performance trends in additive manufacturing technology · 2020-03-26 · eos: technology and...

This presentation may contain confidential and/or privileged information.Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.

Performance Trends in Additive Manufacturing Technology

Anand Prakasam

EOS GmbH

EOS Corporate Presentation | 2

Today’s Presentation format

- AM OVERVIEW

- Key contributors for successful production- validated process

- Comparing the hardware productivity

- Improvements in software, Quality Monitoring , raw materials

- Overview on Additive minds

- Summary

EOS Corporate Presentation | 3Source: McKinsey Global Institute Analysis

3D Printing is seen as one of the twelve economically disruptive technologies

MobileInternet

Automation of Knowledge Work

Internet of Things

CloudTechnology

Advanced robots

AutonomousVehicles

Next-Generation Genomics

EnergyStorage

Advanced Materials

Advanced Oil and

Gas Exploitation

RenewableEnergy

3D Printing

EOS_Company-Presentation.pptx | EOS | 4

“The Manufacturing Technology that will change the World“The Economist, 2011

Media: Additive Manufacturing _ 3D Printing


Yesterday:

Prototyping

Technologicalcapabilities

Until 2020:

Production ramp up

▪ Quality control ▪ Differentiation▪ Total cost of Ownership

(TCO)▪ Automation▪ Technology integration

Today:

Pre-production

▪ Part quality▪ Process robustness▪ Cost per part

Growth of AM Industry


Key elements for Successful Production

Balanced triangle

Process

MaterialSystem

Part qualityProcess robustness

IndustrializationEf

fect

s


Additive Subtractive

Manufacturing Processes


Laser-sintering process: Key-technology for e-Manufacturing

Material ProductLaser-Sintering

Process of Laser Sintering

▪ video

../../presentation _exhibition/eos/Tooling_Video_Animation - Copy.wmv

../../presentation _exhibition/eos/MOV00667.MPG

MOV00667.MPG


Key elements of Additive Manufacturing

Balanced triangle

Process

MaterialSystem

Part qualityProcess robustness

IndustrializationEf

fect

s


Productivity improvement

Productivity can be improved by the following

- Hardware upgrade – Process optimisation , multiple lasers etc

- Software enhancement – Segmentation etc

- Smart AM designs


Hardware Productivity Comparism

• Original STL file

• Possible Orientation

• Build Time Estimation in M290, M400 & M400-4

• Conclusions and Remarks


Original STL files – Build 1


Possible Orientation

• Considered this orientation to accommodate as many parts as possible and to have minimum build time

• Supports generated outside are easily accessible for post processing

• The orientation shown in the image is for M290 and for M400-4, this need to be rotated considering the recoating direction

Build 1


Build Time Estimation – Build 1

Can accommodate 2 parts each (2+2)

Approximate Build Hours : 68 Hours

M290 , DirectPart 30 Microns



M400-4 , DirectPart 30 Microns


Build-1 M4-SF-1 KW laser

With custom layer thickness

Approximate Build Hours : 39 Hrs


Build Time Estimation

Part Name: 248 & 549

System Total no.of Parts Build Time

M290, 1 x 400w 2+2 68 Hrs

M400, 1 x 1000w 4+4 39 Hrs

M400-4, 4 x 400w 4+4 46 Hrs


Original STL files – Build 3

Axial Fan Centrifugal


Possible Orientation

• Considered this orientation to get the minimum build time

• Supports generated outside are easily accessible for post processing

• Supports are generated in the hollow profiles of Centrifugal part, but it’s accessible for removal

• The orientation shown in the image can be used for both M290 and M400-4

Build 3


Build Time Estimation – Build 3



M290 , DirectPart 30 Microns



M400-4 , DirectPart 30 Microns


Build-3 M4-SF

With custom layer thickness

Approximate Build Hours : 8:02 Hrs


Build Time Estimation

Part Name: Axial fan & Centrifugal Version

System Total no.of Parts Build Time

M290, 1 x 400w 2+2 16 Hrs

M400, 1 x 1000w 5+5 8:02 Hrs

M400-4, 4 x 400w 5+5 9 Hrs


EOS M 290: the complete solution that meets all customer requirements

EOSPRINT 2.0 with ParameterEditor

▪ Up to 20% productivity increase possible

▪ Workflow-based graphical user interface reflecting the AM CAM process makes it intuitive and quick to learn

▪ New exposure strategies enable production of previously unbuildable parts by avoiding support structures in areas where they cannot be removed

▪ ParameterEditor provides even greater freedom and openness for material development, application-specific parameter optimization and process development

Productivity

Matthias HerkerApplication Engineer Additive Manufacturing at AUDI AG

Thanks to plane segmentation and new exposure

strategies, we are able to produce faster than ever before

without sacrificing quality. In the future, we will significantly

improve our productivity, cost-effectiveness as well as the

general feasibility.

Samuel BlowerDevelopment Engineer at Materials Solutions

New features such as ‘Flow Optimisation’ have allowed us

to build things that were not possible with the previous

software.


EOSTATE

System

EOSTATE

Laser

EOSTATE

Powder-Bed

EOSTATE

MeltPool

EOSTATE Exposure OT


EOSTATE Monitoring Suite

▪ enables to conduct a real-time quality assurance of all production and quality relevant date

▪ leads to considerable savings in QA efforts and costs

▪ offers the most extensive portfolio in the additive manufacturing market

Elements EOSTATE Monitoring Suite:

Extensive quality control features

Powered

by

Powered by



▪ Reliable and repeatable quality – day in, day out no matter how complex the build jobs are

▪ Homogeneous part properties – from part-to-part, build job-to-build job and machine-to-machine

▪ Comprehensive statistics that give confidence for production and serve as a complete documentation of a customers Quality Management

DMLS quality fulfils the demanding requirements in production

EOS ensures constant metal material quality


EOS applies thorough quality assurance in materials and process development

Source: EOS

Measurement of density and mechanical properties

EN ISO 3369 "Impermeable sintered metal materials and hardmetals – determination of density"

Zwick/Roell Z050, max. force 50kN, force accuracy according to ISO 7500-1, extensometer accuracy according to ISO 9513

Series1

Series2

Series3

1030

1050

1070

1090

1110

1130

1150

12

3

1128

1123

11431139

1147

1133

1140

y-Richtung

yield strength [MPa]

x-Richtung

View on platform:

Mechanical data depending on positio

Density cubes

Tensile bars


EOS has thorough quality assurance procedures for the production of powder materials

Source: EOS

▪ Production batches of powder are tested on an EOSINT M system with defined setup (QA-machine)

▪ Parts tested for tensile properties and density

▪ Results documented as "Declaration of laser-sintered properties"

QA of powder materials (2)


Customer Voices Aerospace

2

7

We produce parts for one of the world's most advanced engines, the geared turbofan, with one of the world's most advanced 3D printing technology by EOS.

Dr. Karl-Heinz DuselDirector of Rapid Technologies at MTU Aero Engines

The thermal elements produced using the EOS M 290 withstand temperatures of up to 1,000°C and continue to be fully functional at twice the speed of sound.

Katharina KreitzManaging Director at Vectoflow GmbH

Borescope boss made of nickel-based alloy Flow measurement probe made of nickel-chromium alloy


Customer Voices Industry

2

8

This is AM in its most advanced form, using the 3D printing system with four lasers developed by EOS enables a highly efficient industrial series production.

Vladimir NavrotskyHead of Technology and Innovation at Siemens Energy Service O&G

EOS technology gave us the opportunity to offer exactly the right solution for our customers who have a specific challenge.

Sebastian KießlingManaging Partner at Euro-K GmbH

Repaired burner tip Complex burner made of EOS NickelAlloy IN718


Customer Voices Medical

2

9

We are amazed by the application possibilities and the high-quality production that can be achieved using the EOS system.

Christoph ErhardtDirector Additive Manufacturing at Alphaform AG

Together with the knowledge of the doctors it was the high quality of the implant that served as a guarantee for the enduring success of the procedure.

Atif CakorR&D Manager at Instrumentaria Co., J.S.C.

Permeable skull implant made of titanium Lightweight hip implant made of titanium


EOS Additive Manufacturing for 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 insertEcoparts 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: Technology and market leader for design-driven, integrated e-Manufacturing Solutions

3

2

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

▪ Privately-owned, founded in 1989 by Dr. Hans Langer

▪ Focus on end-to-end Solutions for Additive Manufacturing: from part design and data generation to part building and post-processing

▪ Active in a variety of industries, focus on medical, aerospace, industrial applications

▪ EOS is committed to: Innovation – Quality – Sustainability

▪ Revenue FY 17/18: ~ 345 Mio €

▪ Revenue Increase ~ 20%

▪ Invest 14% of revenue in R&D

EOS Headquarters in Krailling, Germany


EOS Shaping the future of Manufacturing

Systems Materials Software Services

An integrated portfolio to provide customer value

Process AMConsulting


We are Additive Minds!

>250 Successful Customer Projects

in >25 Countries#1 Consultancy in AM Market > 100 of AM Experts: largest team world wide

8 Trainings &12 Consulting Packages5 global Innovation Centres

ADDITIVE MindsBest-in-class Consulting for Industrial 3D-Printing

For further information:EOS GmbH Electro Optical SystemsRobert-Stirling-Ring 1 82152 Krailling/Munich Germanywww.eos.info

http://www.eos.info/


Design for AM

Lattice Structure Design

Parameter Editing Workshop

Melt Pool Monitoring

360° Improvement Programme

Cost per part optimisation

Factory Layout

Additive Manufacturing Qualification

Operational Qualification Support

Innovation with 3D Printing

Fundamentals of metal 3D Printing

Part Screening & Selection

AchieveAM

Readiness

DevelopAM

Application

Ramp-upAM

Production

Quality & Scale

Production

Additive Minds Consulting

Certification

ScalingProductio

n

Re-/Designfor AM

Process and Material Optimization

Optimizationof

Production

Fast ProductionImplementation

Introductionto AM

Part Selection


Siemens invested €21.4 m into its AM facility

Image Courtesy of Siemens


N New era of Manufacturing

3

9


Customers have a strong footprint in Aerospace

Source: EOS

EOS – sample customers Aerospace Industry (incomplete)


thank you for your TIME and ATTENTION

performance trends in additive manufacturing technology · 2020-03-26 · eos: technology and...

Documents