05/06/2018

Slide 1

Steve Fisher

District Solutions Manager

Renishaw Incorporated

Transitioning from Development

to Production:

Addressing the Next Steps in

Metal Additive Manufacturing

Image courtesy TCT Magazine

About Renishaw

05/06/2018

Slide 2

World leading metrology & engineering company

Metrology Research Healthcare Additive

• FTSE 250 public company, UK headquarters

• Independent

• 4,500 staff in 35 countries

05/06/2018

Slide 3

• From research lab onto the factory floor

• From prototypes & tooling to series production

• From time compression to higher product performance

• From shapes to consistent, qualified parts

• From plastics to high performance alloys

• From 3D printing to an integrated production process

Additive manufacturing3D printing

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Slide 4

Productive machining – the benchmark for industrial AM

• 140 productive hours per week

• 24 hour unattended operation

• > 99.5% process yield

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Slide 5

Metrology underpins modern manufacturing

• Characterisation of processes

• Feedback for process control

• Verification of process outcomes

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Slide 6

The Productive Process Pyramid™

Process control in

manufacturing

Metal AM in production

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Slide 7

Design for AM AM build Gauging Machining Inspection

Pro

cesses

To

ols

Higher production rates with higher precision

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Slide 8

Additive Metal Manufacturing – “Digital Castings”

Design AM parts with final machining in mind• D4AM – design in fixtures

and machining datums!

Additive work-holding considerations

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Slide 11

Additive work-holding considerations

Maximised

encapsulation

reduces

deflection and

chatter

• Probing for machine reference.

• Multiple angular positions.

• Define rotary axis center.

• Used for multi axis machining.

• Reference ‘pad’ delta from

rotary center or pivot point.

• Used for subsequent thermal

tracking.

Automated processing– initial set up

• Zero point fixture system

• Part measurement on Equator

• Complex measurements of

surfaces

• Automatic transfer to CNC

• Writing to chip / tag possible

• Adaptive machining possible

Automated processing - part set up

• Set ‘ballpark’ tool offsets

• Confirm correct tool & build

• Drills, taps, reamers etc. accurately set to each other

• Reduces inspection for set up & adjustment

• Reduces potential of tool breakages

• No dynamic effects on tool or part are compensated.

Automated processing – tool setting

Accurate machining

• Recording process output from

machined features.

• Analysis of recent parts.

• Automatic tool offset update.

• Adjusting process mean to

nominal dimension.

• Reduces measurement /

manual update time delay.

• Eliminates manual errors.

Automated processing – process control

• Verify feature size to design

intent.

• Check for distortion against

pre-machined condition.

• Analysis of surfaces against

CAD nominal.

Final Certification

Build your AM experience and knowledge

05/06/2018

Slide 18

• Try before you buy: develop your product

and process, acquire knowledge, build

your business case

• Global network of centers providing

facilities, machines, post-processing and

engineering support

Thank you

Your product

design

Renishaw

expertise

Your AM

process

Global support

THANK YOU