how does metal 3d printing disrupt conventional manufacturing technology · 2019-04-26 · r&d...
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How does metal 3D printing disrupt conventional manufacturing technology ?Markus Bürger | 10.04.2019
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GKN Powder Metallurgy – At a glance
£ 1,212mn
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Our global footprint
Hoeganaes manufacturing plant
Sinter Metals manufacturing plant
Corporate / sales office / engineering centre
BRAZIL
1
MEXICO
12019
opening
NORTH AMERICA
42 9JAPAN
1
INDIA
CHINA
1
2
21
28manufacturing
plants
3global innovation
centres
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We are the world‘s #1 in powder metal solutions
#1 global producer
of precision powder metal parts
13 million parts daily
#2 global producer
of powder metal
300,000 tons
of powder sold p.a.
A global market leader
in metal 3D printing
Driving business wins
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GKN ADDITIVE - At a glance
2017: £ 180.0002018: £ 1,4mBudget 2019: £ 4m
STRATEGY 2024:£ 100M
We‘re scaling ourbusiness for massive
future growth!
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THINK Materials
Steels
(GA or WA)
4340
5120
8620
4605
1.2709
20MnCr5
Stainless Steels
(GA or WA)
304L
316L
420
17-4 PH
Nickel Alloys
(GA)
IN 625
IN718
Ni-Ti
Aluminum Alloys
(GA)
AlSi7Mg
AlSi10Mg
Titanium Alloys
(GA)
CP Ti
Ti64
Ti6242
Ti5553
Beta 21S
Copper Alloys
(GA)
Pure Cu
CuCrZr
CuNi3Si
Custom Alloys
Providing Support for materials
develop-ment
Additive manufacturing requires advanced powder with characteristics specific to the application. These materials need to be qualified and guaranteed for consistent performance.
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AM meets PM
OUR STRONG METAL PROCESS PORTFOLIO
PM FinishingSintering SizingCompacting
LASER AM Laser Finishing
BINDER AMPrint /Decake FinishingDebinding Sintering
DESIGN
Limited design
freedomtool needed
Full design freedomno tool
Full design freedomno tool
VOLUME (pcs)
>50.000
<2.000
<50.000
LEADTIME(weeks)
12-16
2
2-4
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Design and Process Guidelines – Direct Metal Laser Sintering (DMLS)
Support structure for printing
IT class 11-13 Mechanical properties: better than casting, PM and binder but
worse than forged
Compact & complex design
Build Volume max. 420 x 420 x 400 mm
Materials: 20MnCr5 ,1.2709, 316L
(1.4404), AlSi10Mg, CuCr1ZrWall thickness
>0.5mmSurface: Rz <50 µm
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Design and Process Guidelines – Binder Jetting
Support structure for sintering
IT class 12-14 Mechanical properties MPIF35
Part Size ~ 100 x 100 x max. 80 mm
Build Volume max. 360 x 200 x 80 mm
Material: 316L (1.4404)
Wall thickness 1.5 - 30 mm
Surface: Rz 45 µm
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Expanding our portfolio & creating new markets
UNIQUE METAL PROCESS PORTFOLIO
Component volume
Additive Binder Jet
Additive Laser Powder Bed
Current ‘heartland’
Conventional PM
Metal Injection Moulding
Future opportunities through AM in new markets and with new products
AM offering –Outside of historical accessible segments
Volume Production <50.000
Low Volume Production from 1 to 2.000
Binder Jet
Laser Powder BedProduct life cycle
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AM product solutions
→ Replacement of manualmanufacturing process
→ Higher efficiency andperformance→ 2 weeks delivery
→ Ramping up first series applications
Prototypes Copper Coils Serial Parts
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Why Additive Manufacturing?
Disruptive Points
Customization
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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Full design freedom
Source: EDAG/Genesis
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Customization
Monolithic Design Bionic Design Internal structures
Source: ge.com
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Mass customization
Weight reduction Personalization
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Why Additive Manufacturing?
Disruptive Points
Customization
Toolless
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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Toolless
Plastic componentsPlastic injection moulding- tool costs: 15k – 50k€
Helical gearsPM – surface densified- tool costs: 100 k€
HousingAluminum die casting- tool costs: 100 k€
AxleMachined and broaching- tool costs: 50 k€
Coverdeep drawn sheet metal- tool costs: 20 k€
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Why Additive Manufacturing?
Disruptive Points
Customization
Toolless
Quick time to market
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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Advanced digital systems to support AM
Global Print Network
Shop Floor of the Future
Customer Focus
Virtual Storefront
Advanced planning
Visual shop floor
Global print network
Next
Digital twin (interaction with GQS, Teamcenter)
Backbone (GKN ERP, GKN GQS, GKN Teamcenter)
Databases on premise, Full compliance (e.g. Export)
Management of Laser AM in multiple plants with central intelligence
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Case study – How to reduce complexity in procurement with AM
Plastic componentsPlastic injection moulding- tool costs: 15k – 50k€- lead time: 10 weeks
Helical gearsPM – surface densified- tool costs: 100 k€- lead time: 14 weeks
HousingAluminum die casting- tool costs: 100 k€- lead time: 14 weeks
AxleMachined and broaching- tool costs: 50 k€- lead time: 8 weeks
Coverdeep drawn sheet metal- tool costs: 20 k€- lead time: 8 weeks
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Why Additive Manufacturing?
Disruptive Points
Customization
Toolless
Quick time to market
Reduced inventories
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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Expanding our portfolio & creating new markets
Product life cycle
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Why Additive Manufacturing?
Disruptive Points
Customization
Toolless
Quick time to market
Reduced inventories
GKN PM as one-stop solution provider
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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Expanding our portfolio & creating new markets
UNIQUE METAL PROCESS PORTFOLIO
Laser AMLow volumes < 2.000 pcs
Copper CoilsPrototypes
Aftermarket
Binder AMMedium series <50,000 pcs
Conv. PM & MIM
Large series > 50,000 pcs
Motorsport
From one piece …
… to million pieces
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Uniquely positioned to lead the AM market
From high purity to high productivity Advanced AM materials
Aero and Auto certified
Design to function
Fatigue and topologyoptimization
From high performanceLaser to high productivityBinder
Global footprint
World class production system
Materials Design AM Process
WE OFFER THE WHOLE VALUE CHAIN
Operational Excellence
Automotive (OEMs & tiers)
Industrial
Customers
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Expanding our AM footprint
Radevormwald
Bruneck
Bonn
Danyang
Auburn Hills (opening Q1 19)
Cinnaminson
Germantown
Production site
R&D Sites
Cinnaminson: Materials R&D & Manufacturing Centre Radevormwald: Process R&D CentreBonn, Bruneck, Germantown: Digitalisation Centres
EOS M290Aluminum, copper, stainless
steel
EOS M290Aluminum, Copper, 316L,
Steel
EOS M400Aluminum
Renishaw AM250Steel
Additive IndustriesMetalFab 4 LaserAluminum, 316L
HP Metal Fusion Jet316L
GLOBALLY CONNECTED
HP Metal Fusion Jet316L & low allooyedsteels
EOS M300-4 Q3 19
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Why Additive Manufacturing?
Disruptive Points
Customization
Toolless
Quick time to market
Reduced inventories
GKN PM as one-stop solution provider
ADDITIVE: Why disruptive?
Full design freedom
Monolithic Design
Bionic Design
Internal structures
Weight reduction
Personalization
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THANK YOU