additive manufacturing metal

© 2011 Infotech Enterprises. All Rights Reserved

We deliver Global Engineering Solutions. Efficiently. December 31, 2012

Additive Manufacturing

© 2011 Infotech Enterprises

Definition and Various Techniques

Areas/Industries of application and adoption

Features/Benefits

Limitations

Example of company that manufacture equipment for additive manufacturing

Cost Illustrations

Examples of adoption

Index

2


Additive manufacturing (AM) is a process of making

three dimensional solid objects from a digital model.

Where an object is created by laying down successive

layers of material.

Traditional machining techniques (subtractive

processes) which mostly rely on the removal

AM process takes virtual designs from computer aided

design (CAD) or animation modelling software,

transforms them into thin, virtual, horizontal cross-

sections and then creates successive layers until the

model is complete.

Though many techniques are available, Direct Metal

Laser Sintering (DMLS), Selective Laser Sintering

(SLS), Fused Deposition Modelling (FDM) and

Stereolithography (SLA) are popular. Of these, DMLS

and SLS have been widely adopted.

Additive Manufacturing

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Various Techniques

4

Additive technologies Base materials

Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders

Direct Metal laser sintering (DMLS) Almost any metal alloy

Fused deposition Modelling (FDM) Thermoplastics, eutectic metals

Stereolithography (SLA) Photopolymer

Digital Light Processing (DLP) Liquid resin

Fused Filament Fabrication (FFF) PLA, ABS

Melted and Extrusion Modelling (MEM) Metal wire, plastic filament

Laminated object manufacturing (LOM) Paper, metal foil, plastic film

Electron beam melting (EBM) Titanium alloys

Selective heat sintering (SHS) Thermoplastic powder

Powder bed and inkjet head 3D printing, Plaster-based 3D

printing (PP) Plaster

Source: AIM practice, Infotech, Secondary research incl. Wikipedia


Areas of Adoption

5

Adoption of Rapid Prototyping in respective industries

Additive Manufacturing (AM) Industry projected to be a $5.2 billion industry

by 2020 – Wohlers Associates

Industries such as auto and consumer have maximum

adoption rates of additive manufacturing – prime reasons

being additive manufacturing aids in reduction of their

‘prototyping to manufacturing’ life span thus reducing

time to market

Aerospace and military agencies

have a lower adoption rates due to

regulatory complexities and size

complexities

Source: AIM practice, Infotech, Secondary research incl. Wikipedia


Benefits/Features

6

Helps reduce the need for tooling (moulds/jigs)

Simplifies the supply chain & reduces capital investment - helps variablizing costs of jigs and fixtures

Enables complex geometries

Part consolidation, Optimized geometries, Personalized & customized products

Enables weight reduction and optimization

For e.g. Virgin Atlantic’s first class monitor arm weighs 0.8 kg if machined while 0.37 kg if done through

additive mfg.

EADS quotes that about 150 kg can be reduced from aircraft if 1000 parts are manufactured through AM

techniques i.e. $13.5 M in fuel savings alone per aircraft over 30 years life span

Enables carbon foot print reduction by 50% on a typical long-haul application

Enables faster design to build cycles by cutting down the lead time required for prototyping and mfg. phases

Enables new business and supply chain models

Distributed manufacture with less transportation - production closer to the consumer

Source: AIM practice, Infotech, Secondary research, Econolyst report


Limitations

7

• Large volumes production may not be feasible.

• Process Certification for each Part production.

• Limitation on machine table size.

• Huge size parts cannot fit the table size.

• Initial machine investment & maintenance are very high

Benefits

Challenges

Source: AIM practice, Infotech, Econolyst

© 2011 Infotech Enterprises 8

Laser Sintering Process Technique …..

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3)

• Laser-sintering is an additive layer manufacturing technology and the key technology for e-Manufacturing.

• It enables the fast, flexible and cost-effective production of products, patterns or tools directly from 3D

models

• Production of tooling inserts, prototype parts and end products using Direct Metal Laser Sintering

Process Description

• Building part layer-by-layer

• Starting with thin powder layer on platform

• Fusing powder in shape of 2D cross-section

• Lowering platform about next layer thickness

• Filling lowered volume with powder and fusing again

Beam Source

Powder Laser Beam

Source: AIM practice, Infotech, primary research with supplier, secondary research


Laser Sintering Process Technique …..


Direct Metal Laser Sintering (DMLS)

• Process used for Aero engine parts Manufacture and

Repair or Tooling development

• The technology fuses metal powder into a solid part by

melting process through focussed Laser beam.

• Additive manufacturing process layer by layer

• Parts produced with high Accuracy, Surface quality and

excellent Mechanical properties

• Material ranging from Steel to Super- Alloys and

Composite metals can be processed

• Cost effective mfg. of raw parts substitution of castings.

• Mfg. of tooling, rig and development of hardware.

• Mfg. of functional structures to reduce weight and cost.

• Compressor vane segments with integrated

honeycombs (IN718).

A DMLS Machine

Raw material manufacture

Compressor Vane segments with

honeycombs

Hydraulic manifold -

Structures development

Source: AIM practice, Infotech, primary research with supplier, secondary research


A DMLS Machine Cost - EOS


Machine Cost :

Euros 600,000

Machine cost Includes:

• Machine Installation

• Customization settings

• Training

• Warranty period

DMLS Machine

Machine Cost

• The machine cost : Euros 600,000* (Installation +Training+ Warranty Period).

• The Time required to market the Parts produced would take minimum 1 year –

after machine installation.

* Import duty charges not considered in the cost

Determine material property database

Define process and quality specifications

Improve productivity

Establish a robust manufacturing process

Generate experience as supplier

Conditions - Time to Market

Source: AIM practice, Infotech, primary research with supplier


Comparison - NRE vs. Variable Cost


NRE’s

• Facility – Machine and Manpower.

• 3D Model - CAD Software.

• Technical training

Variable Cost

• Materials used for production process

• E.g. DMLS for Aero requires IN718 or TI64 types of metal powders which

cost approx. EUR 150 - 500 per kg depending upon the grain size. Typical

wastage is around 3-5%. So a kg of part will require about the same

quantity of metal powder

• Maintenance expenses (10-20% of the fixed cost)

• Plus other operational expenses such as power, fuel etc.


Powder / Consumables Cost of Powder Euros/ Kg

EOS Maraging Steel MS1 235.00 EOS Stainless Steel GP1 80.00 EOS Stainless Steel PH1 90.00 EOS CobaltChrome MP1 280.00 EOS Titanium Ti64 (dangerous good - special packaging required) 485.00 EOS Nickel Alloy IN718 155.00 EOS Nickel Alloy IN625 155.00


Profile of EOS – Supplier of Equipment …


DMLS Machine (EOSINT M280)

EOS supplies to MTU

• Partially MTU (USA) is using this process for manufacturing of Aero engine parts and development of Rigs /

tools.

• MTU have 6 EOSINT Machines – 4 Production machines & 2 Technology machines.



Applications

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Metal Applications

14


Aerospace Applications

15


Potential Aero Engine parts

16

• Nose cone

• Swriler

• Vanes

• Blades

• Variable Geometry

parts

• Honeycombs

• Panels

• Fairings

• Bearing Cases

• Discs

• Rings

• Blisk

• Cases

Parts Category


Outlook for Additive Manufacturing (AM)

Source: Boeing Research

• New materials are becoming available for AM processing

• Benefits of AM will be extended beyond current applications with new

materials

• Patent system and excessive litigation, have slowed development in AM

• These technologies are viable in high labour cost nations, even in the face

of competition

• AM equipment needs to become more robust, look to CNC and injection

moulding history

• Analysis methods need to grow with new geometric capabilities


Few benefits/features of DMLS in aerospace sector


Benefits

• No tooling

• Long product lifetime

• Storage of tools and fixtures

• Modifications and upgrades

• Spare parts on demand

• Design for function not for production

• Weight reduction

• Integrated subsystems

• New functionality

• Highest flexibility

• Investing in parts not in tools

• Just in Time Investment


DMLS Specifications and Logistics


EOSINT M280 – Technical Data

Machine Cost :

Euros 600,000

Machine cost Includes:

• Machine Installation

• Customization settings

• Training

• Warranty period

DMLS Machine


3D Printer – Working Principle

3D Printer - SST1200es

21


Laser Sintering Process


EOS materials

• EOS Systems can process a variety plastic and metal powder materials.

Laser Sintering Technology

• Laser-sintering is an additive layer manufacturing technology and the key technology for e-Manufacturing.

• It enables the fast, flexible and cost-effective production of products, patterns or tools directly

from 3D models

• Production of tooling inserts, prototype parts and end products using Direct Metal Laser-Sintering

(DMLS).

Process Video

Videos/FORECAST3D - DMLS Direct Metal Laser Sintering.mp4

additive manufacturing metal

Engineering

additive manufacturing

metal powders

metal foil

lower adoption rates

adoption of rapid prototyping

aim practice

animation modelling

secondary research