pm concept laser de web viewpm-concept laser-9-2015-dzp ... concept laser and the english word ......

____________________________________________________Press Release | Presseinformation | Communiqué de presse | Communicado de prensa | Comunicato stampa | Пресс-релиз | Imprensa | Persbericht | Notatka prasowa

█ Laser Melting with Metals (LaserCUSING)

Finalist of the Deutscher Zukunftspreis (German Future Prize) 2015:

With his nomination for the Federal President's Award for Innovation and Technology, Frank Herzog from Concept Laser is now "among the best".

Berlin / Lichtenfels, September 16, 2015: Together with his two project partners, Frank Herzog, founder and CEO of the specialist for 3D metal printing, has been nominated as a candidate for the German Future Prize 2015. His inclusion in the "circle of the best" is another milestone in the anniversary year of Concept Laser GmbH. The German Future Prize is the Federal President's Award for Innovation and Technology. It is awarded to developers from industry and science who have rendered outstanding services with projects and initiatives to Germany as an innovation location. With his nomination, Frank Herzog is now "among the best".

PR 9-2015 Words: 402 | Characters: 2.508

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Frank Herzog: "After the awards in 2014 (e.g. Bavaria's Best 50) and the Final of the German Industry's Innovation Award, this nomination is a great honor to me. Not least, it is also appreciation of the enormous potential of the LaserCUSING process developed by me."

The project with the title "3D Printing in Civil Aircraft Manufacturing - a Production

Revolution is Taking Off" convinced the jury of the German Future Prize 2015 with

regard to its degree of innovation and economic implementation. And the project team,

consisting of Peter Sander, Head of Emerging Technologies & Concepts at Airbus,

Hamburg, Prof. Dr.-Ing. Claus Emmelmann, CEO of Laser Zentrum Nord GmbH,

Hamburg and Frank Herzog, founder and CEO of Concept Laser GmbH, Lichtenfels

was therefore nominated for the German Future Prize 2015.

The project is mainly about the first additively manufactured titanium component,

referred to as a "bracket", on board the Airbus A350 XWB. It is a "bionic" holding and

connecting element, which is regarded as an important contribution to the lightweight

construction of aircraft. This cross-industry development is revolutionizing the way

structural aircraft components are made and "lightweight construction" is implemented in

civil aircraft. This component was previously a milled part made of aluminum (Al) and is

now a printed part made of titanium (Ti) with a weight reduction of approx. 30%.

Success by means of pioneering spiritFrank Herzog is regarded as a pioneer in the field of powder bed-based laser melting.

The existing plastic sintering technology led to development of the LaserCUSING

method in 1998. During his studies Frank Herzog thought that what worked with plastics

should also work with metals. Part stress and the failure of metal powder to fuse

completely were initially the greatest challenges in the process development. However,


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these problems were overcome by the hard work put into the development of stochastic

exposure and the application of a solid-state laser.

This pioneering work resulted in the founding of the company Concept Laser in the year

2000, which presented its M3 linear prototype machine to the public at the Euromold in

Frankfurt in 2001 and, in this way, celebrated its world premiere in the field of industrial

3D metal printing. Concept Laser, which is situated in Lichtenfels in Upper Franconia,

were able to supply the first systems worldwide only a year later.

Once an exotic outsider, this additive manufacturing strategy has taken over a wide

variety of industrial fields and applications over the years. Over 400 systems installed

worldwide speak for themselves. And 15 years of Concept Laser also means 15 years

of successful process development with numerous innovations and patents. For

example, the company now has its own research and development department with

over 50 employees. Furthermore, Concept Laser GmbH is involved in numerous

research and development partnerships with universities, technological and scientific

institutes and industrial companies. And the company is also the owner of more than 50

granted patents. Concept Laser GmbH has currently approximately 100 pending patent

applications and a majority of them will be granted in the near future. The number of

inventions applied for patents by the company has been steadily growing.

Concept Laser's 15th anniversary in 2015 is a brilliant performance – and it has the

figures to prove it. The growth of + 75 % in 2014 is being consolidated by Concept Laser

at a high standard. For example, a total of 110 laser melting systems were delivered in

the year 2014. This figure is to rise to 150 systems in 2015. This means growth in sales

of + 35% is expected compared to the previous already very successful year.

The LaserCUSING process:


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The term LaserCUSING, composed of the C from CONCEPT Laser and the English

word FUSING (to fully melt), describes the technology. The fusing process uses 3D

CAD data to generate components layer by layer. This process allows the production of

complex component geometries without tools in order to implement geometries as

components that are difficult or even impossible to achieve with conventional

manufacturing methods.

The LaserCUSING process is used to create mechanically and thermally stable metallic

components with high precision. Depending on the application, it can be used with

stainless and tool steels, aluminum and titanium alloys, nickel-based superalloys,

cobalt-chromium alloys or precious metals such as gold or silver alloys.

With LaserCUSING, finely pulverized metal is fused using a high-energy fiber laser. The

material is solidified after cooling. The component contour is created by directing the

laser beam by means of a mirror deflection unit (scanner). The component is

constructed layer by layer (with each layer measuring 15-150 μm) by lowering the

bottom surface of the build space and then applying and fusing more powder.

Concept Laser systems stand out due to their stochastic control of the slice segments

(also referred to as "islands"), which are processed successively. The patented process

significantly reduces tension during the manufacture of very large components.

General aspects of an additive manufacturing strategyNumerous options for lightweight construction and an increase in the performance of

components are opened up by an additive manufacturing strategy. Key words include:

functional integration, lightweight construction potential, bionics and topology,

conservation of resources, waste reduction, geometrical freedom, single shot

production, reduction of assembly work, timely production, also "on-demand" and

improvement of the cost structure, e.g. by unmanned manufacturing 24 hours a day.


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The laser melting process has been made first choice in numerous sectors in relation to

conventional machining strategies by the current challenges posed by manufacturing.

According to manufacturing experts, automation, quality, a wide range of materials,

integration in the production environment and potential build speeds are essential

characteristics of additive manufacturing in the digital era. Additive manufacturing in a

digital process chain is consistently based, not least, on the "Industry 4.0" strategy.

End of short PM -- (word and character numbers apply to this version)

Significance of laser melting to aircraft constructionLaser melting with metals is gaining in significance in aircraft construction as part of an

additive manufacturing strategy. Here too, the typical reasons for the selected process

are quicker throughput times, more cost-effective components and previously unknown

freedom of design. Two new key words, "lightweight" and "bionics" point to an emerging

trend: The design approaches of developers in aircraft construction are changed by an

additive process. In terms of aircraft design, future components will be able to absorb

specific lines of force and yet still be able to fulfill the demands of a lightweight

construction approach. In general, laser melting technology is capable of manufacturing

safety-related components that are even better, lighter and more durable than

conventional components manufactured today. Moreover, the material properties are

slightly different. Prof. Dr.-Ing. Claus Emmelmann, CEO, Laser Zentrum Nord GmbH,

Hamburg: "Materials produced using laser additive manufacturing have greater rigidity

while, at the same time, less ductility; however this can be enhanced with the right heat

treatment." Furthermore, the process is distinguished by sustainability and resource

conservation with simultaneous improvements to the cost structure.


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Geometrical freedom and lightweight construction potentials as driving factorsThe arguments for the laser melting of metals in aircraft construction are geometric

freedom and weight reduction. The "lightweight construction" approach is intended to

help airlines operate their aircraft more economically. The achievable weight reduction

results in a tendency towards lower fuel consumption or the potential to increase load

capacities of aircraft. A new aircraft design requires thousands of flight test installation

(FTI) brackets, produced in very small quantities. Additive "layer manufacturing" allows

designers to come up with new structures. The additively manufactured components are

in fact more than 30 % lighter than conventional cast or milled parts. In addition, the

CAD data are the direct basis for an additive build job. The omission of tools reduces

the costs and shortens the time until the component is available for use by up to 75 %.

Since tools are not required in the process, it is now possible at an early stage to

produce functional samples of components that are similar to series produced

components. This is done without upfront costs for tools. This means that sources of

error can be identified in the early stages of the design process in order to optimize the

processes within the project. Peter Sander, Head of Emerging Technologies &

Concepts, Airbus, Hamburg: "Previously we budgeted around six months to develop a

component – now, it's down to one month."

Bionics in the component or product designLaser melting with metals allows extremely fine, even bone-like, i.e. porous structures to

be produced. "Future aircraft components will therefore have a "bionic" look“ is what

Peter Sander expects. It is not without reason that over millions of years nature has

produced optimized functional and lightweight construction principles which minimize

the amount of resources required in a clever way. Airbus is currently analyzing solutions

found in nature in a structured manner with regard to their applicability. By relying on


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"intelligent exposure strategies" of the laser, it can apply layers to a component in a

strategic manner in order to produce custom properties in terms of structure, rigidity and

surface quality. Peter Sander: "Initial prototypes indicate great potential of a bionically

motivated approach. The process is expected to launch something of a paradigm shift in

design and production."

Quality as a significant parameter For aircraft manufacturers, monitoring during the component's build process is one of

the most important aspects of the industrial application. Peter Sander: "In practice,

"inline process monitoring" with the QMmeltpool QM module from Concept Laser means

the system uses a camera and photo diode to monitor the process within a very small

area of 1x1 mm². The process is then documented." In 2016 this module will be

extended by QMmeltpool 3D. The former, time-related 2D monitoring of the build

process becomes a position-related 3D landscape. Instead of exclusively time-related

data, the system now additionally delivers position-related signals for definitive

allocation, comparable to a computer tomography (CT). These signals make it possible

to generate 3D datasets of the part and its structure. A highly accurate 3D landscape of

the component is thus created. This allows QMmeltpool 3D to provide local indication of

defects in the component. As a result, subsequent inspections and tests can be reduced

to a minimum. Furthermore, the data are available directly after the build process, which

also saves time. Other QM modules for active quality assurance are QMcoating,

QMatmosphere, QMpowder and QMlaser. They measure or monitor, for example, the

laser output and also the optimum layer structure of the metal powder and document the

entire manufacturing process seamlessly. An additional feature in terms of quality

assurance is the capability to work in a closed system to ensure the process remains

free of dust and contamination. All disruptive influences that could have a negative


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influence on the process are intended to be eliminated this way. Frank Herzog: "These

days it's accurate to call this a regulated manufacturing process that provides repetition

accuracy and process reliability." Prof. Dr.-Ing. Emmelmann emphasizes by saying:

"The QA software now enables us to monitor and document key data, such as laser

parameters, melt pool parameters, as well as the composition of the inert gas

atmosphere. Disruptions due to contamination can be eliminated."

Concept Laser can call itself a pioneer in this field too, since the company has been

working on different quality improvement/monitoring modules since 2004.

"Green technology" conserves resourcesMilling of aircraft parts results in up to 95% recyclable waste. With laser melting, the

user receives components with "near-final contours," and the process produces only

about 5 % waste. "In aircraft manufacturing, we work with the "buy to fly ratio", and 90 %

is a fantastic figure. This is, of course, also reflected by the energy balance", according

to Prof. Dr.-Ing. Claus Emmelmann. This makes the process especially attractive when

using valuable and expensive aircraft materials, such as titanium. A tool-less

manufacturing strategy saves time and improves the cost structure. Targeted energy

consumption and conservation of resources are features of the laser melting process.

Frank Herzog: "LaserCUSING is a green technology and improves the often discussed

environmental footprint of production."

Spare parts supply 2.0: Timely, decentralized and "on demand"Spare parts constitute a new playing field for "additive aeronauts". In future it will be

possible to manufacture them "on demand" at decentralized locations without the need

for tools. In the event of a component failure, the spare part can be produced directly on


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site. Decentralized production networks can be created and global and regional

strategies are possible. This minimizes transport distances and, above all, delivery

times. As a consequence, maintenance-related downtimes and inspection times for

aircraft are reduced. In future it will be possible to significantly reduce the large spare

parts depots with parts rarely used that are currently essential given the long life cycles

of today's aircraft. A reduced capital commitment increases flexibility and especially the

time needed to obtain safety-related components. This is especially attractive given the

cost pressure in the aviation industry.

OutlookLaser melting as a 3D printing technology results in "more intelligent components" which

exceed the performance characteristics of conventionally manufactured components in

almost every dimension. In particular, in the aerospace industry, manufacturing experts

are already speaking of a change in paradigms. Although, due to the batch size

structures, the aerospace industry is currently pioneering additive manufacturing, an

initial effect on almost all industrial sectors is expected, due to the increase in build rates

and build envelope sizes. The key areas in this respect are the automotive industry,

dental and medical technology and the tool and machine tool industry. Not least, new

business models are created by decentralized production networks as represented, for

example, by the Laser Zentrum Nord GmbH. This will also make it possible to return the

value created by production from low-wage countries to traditional development and

industrial locations in Europe or the USA in order to increase the innovative power and

speed there.


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End of long version of PM -------------------------------------------------------------------------

Background information on the "Deutscher Zukunftspreis 2015"

With this award, the President of the Federal Republic of Germany honors researchers

and developers, who implement their innovations successfully in marketable products

and, in this way, generate new jobs. The award is endowed with € 250,000. The

German Future Prize will be awarded in Berlin on December 2nd, 2015.

In a strict, multi-stage procedure, the nominations submitted by the institutions invited to

make recommendations are assessed by ten experts from science and industry and

three or four projects are finally nominated for the final round and, in this way, become

the focus of public attention. These teams belong to the "circle of the best" for the

Federal President's Award for Innovation and Technology.

On December 2nd, 2015 the prize will be awarded. In a festive ceremony, the German

President Joachim Gauck will honor the team from the circle of the best who - according

to the jury - was able to beat the other projects.

Reprint permitted – Copy requested

Captions ████████████████████████████████████████


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Caption 0: German Future Prize - Federal President's Award for Innovation and

Technology" (image source: © Deutscher Zukunftspreis)

Caption 1: Frank Herzog, CEO of Concept Laser: "After the awards in 2014, such as

Bavaria's Best 50, and the Final of the Innovation Award of the German Industry 2014,

this nomination is a great honor to the team and me. Not least, it is also appreciation of

the enormous potential of the LaserCUSING process."

Caption 2: The LaserCUSING process (illustration of the process)

Caption 3: Bionic cabin "bracket" for the Airbus A350 XWB made of Ti, manufactured by

means of the LaserCUSING process (image source: Airbus)

Caption 4: Airbus A350 XWB (image source: Airbus)

Caption 5: The X line 2000R® combines the largest build envelope worldwide

(800x400x500 mm3) for laser melting with metals with increased build rates. The X line

2000R's® multi-laser technology, with 2 x 1,000 watt lasers, has a direct impact on the

exposure time.

All image sources: Concept Laser GmbH, Lichtenfels, Germany (unless stated otherwise)

Concept Laser trade fair appearances ██████████████████████


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MSV, Brno (CZ) 14.09 – 18.09.2015WESTEC, Los Angeles (USA) 15.09 – 17.09.2015Dental Expo, Moscow (RUS) 28.09 – 01.10.2015TCT, Birmingham (UK) 30.09 – 01.10.2015

Contacts ███████████████████████████████████████

Concept Laser GmbHAn der Zeil 8

D-96215 Lichtenfels

Germany

Phone:+49 (0) 9571-1679-0

Internet: www.concept-laser.de

Press contact:Daniel Hund

Phone: +49 (0) 9571 / 1679-251

E-mail: [email protected]

Concept Laser at a glance ██████████████████████████


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mailto:[email protected]

http://www.concept-laser.de/


Concept Laser GmbH is an independent company based in Lichtenfels, Germany. Since its

founding in 2000, it has been a leading innovator in the field of laser melting technology with the

patented LaserCUSING® across many industries.

The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING

(to fully melt) describes the technology: The fusing process uses 3D CAD data to generate

components layer by layer.

This process allows the production of complex component geometries without tools in order to

implement geometries as components that are difficult or even impossible to achieve with

conventional manufacturing methods.

With the LaserCUSING® process, conformal cooling can be used to create tool inserts as well as

direct components for the jewelry, medical, dental, automotive and aerospace industries. This

applies to prototypes and series parts.

The company offers both standard systems and custom concepts for metal laser melting. At

Concept Laser, full-service as an option means that customers can either purchase their own

metal laser melting systems or rely directly on services, including development services.

Laser machining systems from Concept Laser process powder materials made from stainless

steel, hot work tool steels, cobalt-chromium alloy, nickel-base alloy as well as reactive powder

materials such as aluminum and titanium alloys. Precious metals such as gold or silver alloys for

jewelry making are also an option.

LaserCUSING® offers new perspectives in terms of cost and speed for efficient product

development in industries such as:


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• Jewelry

• Medical and dental technology

• Aeronautics and space industry

• Tool and mold construction

• Automotive and motor sports

• Mechanical engineering

The systems reduce development time and costs substantially while offering much greater

flexibility in product development.

The high quality standards, level of experience and successful track record of Concept Laser

guarantee reliable and cost-effective solutions with proven performance in everyday production,

with a particular focus on unit cost reductions.

The art of LaserCUSING® by Concept Laser

Ideas for laser melting with metals in the following areas of application: automotive and motorsport, aerospace, medical and dental technology, die and mold making as well as the wider engineering business.


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