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EOS – Leader in e-Manufacturing Solutions Corporate Presentation

Interplastika 2017

EOS Corporate Presentation | 2

EOS: Technology and Market Leader for Design-Driven, Integrated e-Manufacturing Solutions

EOS Management

Dr. Adrian Keppler , Eric Paffrath, Dr. Hans J. Langer, Dr. Tobias Abeln , Christian Kirner (from left to right)

Family-owned, founded in 1989, Headquartered in Krailling near

Munich, Germany Integrated solution provider for

Additive Manufacturing Solution portfolio: Additive

Manufacturing (AM) systems, materials (plastics and metals), software and services

Complete end-to-end solutions: from part design and data generation to part building and post-processing

EOS enables competitive advantages for a variety of industries, such as medical, aerospace, tooling, industry, lifestyle products and automotive

EOS is committed to: Innovation – Quality – Sustainability

EOS Headquarters in Krailling, Germany


North America

~20% of global client base

Europe & Rest of World

~ 60% of global client base

Asia- Pacific

~20% of global client base

EOS: Global Presence

EOS worldwide installed base EOS global footprint

2,400 Systems 40% Metal systems 60% Polymer systems

Customers in 52 countries EOS Sales & Service offices in 11 countries,

distribution partners in 22 countries Over 1.000 employees worldwide

(70% Germany, 30% International) Strong patent portfolio: More than 650 active

patents in more than 100 patent families R&D Spendings of approx. 14% of Sales

Source: EOS. Installed base (includes purchased and rented systems) and staff figures as per 11/2015.


EOS: A Success Story

43 44 48 54 61 72 62 63

99 113

130

172

263

315

0

500

1000

1500

2000

2500

0

50

100

150

200

250

300

350

177 162 208 252 232

284 332 328

501

Gross Sales in m€ (left-hand scale) € Employees

Accumulated No. Of Systems Sold (right-hand scale)

541

Source: EOS. Figures for EOS Group, for financial years ending 30 September. Number of Employees: Headcounts.

1.000


EOS Additive Manufacturing: Functional Principle

Functional principle for polymer and metal materials. Source: EOS

From a 3D CAD model…

… to complete parts

Application of powder Exposure by Laser

Lowering of platform Re-application of powder Exposure by laser


Industrial Companies Face Similar Challenges – Additive Manufacturing Offers Unique Solutions

Challenges of industrial companies

Freedom of design Lightweight Complex component

Additive Manufacturing advantages

Faster Time-to-Market combined with shorter Lifecycle

Productivity increase: Need for cost reduction

Flexible production ("factory around the corner")

Innovation → Increase of customer value add

Customisation of products

Focus on Sustainability

Customisation Customer specific adaptations Cost efficient small series

Cost advantage Integrated functionality

without assembly

$

$

Productivity advantage Rapid prototyping and serial

applications


AM can resolve constraints of the conventional design of an existing solution by e.g.

Reducing part complexity

Reducing costs normally caused by e.g. tooling needed after manufacturing

Additive Manufacturing Opens Two Roads to Success

Enabling a completely new design approach

AM can enable design that in conventional manufacturing environments has not been possible before

Leading to completely new solutions, e.g Move from metal to plastic Making a part lightweight, yet functional

Resolving the constraints of conventional manufacturing

1 2

Example: Washing rotor (Hettich)

From 32 components to 2 laser-sintered parts + 1 steel ring

No tooling necessary

Functional integration, product customization, production on demand

Example: Load-bearing engine block (WITHIN Labs)

New design not possible with conventional methods

Integrated conformal cooling channels, lightweight design

Reduced cycle times, increased part quality, weight reduction

Image sources: Hettich, WITHIN Labs


Agenda

EOS – Leader in e-Manufacturing Solutions

e-Manufacturing Solutions for Many Industries


Business Positioned in Line with Market Demand: EOS Offers Solutions for Many Industries

*With EOS technology partners

Medical Tooling Lifestyle Automotive Rapid Prototyping

Industry

EOS Distribution Channels: Regional, Industry-Specific, Distributors, Sales Partners

Aerospace

EOS Portfolio

Market priorities

Sustainability

Productivity

Customisation

Products Solutions Services

Application specific (e.g. lightweight)

Systems Material Software Process Service

Design* Build Surface

engineering

Finish*


Customers from Numerous Industries Rely on EOS Technology

Sample customers.

OEMs Service Providers


EOS Polymer Laser Sinter Portfolio


Part Production

Overview – Polymer LS portfolio

Data Preparation Quality Assurance

Professional Services IPCM-P Powder Handling Modules

Software Materialise Magics EOS EOSPACE EOS RP Tools EOS PSW

Recording and reporting EOSTATE Base EOSTATE QA EOSTATE Controlling EOSTATE MPM

Applications Training Technical Service

FORMIGA P 110/EOSINT P 396/EOSINT P 770

Materials Polyamide 12 Polystyrene EOS PEEK HT

Parameter Sets TopQuality Performance Balance

Speed TopSpeed


EOS Systems for the Additive Manufacturing of Polymer Parts

Usable build size Width 200 mm Depth 250 mm Height 330 mm Max. volume: 16.5l per build Main properties Highest detail resolution and

final part accuracy Production flexibility Small machine footprint

(1350x1040x2200 mm) for fit into every production environment

Usable build size Width 340 mm Depth 340 mm Height 600 mm Max. volume: 69.4l per build Main properties The “workhorse” in the mid-

volume segment High mechanical

homogeneity across full build volume thanks to EOSAME feature

Usable build size Width 700 mm Depth 380 mm Height 580 mm Max. vol.: 154.3l per build Main properties High-volume production Large part sizes Double-laser system Extensive portfolio of

periphery for maximum system productivity (e.g. CoolDown Station)

Usable build size Width 700 mm Depth 380 mm Height 560 mm Max. volume = 149l per build Main properties First and only ultra-high-

temperature material system (EOS PEEK HP3, melting point of 372°C)

Option to reduce build size enabling cost-effective production of fewer parts

EOSINT P 800: For high-performance polymer parts

EOSINT P 770: Largest build volume for polymer parts

EOS P 396: Productive mid-volume polymer laser sintering system

FORMIGA P 110: Compact system for RP applications and small series


Part Production – EOS Polymer Materials

Source: P Materials PPT

Wide range of materials covering a wide range of applications

Composition Trade name Color of laser-sintered parts

Main feature Typical applications

Polyamide 12 PA 2200 White Multipurpose material Balanced property profile Variety of certificates available (Biocompatibility, Food contact, ecological)

Functional parts

PrimePart PLUS Natural Economic multipurpose material Balanced property profile

Functional parts

PA 2202 black Anthracite black Balanced property profile Anthracite black color

Functional parts in anthracite black colour

Polyamide 12, glass bead filled

PA 3200 GF Whitish High stiffness High wear resistance Improved temperature performance

Stiff housings Parts with requirements on wear and abrasion Parts used under elevated thermal conditions

Polyamide 12, aluminium filled

Alumide® Metallic grey Easy post-processing, good machinability High temperature performance Thermal conductivity (limited) High stiffness

Applications with metal-like look Parts which need machining Parts with thermal loads

Polyamide 12, carbon fibre reinforced

CarbonMide® Anthracite black Extreme strength and stiffness Thermal and electrical conductivity (limited) Best strength/weight-ratio

Light and stiff functional parts Metal replacement

Polyamide 11 PA 1101 Whitish Very high ductility / elongation at break Acceptable tensile strength Based on 100% renewable sources (castor/ricinus oil)

Functional parts which need impact resistance Applications for which no splintering is allowed

(e.g. in passenger compartment in cars) Parts with functional elements (e.g. film hinges) which need

high elongation and/or have risk to break For special applications Polyamide 12

PA 2201 Natural Multipurpose material Material certificates available (Food contact)

Medical, food

PA 2105 Gum colour High surface quality and detail resolution Dental Polyamide 12, flame retard.

PA 2210 FR White Non-flammability Halogen-free

Aerospace Electric & Electronic

Polystyrene PrimeCast® 101 Grey High dimensional accuracy Low residual ash-content

Patterns for investment casting Master patterns for vacuum casting

Polyaryl-etherketone

EOS PEEK HP3 Beige-brown High performance material Excellent temperature performance, strength, stiffness & chemical resistance Excellent wear resistance Inherently flame retardant Biocompatibility and sterilizability

Metal replacement Aerospace Automotive and motorsports Electric & Electronic Medical Industrial


EOS Additive Manufacturing (AM) Automotive Applications

Individualised parts Lightweight, complex components Integrated functionality

Sources Images (left to right): University of Warwick; Fraunhofer IPA; Rennteam Uni Stuttgart

Challenge: Build a reliable, lightweight axle pivot with high rigidity in short time

Solution: Production of topology-optimised steering stub axle using EOS technology

Optimised: Perfect form and contouring – weight reduced by 35%, rigidity increased by 20%

Speedy: Significantly shorter development and production time

Safe: Reliable on the track

Challenge: Build lightweight drive shaft for Formula Student racing car

Solution: Carbon-titanium drive shaft with laser-sintered double-walled ends

Flexible: Part design without design restraints

Economic: Weighs only 350 g (length 50 cm). 70% weight reduction (vs metal version), supports trend towards reducing CO₂ emissions

Challenge: Create light-weight car seat with innovative ergonomic design

Solution: Functional integration via laser-sintered plastic elements

Comfortable: Thanks to anatomical seat adjustment

Economic: Significant weight reduction

Functional integration: Reduces installation costs – pneumatic actuators replace servomotors; integrated heating and ventilation

University of Warwick drive shaft

Rennteam Uni Stuttgart

axle pivot Conceptual

car seat


EOS Additive Manufacturing Industry Applications Gripper: Lightweight and complex components

Special purpose machinery: Integrated functionality

Sources Images (left to right): Festo; Kuhnstoff; EOS; components built into EOS systems; 3T RPD/WITHIN Labs

EOS FORMIGA P 1 Laser adjustment unit

Challenge: Production of a bionic gripper that can reliably pick up and safely put down objects gently and flexibly

Solution: Small batch production using EOS FORMIGA P 100

Optimised: Function integration reduces number of single parts and assembly expenditure

Economic: Light-weight and long-lasting through innovative manufacturing method

Efficient: Tool-less production saves time and money.

Festo gripper Bionic Assistance System

Challenge: For EOS FORMIGA, produce device to adjust laser mirror in Y and Z direction

Solution: Production with EOS plastic laser-sintering technology using EOS material PA2200

Optimised: Functional integration: Integrated cam levers to fix

regulating screws Integrated control angle markings

(no stickers required) Economic: Manufacturing on

Demand possible, enabling adjustments and offering spare parts

Footwear & Sports

Ross Barber shoes

Challenge: Produce high-fashion men footwear with a complex design

Solution: EOS plastic laser-sintering of sole and cushioning structure

Freedom of Design: 8 unique designs with organic structure

Optimised: Innovative AM technology (sole production) combined with traditional craftsmanship (leather shoe uppers)

Economic: Design could only be manufactured with EOS technology


EOS Additive Manufacturing Medical Applications

Surgical Instruments

Medical Devices

STarFixMicroTargeting™ platform Hettich wash rotor Rotolavit

Challenge: Simplify production of washing rotor ROTOLAVIT

Solution: Laser sintering on EOSINT P 395 with PA 2200 as series material

Result High functional integration 3 parts (laser-sintered parts

plus 1 steel ring) instead of 32 parts

Finish and assembly effort reduced

Challenge: Manufacturing patient-matched frameless stereotactic fixtures

Solution: Small-batch production of precision surgical components using EOS FORMIGA P 110

Result Customised design shortens

surgery time Parts consolidation resulting

in in simpler designs with more features

Uses less material, faster manufacturing turnaround


EOS Additive Manufacturing Tooling Applications Smarter design of conformal cooling channels: Cost savings, cycle time reduction, increased performance, scrap rate reduction

Injection Molding Repairing Die Casting Rapid Tooling

Salcomp tool insert and injection-moulding part PEP (Pôle Europeen de Plasturgie) tool insert Ecoparts tool insert

Challenge: Enable precision cooling for production of mobile phone plastic parts

Solution: Improved cooling design. Manufacture of core inserts using EOS technology

Result Production increased by

56,000 units/month Rejection rate reduced

from 2% to 1.4% Annual cost savings of

approx. 20,000 euros

Challenge: Repair a partially damaged tool insert

Solution: Generation of a new reference surface; Positioning of part in EOS machine. On-top construc-tion of missing parts

Result Save costs of a complete

new insert construction Reduction of lead time:

partial construction instead of complete construction

Challenge: Injection moulding tooling for 50,000 electrical component parts

Solution: Redesign of inserts with conformal cooling channels; inserts built in EOS MaragingSteel MS1

Result Lead time and cost

reduction Higher mould productivity Better thermal management

Challenge: Build a tool insert for a die casting application

Solution: Cooling system optimisation; insert built via DMLS on EOSINT M 270 in EOS MaragingSteel MS1

Result Significant cycle time

reduction Improved life time of

inserts

Innomia tool insert for die casting

Sources images (left to right): Innomia, Ecoparts, PEP


EOS Case Studies Customer Solutions


EOS and the University of Michigan developed biocompatible material for implants

Source: University of Michigan

Additive manufactured tracheal implants Medical

Challenge To build life-saving, patient-specific implants from a resorbable material by means of Additive Manufacturing.

Results Patient-specific implants for children of all ages Cost-effective, even in small quantities From design to print within two days

Solution Manufacturing with the FORMIGA P 100


Customized 3D-Printed Polymeric Cranial Implants received…

Source: Oxford Performance Materials

…First Approval from US Regulator FDA.

Additive manufactured cranial implant made of PEKK Medical

Challenge Production and approval of patient-specific polymeric cranial implants based on CT or MRI scans.

Results Customized: fewer side effects due to patient

specific manufacturing Osteoconductive: bone cells grow into PEKK

implant and increase its long term stability Economic: better treatment outcome at reduced

costs

Solution Speedy manufacturing of individual cranial implants made of PEEK on an EOSINT P 800.


Complex structures and custom design in the production of orthoses

Source: plus medica OT

Additive manufactured orthoses made of PA 11 Medical

Challenge Design, CAD engineering and production of orthoses that combine several functions

Results Functional: complete freedom of design for

structures and material thicknesses Standardised: high quality and precision,

independent from level of craftmanship Systematic: each orthoses is individual, but the

design of functional parts such as tab locks, integrated velcro holders, and joints can be transferred

Solution Construction of individually tailored orthoses, using PA 11 with the EOS P 396.


Innovative EOS technology puts Williams Martini Racing’s Formula 1 team on the podium

Automotive Front-wing-cascade mock-up made of CarbonMide

Challenge Simpler, quicker, more economical construction of design prototypes for the front wing cascades of Formula 1 racing cars

Results short production times enable more iterations

during product development and reduce costs expensive mold-making is only required for final

part exact simulation of the characteristics of the

actual component

Solution Additive manufacturing with EOSINT P 760

2

Source: Williams Grand Prix Engineering Limited,


Serious Power: Additive Manufactured Cooling System for Formula Student Race Car

Source: DHBW Engineering Stuttgart

Component to dissipate cooling air made of PA 2200 Automotive

Challenge Build a high-performance cooling unit for a battery container of an electric car

Results Reduction of the component weight by 80% to

just 77 g Design allows for the fast servicing of safety-

relevant parts Well over twice the cooling performance

compared to the previous year's car

Solution Manufacturing with the EOS P 396


Done within shortest time with Laser-Sintering…

Quelle: Poggipolini, EOS

Racing Car parts with EOSINT P

Challenge Fully working Gearbox Housing

• Result Racing car parts within record short time

Solution Laser-SinteringonEOSINT P 700 with PrimeCast 100; DirectPattern® for Titan Casting

… fully functional Gearbox Housing.


Bell Helicopter and Harvest Technologies Produce Flight-Certified Hardware…

Source: Bell Helicopter

Helicopter with additive manufactured ductwork Aerospace

Challenge Design and production of flight-certified components.

Results Optimised: part-integrating capability eliminates

assembly costs Efficient: tool-less production saves time and

money Fast: clean surface of components reduces post-

processing costs and shortens lead times

Solution Efficient production of components for commercial aircrafts using Additive Manufacturing.

…Using EOS Technology


Staff and students at the University of Southampton …

Source: University of Southampton

… fly the world's first laser-sintered aircraft.

SULSA aircraft made of PA 2200 Rapid Prototyping

Challenge To design an aircraft to demonstrate the use of leading-edge manufacturing technology in the production of UAVs.

Results Optimised: functional integration simplifies

assembly and excludes the need for fasteners Freedom of design: production of complex

structures to achieve the best-possible flight characteristics

Speedy: from the sketch to the maiden flight in less than one month

Solution Manufacturing of a flight-capable prototype within one week, using the EOSINT P 730.


Multi-dimensional Circuit Carriers Created with EOS Technology

Source: BetaLAYOUT

Functional circuit carrier made of PA 3200 GF Industry

Challenge Production of individual circuit carriers that is given functionality after via laser direct structuring

Results access to advanced technology for research and

development tool-free production reduces costs service provider of tailor-made products

Solution Additive Manufacturing with the FORMIGA P 110


EOS Technology and Materials Provide Low Costs, High Quality and…

Source: Anubis

Laser sintered framework to hold electronic components Industry

Challenge Production of customised fasteners for a mass flow meter.

Results Design flexibility: unique frames to hold delicate

electronic components Evolutionary: technology enables continuous

testing and optimisation of parts Economic: rapid product development at low

costs

Solution Fast development of the framework design and inexpensive production with a FORMIGA P 100.

…Quick Turnaround Times for Flow Meter Parts.


Lighter, yet more powerful: additive manufactured vacuum grippers for smarter packaging

Industry Gripper made of PA 2200

Challenge Building a lighter, yet more powerful vacuum gripper for a major American food producer’s equipment supplier.

Results 500g light gripper has four times the power ready to use in just one week less parts make assembly very easy freedom of design enables optimized production

processes

Solution Additive Manufacturing with FORMIGA P 100

3

Source: Anubis 3D


Improved Runner Performance: New Balance Uses EOS Technology to Individualize Spike Plates

Source: New Balance

Additive manufactured spike plates (above dyed) Lifestyle Products

Challenge Improve performance of professional athletes with individual spike plates for running shoes

Results Customized fitting based on analysis 5% weight reduction Production of several models within a short

period of time

Solution Manufacturing with the EOSINT P 395


Bobby Tailor produces custom-made Bobby Cars for the discerning young motorist

Manufacturing Service Provider Wheel rim of the Bobby Car made of PA 2200

Results Quickly produce one-off pieces that fulfill

customers’ desires Series production of small batch sizes EOS technology as the basis for an entire business

model

3

Source: Bobby Tailor

Solution Additive manufacturing with EOSINT P 395

Challenge The economical manufacture of high-grade components for luxury Bobby Cars from PA 2200.


Thank you for your attention! www.eos.info

eos – leader in e-manufacturing solutionsinterplastica.ru/files/8.pdf · eos formiga p 110 result...

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