Metal AM as a Part of an Assembly

Kim-Niklas ”The Bicycle Baron” Antin

Aalto University

Lots of hype –only a few viable application so far

• AM is not suitable for everything

• Important to know whereto use it

• Case studies are needed to show the way: No morechess pieces!

Case study: AM for joining bicycle tubes

1. Print wax patterns, make mould and cast

2. Print mould and cast

3. Print metal parts directly

4. Composite parts using AM tools

Case 1: AM wax patterns for investment casting

1. CAD/FEA2. Tool design3. Casting simulations4. Making master die5. Casting/Printing patterns6. Creating pattern cluster7. Building up ceramic mould8. De-waxing and sintering9. Making part (casting)10.Breaking mould11.Post-machining

Step 1. CAD

Step 5. Print wax patterns

Step 6. Create pattern cluster

Step 7. Build up ceramic mould

Step 9. Casting

Step 10. Break the mould

Case 1: Finished bike

Case 2: AM sand moulds

1. CAD/FEA2. Tool design3. Casting simulations4. Making master die5. Printing patterns6. Creating pattern cluster7. Building up mould8. De-waxing and sintering9. Making part (casting)10.Breaking mould11.Post-machining

Step 1a. FEA (optimization)

Before After (Max. stiffness)

Step 1b. FEA (verification)

Step 2. Mould design

Step 3. Casting simulations

Step 7. Printing mould (Binder jetting)

Step 11. Post-machining

Case 2: Finished bike

Case 3: Direct AM

1. CAD/FEA2. Tool design3. Process simulation/CAM4. Making master die5. Printing patterns6. Creating pattern cluster7. Building up mould8. De-waxing and sintering9. Making part (printing)10.Breaking mould11.Post-machining

Case 3a: Direct AMSteel lugs before removing

support material

Case 3b: Direct AM

Method Price Time Image

AM Patterns €

AM Moulds €

Direct AM €

Comparison of methods

Case 4: Composite parts

1. CAD/FEA2. Tool design3. Laminate simulation4. Printing tools5. Surface preparation6. Laminating7. Vacuum bagging8. Finishing

Step 1. CAD

Step 2. Tool design

Step 5. Surface preparation

Step 6. Laminating

Step 7. Vacuum bagging

Step 8. Finishing

Case 4: Finished bike

Conclusions

• AM can be used in many ways to achieve thesame goal

• No need to set up a factorySmall companiesenter the market

• Knowing strenghts and weaknesses of AM is crucial for successCase studies are needed

@ideas2cycles