EBM: Electron Beam Melting ; LBM Laser Beam Melting
LBM EBM
Page 28
FDM
SLS
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3D Printing “ALM”: Technologies Film FDM Stratasys Material Ultem (PEI)
ETCG ALM 3D Printing Overview October 2015
Page 29
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3D Printing “ALM”: Technologies LaserBeamMelting Powderbed Material Titan
ETCG ALM 3D Printing Overview October 2015
Page 30
© AIRBUS Operations S.A.S. Tous droits réservés. Document confidentiel.
ALM Process October 2015
Ti6-4 Powderbed Laser-/Electro Beam TRL6 Eo2015 All Material/Process Requirements defined
ESCMU View about ALM qualification Strategy
Page 31
ETCG ALM 3D Printing Overview
October 2015 ETCG ALM 3D Printing Overview
Airbus Emerging Technologies & Concepts
Peter SANDER
ALM / 3D-Printing Overview Future Machine Development´s
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Volume: Factor 7 2012 2014 Deutsche Technik!
Airbus ALM/3D Printing Trends
Page 33
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Airbus ALM/3D Printing Concept X-Line 1000 and new X-Line 2000 Serial Printer
X-Line 2000: Volume: Laser Power 800x400x550 2x1000W (e.o. 2015)
Page 34
Complete Closed Double place system
3D Printing de-packing in parallel
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Airbus ALM/3D Printing AeroSud aeroswift Project
Volume: Laser Power Max. Build up rate 2000x600x600 5KW 250cm³/h
First Demo Parts 2015 Serial Mode 2017 2013:
Page 35
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Trend: Increase of Speed: Factor >100 to FDM?
Airbus ALM/3D Printing Trends HP Plastic Printing
Seite 36
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Trend: Expected Increase of Speed: Factor 100-1000 In the next 10-20 years
Airbus ALM/3D Printing Trends
Page 37
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
On the way to Additve Layer Manufacturing: Chances & Challenges for the future industrial production Agenda 2 – ALM Platform Airbus & linked Universities Demonstartor activities Industrial Needs
Page 38
Von der Wissenschaft der TUHH, zum bionischen Flugzeugbau?!
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Airbus new E2E ALM TP (Technical Product ) ETCG ALM 3D Printing Overview
Engineering capabilities
Qualification & Certification
Manufacturing technology
Material development
Industrialisation
October 2015
Page 39
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM&Bionic Plateau Kick off September 25th Hamburg, B.25, R.5501.1
September 2015 ETCG
Page 40
Topology Optimized Bionic Design isn't an engineering gimmick 30% weight reduction leads 1:1 to 30% cost reduction because the material doesn´t need to be printed: Bionic Design is one of the key enabler for low cost ALM Parts (exactly the opposite to the “black metal” approach) The Bionic Partition enables massive cost improvements 2018 onwards
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
ALM Design & Production in Praxis 4-day Training for Airbus Employees
October 2015 ETCG ALM 3D Printing Overview
41
Training Design tested 12/2014 Trainings scheduled for 55 P. for 2015 Training Certificate
Requirements: 2016: 250 to be trained
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Technologieentwicklung Europaweit im Technical Product (TP)
September 2015 Peter Sander, Airbus Hamburg, ETCG
2015 Titanium ALM: Powder bed Technology TRL6 First Version of integrated toolset (automated data transfer) testing phase
and skill development 1st set of design concepts enabled by ALM and
1st set of Ti demonstrator / pilot parts defined
2016 Plastic Laser Sintering (PA/PEK) TRL6 Nickel / INCONEL Powder Bed TRL6 Ti Powder Bed full process qualification
2017 / 2018
Aluminum ALM: Powder Bed TRL6 Titanium ALM: High Deposition Rate Technology TRL6 Enhanced / reinforced plastic ALM TRL6 2nd version of Development Toolset
(incl. material properties, process parameters, manufacturing simulation, use of microstructures)
1st Bionic components in the aircraft
2020 Fully Integrated Stress/ Design Toolset rolled out.
KEY deliverable, aligned with A350 needs
KEY
KEY
KEY
2025 Bionic / integrated components
2030+ Bionic aircraft
KEY
KEY
Page 42
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
3D Printing / ALM Linked Universities/Institutes
Seite 43
October 2015 ETCG ALM 3D Printing Overview
Emerging Technologies & Concepts
Peter SANDER
Future ALM/3D Printing enabling Landscape
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Agenda: 2 – Landscape 2014 - R&T
Page 45
Future ALM/3D Printing enabling Landscape
Stade BRE: Materialwissenschaften & Bionik Hamburg: ALM Design mit Designprinciples aus/mit Erstmustererprobung Varel: ALM Industrial, Seriendruck und industrielle Weitereverarbeitung
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM-Kernprozeß Kompetenzen: Wo kann wer mit was unterstützen?
Month 20XX Use Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 LZN 10 10 10 10 10 8 TUHH
DLR
IFAM
ISEMP Simulation
IWT
BIAS
Bewertung durch Unternehmen/Institute selbst,Skala von 0 (keine Kompetenz) bis 10 (hohe Kompetenz).
Zulassungen im A
C
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM-Bauweisen und industrielle Konzepte Wo kann wer mit was unterstützen?
Month 20XX Use Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference
B1 B2 B3 T1 T2 T3 I1 I2 I3 I4 I5 I6 Reverse
Eng. M1 M2 M3
HSU x x Bionic HS Bremen 10
Bewertung durch Unternehmen/Institute selbst, Skala von 0 (keine Kompetenz) bis 10 (hohe Kompetenz).
Bionic Solutions UAV´s Topologie optimierte Bionische Bauweisen
Toleranzfreie Fertigung
Individualfertigung Statt Standardisierung
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
2025 Nur ein Szenario: Enabler: Bauteilspezifische, und Universaldrucker haben den 250fachen Output gegenüber 2015 erreicht Pulverkosten sind auf dem Niveaus von allen Standardhalbzeugen Produkte: Sind Kundenspezifisch + gewichtsminiert nur das sichert den Marktanteil - Individuelle zweckoptimierte Produkte haben Standardprodukte abgelöst - Standardisierung hat generell an Bedeutung verloren, jedes noch so kleine Bauteil wird auf den Ressourceneinsatz im individuellen Betrieb optimiert - Toleranz-Systemen haben an Bedeutung verloren, die Wertschöpfungsketten orientieren sich erstmalig am teuersten, komplexesten Bauteil, Anbauteile werden angepasst gefertigt - Alle Produkte und Einzelteile sind mit ihren individuellen Ist Daten im 3D verfügbar und können jederzeit verwendungsnah nachgefertigt werden
Die Frage: Wie wird sich die anstehende Väranderung durch ALM auf Ihr Forschungsgebiet auswirken Wie ist Ihre Sicht 2025 ?
Page 48
Future ALM/3D Printing enabling Landscape
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Page 49
Future ALM/3D Printing enabling Landscape
Agenda: 3 – Proposals - Way forward A - Bis Ende Januar 2016 Bilateral Meeting “vor Ort” bei Ihnen ( Bitte Ansprechpartner benennen) B - Ende März 2016 Airbus Worshop unter Einbindung aller Beteiligten - Szenario 2025 - Angebotene Beiträge der Institute/Univ. zum 2025 - Start - Netztwerk zur beschleunigten ALM-Produkt-Entwicklung
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
On the way to Additve Layer Manufacturing: Chances & Challenges for the future industrial production Agenda 2 - 3D Printing Platform Airbus & linked Universities - Flying Parts & Demonstartor activities >120 up to now
Page 50
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Airbus Additive Layer Manufacturing Germany Ongoing ALM coops: Exchanges Airbus-LZN Workshops
Page 51
>120 ALM Projects performed up to now in Germany We are very open to extend our network / ALM-Cooperation´s!
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM – 3D Printing Tooling on demand
ETCG ALM 3D Printing Overview October 2015
Holger Loges
Trend: Tooling on demand Short term low cost problem solving
Page 52
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
A350-1000 Flap Test Rigg´s, High-Lift Test Equipment
ALM – 3D Printing Test Equipment
Page 53
Dynamic Test passed
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM – 3D Printing Tooling on demand
Airbus Emerging Technologies & Concepts ALM Overview June 2015
Page 54
Kosten 511 € für 2 Stk. Kosten dürften bei höheren Stückzahlen pro Stk. deutlich sinken, da die Teile gut stapelbar sind
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM – 3D Printing Interims Parts on demand
Airbus Emerging Technologies & Concepts ALM Overview June 2015
Thomas GADEN Manufacturing Process Planner Manufacturing Engineering Primary Structure - DAKTD1 Delivered 12.01.15 LZN AIRBUS Phone: +49(0)40 743 67566 Fax: +49(0)40 743 870 67566 Mobile: +49 171 861 99 63
Page 55
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Page 56
Trend: Very attractive for low production rate´s & Local Production on demand >70% lead time & cost reduction possible
Airbus ALM/3D Printing FDM
A350 Flight Test Installation Brackets FDM ^ FDM A350 Serial Parts: >70% cost and lead time reduction 04/2015: 78 Part No with >500pcs
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
First 3D Printed Spare Part at AIRBUS A real out of production demonstrator “Belt Mold”
ETCG ALM 3D Printing Overview
ALM - Belt Mold • purchase price/part: ~ $ 265,-* • lead time: ~ 1 to 2 weeks
Request
AIRBUS Innovation Cell
All Test passed Flying with Air TransNet Feb 2014
October 2015
Trend: Certified spare part printing cells Instead of stocks (Frankfurt/Singapore..)
Seite 57
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
ALM / 3D Printing Awards 2015
ETCG ALM 3D Printing Overview October 2015
Seite 58
Digital Business Innovation Award 2015
Munich, January 27.th
October 2015 ETCG ALM 3D Printing Overview
Airbus Emerging Technologies & Concepts
ALM / 3D-Printing
Awards: Finalist German Innovation Award Feb.14 German Design Award special mentioned in Gold Feb.15
Airbus ALM / 3D-Printing First flight Bionic Cabin Bracket June 20.th
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Airbus ALM/3D Printing FCRC Cabin Bracket – Installation 2013
Bracket installed on FCRC Cabin Monument (TLS):
October 2015 ETCG ALM 3D Printing Overview
Installed on A350 MSN 5 Task 2014: Weight Reduction 50% & Industrialisation for serial production 2016 onwards
Seite 60
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Additive Layer Manufacturing FCRC Bracket Structure test´s >120KN / Strength >1000 N/mm²
October 2015 ETCG ALM 3D Printing Overview
Seite 61
All test´s passed Capability Ti6-4 FCRC Bracket > 12 tonn´ s
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
A350-1000 FTI Metal parts
Material: Ti6-4 LZN done CW 37 Delivery to TLS, CW38
October 2015 ETCG ALM 3D Printing Overview
Airbus ALM/3D Printing A350 FTI Metal
Page 62
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
A350-1000 FTI Bulkhead seal connect
October 2015 ETCG ALM 3D Printing Overview
Airbus ALM/3D Printing Alu FTI parts
Page 63
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Non solid A380 Antenna Adapter Request: CW 26/2015 Start Production: CW 28 Delivered: CW29 Ti6-4 (1240€)
Material: Ti6-4 Grade 2
October 2015 ETCG ALM 3D Printing Overview
Airbus ALM/3D Printing A380 FTI Metal
Page 64
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Pax & Emergency Exit Doors, first request Feb. 27.th Alu sheet metal profiles
ALM – 3D Printing A350 door approach
Page 65
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Pax & Emergency Exit
ALM – 3D Printing A350 door approach
Page 66
First Flight A350 MSN 002: April, 02.nd 2015 Still in use
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Benefits: Reducing the part count for the specific function from currently 126+ items down to 1. Lead time reduction from 20 days to 2 days, weight reduction 50%
Reduction of complexity: Hydraulic Reservoir Rack (Assembly)
Why did the jury vote for it? Reducing the part count for the specific function from currently 200+ items down to 1 for future big size 3-D printing machine
Idea Space campaign winner, cluster reduction of complexity
Short Description: • Hydraulic Reservoir Rack
Assembly consists of: • 126 Drawing parts • 27 Fastener • 61 Anchor nut
Material: Al
October 2015 ETCG ALM 3D Printing Overview
Page 67
Trend: ALM enables 126:1
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Ti6-4 Fuel Connector
Page 68
Trend: No casting tool's needed 14:1 part approach ALM highly competitive
Airbus ALM/3D Printing Fuel connector
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM – 3D Printing Systems: 5 Fuel Connector´s, first drawing released Feb.15
October 2015 ETCG ALM 3D Printing Overview
Page 69
Trend: No casting tool's needed Tool cost: 500.000€/set
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM Manifold Approach together with Liebherr
October 2015 ETCG ALM 3D Printing Overview
Status: TRL5, Target: Flyable Hydraulic Unit end of 2015
55% weight reduction 10% cost reduction 2016 onwards
ALM – 3D Printing Systems
Page 70
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ETCG ALM 3D Printing Overview
Fuel Cell Cooling System
First printout Of a Al-cooler in 1-shot successful Demonstrated at LZN
October 2015
ALM – 3D Printing Cooling Systems
Trend: No tooling needed 3D Design, ALM, Test, redesign, ALM.. Product development in weeks
Page 71
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Airbus Emerging Technologies & Concepts
October 2015 ETCG ALM 3D Printing Overview
Page 72
Learn out of nature & Print the future ! 3 – Bionic Solution Print the future
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ETCG ALM 3D Printing Overview
Feb 2012 Giant Water Lilly - How it starts
Page 73
October 2015
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Page 74
Trend: No tooling needed, heat resistant ALM-Sheet metal competitive CFRP
Airbus ALM/3D Printing Tailcone Demonstrator in Al
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Concept Study – Spoiler A330
Oliver Seack, Airbus Bremen
Page 75
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
Bionic Spoiler pre study Bremen Oliver Seack
First Outcome´s Bionic Spoiler Demonstrator
Page 76
Prof. Antonia Kesel Uni BRE 2m ALM Powderbed machine South Africa
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
October 2015 ETCG ALM 3D Printing Overview
Seite 77
TOPOLOGY OPTIMISATION AIRBUS VISION 2050 ENABLER
Bionic AC Structures... ?
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Trend: No tooling needed Sheet metal competitive CFRP
ALM means October 2015 ETCG ALM 3D Printing Overview
Trend: No tooling needed ALM highly competitive to casting
Trend: Very attractive for low production rate´s
Trend: Certified spare part printing cells Instead of stocks (Frankfurt/Singapore..)
Trend end of 2018: > 30T printed parts/month 270T less raw material/month
126 1 parts Trend Multi functional parts 125 tooling's not needed 125 tool maintenance not needed 125 stock / Logistic “ - “
Production on demand Located at the point of use
Trend: 2016 onwards competitive to milling parts Every industry will be affected
Page 78
Trend: No tooling needed Product development in weeks
Trend: 50% reduction of Production steps
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
ALM also means October 2015 ETCG ALM 3D Printing Overview
Page 79
Risk: 3D Scan – “copy”-print ?
Risk: 50% Conventional Industrial Infrastructure old in a few years ?
Airbus „ Form 1“
Specific know how needed Not only 3d-Model & Print
Risk: ALM lead´s very Co² optimized products production and product use New „Bionic“ design has to be validated 2-4 years
If of interest – You have to speed up!
© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.
October 2015 ETCG ALM 3D Printing Overview
Page 80
Extended Workbench 1
Industrial Start-Setup ALM Machine Availability June 2015
Extended Workbench 2
1x (+3x)
1x
2x
Extended Workbench 3 3x
Hamburg H.31 1x
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015 ETCG ALM 3D Printing Overview
On the way to Additve Layer Manufacturing: Chances & Challenges for the future industrial production Agenda 1 – 3D Printing / ALM – an Overview
- ALM activities WW (some..) - ALM Motivation - ALM Materials&Processes
3 - 3D Printing Platform Airbus & linked Universities - Demonstartor activities - Industrial Needs 3 - Emerging Technologies & Concepts Way of Working
Page 81
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
1. Introduction What is innovation?
October 2015 ETCG ALM 3D Printing Overview
Page 82
Innovation is the creation of better or more effective products, processes and technologies that are accepted by
markets and society.
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ETCG ALM 3D Printing Overview
How to find the Ideas and disruptive idea owners? Airbus Idea Space
Seite 83
October 2015
Speed and individual help for disruptive idea´s and - owners
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3D Printing Challenge on Idea-Space to find new ALM Ideas October 2015 ETCG ALM 3D Printing Overview
192 3D Printing Ideas collected in 5CW GB / F / G / ES/ USA 13 Finalists-Projects printed in 6 CW and awarded September 05.th
Page 84
Campaign Finalists Ceremony Day of the Winners
3D Printing Challenge 2014 Find the best parts for 3-D printing
LZN September 05.th, the Finalists from GB/F/USA/G presented their ALM Projects
Empowered by LZN & Concept Laser
October 2015 ETCG ALM 3D Printing Overview
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
ALM ProtoNet Partners And finalists Deutscher Zukunftspreis:
October 2015 ETCG ALM 3D Printing Overview
86
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
October 2015
© Airbus S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
ETCG ALM 3D Printing Overview
Page 87
Thanks for your Attention!
I like to extend my network on ALM!
peter.sander@airbus.com
Airbus 3D Printing Video on YouTube http://www.youtube.com/watch?v=Cy3V3KR1LW
Download the new Airbus FAST Magazine with 3D Printing: http://www.airbus.com/support/publications/?eID=maglisting_push&tx_maglisting_pi1%5BdocID%5D=42444
3D Printing Revolution:
http://www.harvardbusinessmanager.de/heft/
Nominiert für den Deutschen Zukunftspreis: „Eine Fertigungsrevolution hebt ab“ http://www.deutscher-zukunftspreis.de/de/nominierteDie Welt: Das sind die besten deutschen Erfindungen 2015
top related