on the way to additive layer manufacturing: chances ... files (norbert)/2... · additive layer...

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

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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

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

July 2015


Harvard Business Manager


July 17.th 2015


DVZ


ALM – AM – 3D Printing Wohlers Report 2015, Market Growth


http://wohlersassociates.com/

© AIRBUS Operations GmbH. Alle Rechte vorbehalten. Vertrauliches und geschütztes Dokument.


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/


ALM 3D Printing in Space, house printing China


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?


ALM 3D Printing Pavillion - China

March 2015 ETCG ALM 3D Printing Overview

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


Jewellery Complete new design freedom – fully customized


Trend: ALM enables Fully Customized Products


ALM Werkzeuge/Maschinenteile (Concept customer event 09/14)



Cars only to show that it could work


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


Cars New light weight concepts, enabled by ALM



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

https://www.youtube.com/watch?v=yzkbgSfPNnk

Topology optimized Clamp > 50% weight reduction


Maersk On Board spare part cell


Trend: Production on demand Located at the point of use

http://3dprint.com/9021/maersk-ships-3d-printers/


US Army In field spare part cell


Production on demand Located at the point of use


BIONIC_3d_printing

Web search & Overview 2013/02/06

Matthias Hegenbart

USA NASA ALM In space


Trend: Production on demand Located at the point of use


ALM Approaches USA, NASA


http://www.nasa.gov/exploration/systems/sls/3d-printed-rocket-injector.html

October 2015

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115 parts 2 parts Trend Multi functional parts


ALM Approaches USA, Space X


http://www.spacex.com/news/2014/07/31/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed

October 2015

Seite 19


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

http://www.gizmag.com/3d-printed-jet-engine/36273/


ALM Aircraft Engine Activities


http://www.flightglobal.com/news/articles/rolls-royce-to-fly-trent-xwb-with-largest-ever-3d-printed-409207/

ALM Roadmap Team Airbus Group


Airbus Group


ALM Flying Approaches Airbus Group

June 2015 Airbus Emerging Technologies & Concepts ALM Overview

EF2000


ALM Airbus Group Airbus Helicopters, Inox exhaust noozle, 1. Flight April 1st 2014

June 2015 Airbus Emerging Technologies & Concepts ALM 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


ALM Motivation General statements


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


ALM Motivation 50% Reduction of process steps conventional ALM


PAG starts ALM Production in VAR July 2014

Trend: Near End Contour Relevant reduction of production steps


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

FDM

SLS


3D Printing “ALM”: Technologies Film FDM Stratasys Material Ultem (PEI)



3D Printing “ALM”: Technologies LaserBeamMelting Powderbed Material Titan


© 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




Peter SANDER

ALM / 3D-Printing Overview Future Machine Development´s



Volume: Factor 7 2012 2014 Deutsche Technik!

Airbus ALM/3D Printing Trends



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)

Complete Closed Double place system

3D Printing de-packing in parallel



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:



Trend: Increase of Speed: Factor >100 to FDM?

Airbus ALM/3D Printing Trends HP Plastic Printing

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Trend: Expected Increase of Speed: Factor 100-1000 In the next 10-20 years

Airbus ALM/3D Printing Trends



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

Von der Wissenschaft der TUHH, zum bionischen Flugzeugbau?!


Airbus new E2E ALM TP (Technical Product ) ETCG ALM 3D Printing Overview

Engineering capabilities

Qualification & Certification

Manufacturing technology

Material development

Industrialisation

October 2015


ALM&Bionic Plateau Kick off September 25th Hamburg, B.25, R.5501.1

September 2015 ETCG

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


ALM Design & Production in Praxis 4-day Training for Airbus Employees


41

Training Design tested 12/2014 Trainings scheduled for 55 P. for 2015 Training Certificate

Requirements: 2016: 250 to be trained


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



3D Printing / ALM Linked Universities/Institutes

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Emerging Technologies & Concepts

Peter SANDER

Future ALM/3D Printing enabling Landscape



Agenda: 2 – Landscape 2014 - R&T


Stade BRE: Materialwissenschaften & Bionik Hamburg: ALM Design mit Designprinciples aus/mit Erstmustererprobung Varel: ALM Industrial, Seriendruck und industrielle Weitereverarbeitung


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


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



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 ?





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



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



Airbus Additive Layer Manufacturing Germany Ongoing ALM coops: Exchanges Airbus-LZN Workshops

>120 ALM Projects performed up to now in Germany We are very open to extend our network / ALM-Cooperation´s!


ALM – 3D Printing Tooling on demand


Holger Loges

Trend: Tooling on demand Short term low cost problem solving



A350-1000 Flap Test Rigg´s, High-Lift Test Equipment

ALM – 3D Printing Test Equipment

Dynamic Test passed


ALM – 3D Printing Tooling on demand

Airbus Emerging Technologies & Concepts ALM Overview June 2015

Kosten 511 € für 2 Stk. Kosten dürften bei höheren Stückzahlen pro Stk. deutlich sinken, da die Teile gut stapelbar sind


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



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


First 3D Printed Spare Part at AIRBUS A real out of production demonstrator “Belt Mold”


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


ALM / 3D Printing Awards 2015


Seite 58

Digital Business Innovation Award 2015

Munich, January 27.th



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 ALM/3D Printing FCRC Cabin Bracket – Installation 2013

Bracket installed on FCRC Cabin Monument (TLS):


Installed on A350 MSN 5 Task 2014: Weight Reduction 50% & Industrialisation for serial production 2016 onwards

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Additive Layer Manufacturing FCRC Bracket Structure test´s >120KN / Strength >1000 N/mm²


Seite 61

All test´s passed Capability Ti6-4 FCRC Bracket > 12 tonn´ s


A350-1000 FTI Metal parts

Material: Ti6-4 LZN done CW 37 Delivery to TLS, CW38


Airbus ALM/3D Printing A350 FTI Metal


A350-1000 FTI Bulkhead seal connect


Airbus ALM/3D Printing Alu FTI parts


Non solid A380 Antenna Adapter Request: CW 26/2015 Start Production: CW 28 Delivered: CW29 Ti6-4 (1240€)

Material: Ti6-4 Grade 2


Airbus ALM/3D Printing A380 FTI Metal



Pax & Emergency Exit Doors, first request Feb. 27.th Alu sheet metal profiles

ALM – 3D Printing A350 door approach



Pax & Emergency Exit

ALM – 3D Printing A350 door approach

First Flight A350 MSN 002: April, 02.nd 2015 Still in use


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


Trend: ALM enables 126:1



Ti6-4 Fuel Connector

Trend: No casting tool's needed 14:1 part approach ALM highly competitive

Airbus ALM/3D Printing Fuel connector


ALM – 3D Printing Systems: 5 Fuel Connector´s, first drawing released Feb.15


Trend: No casting tool's needed Tool cost: 500.000€/set


ALM Manifold Approach together with Liebherr


Status: TRL5, Target: Flyable Hydraulic Unit end of 2015

55% weight reduction 10% cost reduction 2016 onwards

ALM – 3D Printing Systems



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




Learn out of nature & Print the future ! 3 – Bionic Solution Print the future



Feb 2012 Giant Water Lilly - How it starts

October 2015



Trend: No tooling needed, heat resistant ALM-Sheet metal competitive CFRP

Airbus ALM/3D Printing Tailcone Demonstrator in Al



Concept Study – Spoiler A330

Oliver Seack, Airbus Bremen



Bionic Spoiler pre study Bremen Oliver Seack

First Outcome´s Bionic Spoiler Demonstrator

Prof. Antonia Kesel Uni BRE 2m ALM Powderbed machine South Africa



Seite 77

TOPOLOGY OPTIMISATION AIRBUS VISION 2050 ENABLER

Bionic AC Structures... ?

Vorführender

Präsentationsnotizen

With the bionic design and the 3d printing we can build the bionic airplane


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

Trend: No tooling needed Product development in weeks

Trend: 50% reduction of Production steps


ALM also means October 2015 ETCG ALM 3D Printing Overview

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!



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



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


1. Introduction What is innovation?


Innovation is the creation of better or more effective products, processes and technologies that are accepted by

markets and society.

Vorführender

Präsentationsnotizen



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


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

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



ALM ProtoNet Partners And finalists Deutscher Zukunftspreis:


86


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.


Thanks for your Attention!

I like to extend my network on ALM!

[email protected]

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

mailto:[email protected]

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