centre for additive layer manufacturing - university of … · calm’s vision 1) continue to grow...
TRANSCRIPT
Centre for Additive
Layer Manufacturing James Bradbury and Richard Davies (ALM Engineers)
7th March 2012
CALM Business Technology Centre
• £2.6M investment: • The Regional Development Agency (RDA) • The European Regional Development Fund (ERDF) • The University Of Exeter • The European Aeronautic Defence and Space Company (EADS)
• A New £1M Centre based at The University Of Exeter:
• CALM is an industrial facing initiative • Sole focus will be on AM technologies • Operational from July 2011
CALM’s Vision
1) Continue to Grow and work with SME’s on Additive Layer Manufacturing (ALM)
2) Deliver world class research on Additive Layer Manufacturing (ALM)
What is Additive Layer Manufacturing?
What is ALM?
Design (CAD) ALM
System
Functional component
Different ALM processes
Please note: This is part of a promotional video created by EOS GmBh
Case Study - Tooling insert application
CALM Equipment and resources
CALM’s Equipment High temperature Polymer Laser Sintering (LS) System
The only PEK ALM System in the UK
Material: PEEK (Polyetheretherketone) Tolerance: >100mm +/-0.5%, <100mm +/-1% Max sizes: 700x380x560mm (x,y,z) Speed (z-height): 6mm/hr or 8mm/hr
Polymer LS Systems
CALM’s Equipment
Material: Nylon 12 (Polyamide/filled) Tolerance: >100mm +/-0.2%, <100mm +/-0.5% Max sizes: 200x250x330mm (x,y,z) Speed (z-height): 20mm/hr
Metallic - Powder Bed Laser Melting (LM) System
CALM’s Equipment
Material: Steel grades, Titanium alloys, Nickel alloys, Aluminium alloys. Tolerance: +/-0.25mm Max sizes: 250x250x300mm (x,y,z) Speed (z-height): 5mm/hr
CALM’s Equipment
x1 Metallic – Powder Feed Laser Consolidation (LC) System. The only ALM System in the Europe
Material: Steel grades, Titanium alloys and Nickel alloys, Tolerance: +/-0.25mm Max sizes: 200x200x500mm (x,y,z) Speed (z-height): 10mm/hr
Material Extrusion System
CALM’s Equipment
Material: ABS (Acrylonitrile butadiene styrene) Tolerance: +/-0.2mm Max sizes: 200x200x300mm (x,y,z) Speed (z-height): 5mm/hr
3D Printing System
CALM’s Equipment
Material: Acrylic Plastic Tolerance: +/-0.1% Max sizes: 300x185x200mm (x,y,z) Speed (z-height): 12mm/hr
Test Equipment • Analysis and Test Equipment:
• Mechanical testing • Thermal Analysis • Rheology • Microscopy • Surface Analysis • Spectroscopy
• Machine Workshop:
• CNC turning • CNC horizontal and vertical milling • Drills • Grinders • 5 axis rotor • 4 axis spark eroder
What are the advantages of using
Additive Layer Manufacturing?
• Environmental aspects • Clean – No cutting or cooling fluids
• Product life cycle
• Single step process
• Material utilization • 90% recycling rate
• Minimizing material waste
• Geometry freedom (Design) • Organic structure
• Freeform shapes
• Complex structures
What Advantages can ALM give you?
•Repairs • Products in service
•Multi part manufacture • Batch manufacture
• Reduction in Storage and inventory
• Varying material properties
• Optimize design • CFD (Computational Fluid Dynamics)
• FEA (Finite Element Analysis)
• Design for the application
• Weight Saving
What Advantages can ALM give you?
What Advantages can ALM give you? • Functionally graded materials
• Multiple materials
• Structured matrix
•Lead time • Design to functional part
• No tooling required
• Reverse Engineering • In production solutions
• CAD creation
• Assemblies • Moving parts
• Multiple part manufacture
Where Additive Layer Manufacturing need to improve from an environmental point of view.......
• High power Laser • Power source – bonds powder together
• High use of Energy
• Gas Atomization • Raw material process
• High use of Energy
Case Study
Topology Optimization of an Additive Layer Manufactured
(ALM) Aerospace Part
Existing component cast in HC101
steel and post machined for accuracy
Design optimisation using a new Titanium
material, Ti6AI4V
For every 1kg reduction in weight, airlines can save
around $3,500 of fuel over an aircraft’s life
The new design weighs 326g compared to the original
918g, a reduction of 64%
What can CALM offer you?
What can CALM offer businesses? CALM exists to help South West businesses discover
how Additive Layer Manufacturing (ALM) could add value to your
products and processes
CALM has a range of ways this
happens in practice…
CALM Services*
Open days
3D printing workshops
Build an ALM part
Computer Aided
Design for ALM
ALM opportunity review – site
visit
Fully defined, research projects
* FREE / Subsidised to qualifying SMEs in South West
Individual work
package
Wednesday 28th March 2012
"It was so helpful to experience the whole process of ALM, tutored by such a knowledgeable team.
Opened my eyes to the range of possibilities." Roger Cooper - Valueadding.com
"Anyone remotely interested in ALM should attend and they may be surprised by the
possibilities." Glyn Cowles - Proximus IT Services Ltd
"Excellent workshop. Expectations and objectives met and furthermore exceeded. Very worthwhile.
Thanks to the CALM team for a great day." Adrian Ryder - Manage 2 Ltd
3D printing workshops
Individual consultation
Daily individual consultation arranged at your convenience.
Immediate part manufacture
Product and component manufacture for customers projects.
On Site ALM opportunity reviews
Weekly onsite ALM opportunity reviews at your convenience.
Classification of a Small to Medium Enterprise (SME)
Is your business classified as an SME and does your
business meet the following criteria?
The Business is less than 25% externally owned The Business independent or does not own 25% or more of another business Turnover is less than €50 million OR Balance sheet totals less than €43 million The Business has less than 250 employees Have not received more than €200,000 of government funds over the last 3 years
CALM’s Target area
Devon: Exeter, Plymouth, Torquay and Paignton Somerset: Taunton, Bath, Bridgewater and Weston-Super-Mare Dorset: Dorchester, Weymouth, Bournemouth and Poole Wiltshire: Bath, Swindon, Salisbury and Chippenham Bristol: Whole county Gloucestershire: Gloucester, Cheltenham, Stroud and Yate
CALM - Case Studies For more information on Case Studies completed
by CALM please e-mail [email protected];
For more information contact:
Sara Flint
James Bradbury
Richard Davies
Ed James
www.exeter.ac.uk/CALM
Tel. 01392 726 618