sustainability approach by design optimization for advanced layer manufacturing

This presentation may contain confidential and/or privileged information.

Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.

Sustainability approach by Design Optimization for Advanced Layer Manufacturing

Udo BehrendtBusiness Development

Manager Aerospace

E-Manufacturing_May2012_UB.pptx | EOS | 2

~ 1200 systems thereof ~ 450 M-systems

EOS is a ''global organization'' with a significant installed machine base

EOS installed base

Customers in more than 50 countries

EOS sales/service/application in

11 countries

Revenue 108 Mio € (FY 2011/2012)

Worldwide ~ 450 HC

Strong patent portfolio

EOS global footprint

EOS sales/services offices EOS technicalcenter R&D/application office Distributors

AMS RMS EM-PI-ES PROTEC 3D DESIGN LRPS PROMECH ALPHA

DETEKT

DIGITAL-

CAN

NDES

FREEFORM

BIBUS-MENOS

TEMACONSULT

AB-UNIVERSAL YING FENG

SNC

DOYANG

ROLAND-SINGER

Europe:

~750

Asia: ~200

ROW: ~120

NA: ~150


Focus industries

� Lightweight

components

� Substitution metal

by plastic

� Footwear

� Web platforms

� Jewelry / Interior

� Micro electronics

� Micro tooling

EOS is focusing on selected industries

MedicalAerospace /

Turbines

Tooling

Automotive /

Industrial Applications

Consumer

Goods & Lifestyle

Micro

Laser Sintering

� Dental applications

� Implants

� Medical devices

� Aero engine parts

� MRO applications

� Airplane

components

� Injection

molding tools

� Packaging

components


Strong focus on engine and interior market

Focus markets M – Aerospace

Selective growthInvest & Growth Further investigation

� AM is established at jet engines

� High temperature super alloys

� Different applications

� Already used in several aircrafts

� Low weight solutions

� Cost reduction

� Customizing/VIP

� High value through AM

� Most UAV's already containing AM parts

� Fast growing market

� Test bench for new technology

Jet Engine Interior UAV

Focus markets M – Aerospace


Industry view

Source: Press

Citation´s

� “….in our lifetime, at least 50% of the engine will be made with additive

technologies…” - Robert McEwan, General Manager, Airfoils and Manufacturing, GE Aviation, 2011

� “On a 6,000-pound engine, we expect to

save 1,000 pounds….” Todd Rockstroh, GE Aviation in Modern Machine Shop, March 2012

� “I truly believe that additive manufacturing will develop to become the most important, the most strategic and most useful manufacturing technology ever…” – T. Wholers, Wholers

Associates Inc., August 2012


� No Tooling

� Long product life cycle

� Low quantities / Modifications / Upgrades

� Spare parts on demand

� Higher flexibility

� Lose Weight

� Light weight structures

� High integrated subsystems

� Improved functionality

� Reduced Cost

� Investing in parts not tools (Just in time investment)

� Less part counts

� Reduced assembly and quality control

� Novel Materials

� Higher melting points

SOURCE: EOS

ALM – Benefit´s for the aviation industry

Source: 4dsysco.com

Source: medicom.de

Source: ewstvlowcost.com


Hydraulic Manifold(Oil block with lattice structure)

Source: 3T RPD, Within

Design study for a medical instrument

� Special surface structure with grooves or cavities for defined positioning

� Hollow and thin-walled design

� EOS StainlessSteel PH1

� Building time: 25 h

Project: 3T RPD, Within


From block to advanced solution…


From nature to product….

Source: IPA, Messe München

Project partner:

� The gripper is able to withstand 2 bar permanently (>15.000.000 cycles in fatigue testing)

� End stops for angle limitation are realised

� High gripping power

� Extremely low weight

� Walter Reis Innovation Award for Robotics 2006


Integrated functionality

Source: HP

Complex plastic parts in small quantity for EOSINT Systems


Production Applications – Multi-Functional Designs reduce cost and weight

Attach Straps Eliminated

� Part Count Reduction

� Quick & Easy Installation

Multiple Ducts Combined

to Single-Piece Duct

PA 2210 FR / PA 2241 FR

� UL 94 V0 confirmed

� FAR/JAR qualification

� Tested on:

� Flammability

� Smoke Density

� Smoke Toxicity

� Heat Release

Conformal Shapes Achieved and Internal Flow Features Added

Previous (Kevlar/Rotomold) Configuration New (SLS) Configuration


Southampton University Laser Sintered Aircraft

SULSA - UAV

− Project created in about one month

− Built in five parts with ~ 3 kg weight

− Wingspan ~ 2 meters

− Flaps with hinges integrated (no fasteners or screws used)

− Snap fit techniques for easy and quick assembly

− Geodetic structures and ell iptical wings

The world first printed Aircraft with historical Design´s

Source: 3 T RPD


Complex Metal Parts

Source: EOS GmbH


CobaltChrome MP1 superalloy for fully-functional aircraft engine parts

Source: PEP/Turbomeca/Best in Class

Prototypes for Test Rigs

Requirement

� Functional prototypes for developing helicopter gas-turbine engine components

� Capable of running in test-bed conditions, e.g. high strength at high temperature

Solution

� EOSINT M 270 with EOS CobaltChrome MP1 superalloy

Result

� Can be built fully dense in 82 hours

� Can be automatically polished

� Properties fulfill requirements for running on test-bed

Straightener for an helicopter gas-turbine engine. PEP/Turbomeca/Best in Class

E-Manufacturing_May2012_UB.pptx | EOS | 15Source: Materials Solutions

Aerospace applications

Demonstration part

EOSINT M enables product optimization

� For aerospace devices

� New design concepts

Aerospace part design

� High complexity

� Thin walled

� Large size (max Ø 248mm ~10 inches)

New materials

� EOS Nickel Alloy IN718

� EOS Nickel Alloy IN 625

� Hastalloy X

Thin walled turbine combustion chamber, produced on EOSINT M 270, material EOS Nickel Alloy IN 718


With the design freedom of EOSINT M you can integrate all sorts of functionality into products

Source: 3T RPD, Assystem

Integral instrumentation with curved pathways

Cooled aerofoils

Flange design for weight saving and load distribution

Enclosed and perforated honeycomb structure

Weight saving internal cavities oil ways and service channels Complex bosses


Door hinge build with DMLS

Source: Evo Maganize and EADS IW Filton, from:

http://www.evo.co.uk/features/features/261526/3d_printing_is_this_the_future.html

Challenge

� Create a "light weight" nacelle hinge

Solution

� Stress and load path proved design by EADS engineers

� Highly complex design built as "one piece" with integrated function

� Built on M270 Xt

� Material: Ti64

Benefits

� A 60% weight saving was achieved through topology optimization

� Significant cost reduction

Optimized A320 Nacelle Hinge – DMLS and ConventionalEOS Ti64 produced on EOSINT M 270Xt at EADS IW


P3 used EOSINT M 270 to produce a bionic bracket that is 40% lighter than the original

Source: EOS GmbH, P3

Project summary

Requirements

� Reduce weight by keeping product requirements for use in aerospace industry

Solution

� Innovative designed bionic bracket

� Manufactured on EOSINT M 270 using aluminum material

Result

� Weight reduction by 40% (23g)

� Concave bionic bracket weights only 33g(original bracket weights 56g)

� Built full automatically in one piece

� Integrated thread and thus reduction ofassembly parts

Original milled and new designed bracket manufactured on EOSINT M 270

Project partner


Fuel Injection & Swirlers

Challenge

� Improve fuel efficiency of jet engines

� Optimize airflow and fuel swirling

� Cooling with integrated fuel channels

Solution

� Laser sintered on M 270

� Material: EOS CobaltChrome MP1

Benefits

� Highly complex design built as "one piece"

� Cost - < 50%

� Weight reduction - < 40%

� Increased robustness – no joining sections


Gas – Turbine development with EOSINT M 270

Source: Sturzkopf

Project: R. Sturzkopf, Munich

� Gas Turbine TJ 42

� Turbine wheels in IN 718

� Maximum RPM: 100,000

� Maximum EGT: 750°C

� Turbine weight: 3kg

� Thrust @ max. rpm: 420N

� Thrust-weight-ratio: 14(note: Typical values are about 8 for standard aircraft engines)

� So far 5 test cycles completed, no creep, …

� Application: UAV, auxiliary engine for glider

Gas turbine TJ 42 on a engine test rig

Gas turbine TJ 42 EOS NickelAlloy IN718 turbine wheel


Tel:

Fax:

eMail:

web:

+49 89 89 336 2220

+49 89 89 336 2288

[email protected]

www.eos.info

Contact

EOS®, EOSINT®, DMLS®, DirectPart®, DirectTool®, DirectPattern®, DirectCast® and Alumide® are registered trademarks of EOS

Udo Behrendt

(Business-Development-Manager Aerospace)

EOS GmbH

Electro Optical SystemsRobert-Stirling-Ring 1D-82152 Krailling (Munich) Germany

sustainability approach by design optimization for advanced layer manufacturing

Technology

pound engine

ge aviation

additive manufacturing

interior marketfocus

design optimization

aviation industry source

aircrafts low weight

strong focus