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THE TRIALS AND TRIUMPHS IN AM AM: THE DRIVER OF THE AUTOMOTIVE INDUSTRY THE CHALLENGE OF VERIFICATION IN AM
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EDITOR’S NOTE & CONTENTS
Additive Manufacturing 2018
TRANSFORMATIVE POWER OF ADDITIVE TECHNOLOGY
CONTENTS
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dditive manufacturing (AM) is truly innovative; it opens up new opportunities and lends itself to many possibilities for companies looking to improve manufacturing efficiency. AM significantly streamlines traditional methods and has the potential to become the norm over the decades to come.
The terms 3D printing and AM have become interchangeable. 3D printing technology has been in existence for over 30 years, but after the expiration of one of the technology’s last patents in 2009,there has been tremendous industry growth as well as huge steps in advancing the technology to make it more efficient and cost effective. The
implementation of 3D printing will require further advancements in technology including reducing costs of printers and printer material and increasing printer capabilities to be faster, more accurate, and work autonomously.
AEROSPACE
AUTOMOTIVE
FEATURES
The Quest For An Edge: Singapore And The Metal 3D Printing Industry Advances such as robotics, advanced manufacturing, Internet of Things (IOT), and big data analytics are creating new business opportunities at an unprecedented rate, and Singapore has no plans to be left out. Contributed by NAMIC
Artificial Intelligence Advances Additive Manufacturing Alexandre Lalumiere, Director, 3D printing, Asia Pacific and Japan, Hewlett-Packard, speaks to APMEN on the numerous benefits of AM and the cost savings manufacturers can achieve with additively manufactured parts.
Translating Research Into Application A PMEN speaks to Lim Jia Hao, Development Engineer, AM at the Advanced Remanufacturing and Technology Centre (ARTC), Agency for Science, Technology and Research (A*STAR).
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TOOLING The Road Ahead: Rapid Prototyping In The Automotive Industry The use of 3D printing for prototypes has sparked a rapid evolution in design, development and the manufacturing of products in many industries, including automotive. Contributed by Stratasys
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Additive Manufacturing: The Driver 14 Of The Automotive Industry What comes next is never easy to predict, but one pervasive technology that will greatly benefit the automotive industry is additive manufacturing (AM). Contributed by Terrence Oh, Senior Vice President (AsiaPacific), EOS
MEDICAL Additive Technology: Uses and Benefits The paradigm shift toward additive manufacturing carries the promise of producing geometrically complex objects which could not be produced using traditional methods. Contributed by Trumpf
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Ahmad Alshidiq Senior Editor
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22 Accuracy In Complex 3D Printing APMEN inter views Wu Yong Lin, MD of Forefront Additive Manufacturing Pte Ltd, a user of Sodick AM solutions, on achieving accuracies in 3D printing complex parts. A Perfectly Fitting Metal 3D Implant With Excellent Surgical Results AM advancements have inspired a growing number of surgeons to use metal 3D printed implants for excellent surgical results. Contributed by Shaun Lim, Strategic Business Development Manager, Renishaw, ASEAN
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The Challenge Of Verification In Additive Manufacturing The greatest challenge lies here in AM lies in the verification of the 3D printed parts’ absolute reliability. Contributed by Zeiss
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Size Matters: Large Format Metal Printing For Heavy Industries Companies in the marine and offshore industry are also looking at leveraging metal additive manufacturing as part of their new growth, cost control or sustainability strategy. Contributed by Mr Matthew Waterhouse, CEO of 3D Metalforge Pte Ltd and CEO of 3D Matters Pte Ltd
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Siemens’ Additive Manufacturing Tour, Hannover Messe 2018 Siemens’ AM Influencer Tour at Hannover Messe 2018 delved into the transformative prowess of AM and how best to go about unlocking its value.
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AEROSPACE
Additive Manufacturing 2018
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THE QUEST FOR AN EDGE:
SINGAPORE AND THE METAL 3D PRINTING INDUSTRY
With strong government support, Singapore has developed a burgeoning additive manufacturing ecosystem, and metals are emerging as the leading material. Manufacturing is going through exhilarating times. Advances such as robotics, advanced manufacturing, Internet of Things (IOT), and big data analytics are creating new business opportunities at an unprecedented rate, and Singapore has no plans to be left out. AUTHORS: Albert Sutiono, Senior Technical Programme Manager, NAMIC I Ong Ken Lip, Industrialisation and Partnerships Deputy Director, NAMIC Mahendran V Reddy, Design and Emerging Business Deputy Director, NAMIC I Lynnette Lee, Editorial Writer
Introduction dditive manufacturing (AM) is a game changer, particularly in metal. It whittles down the machinery needed, which translates into cost savings and shorter lead-times. Lighter, more complex parts can also be produced without compromising complexity, rigidity, and strength. The opportunity is immense – according to Frost and Sullivan, the global AM market is expected to grow at a compound annual growth rate of 15%
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until 2025 and reach US$21.5 billion. Manufacturing is a key industry in Singapore – employing 13.7% of the workforce and contributing 20% of the country’s GDP since 1980. The manufacturing sector’s economic performance in 2017’s third quarter exceeded expectations, reaching S$21.9 billion and growing 18.4% year-on-year. As part of Industry 4.0 adoption and to develop Singapore’s competitive advantage in it, the government identified
advanced manufacturing as one of the key ways to achieve its ambitions and rejuvenate the industry. The Metal AM Industry Metal currently makes up over 50% of the AM industry. Innovation in metal inks, printing techniques and equipment design have encouraged metal AM to flourish. Electron Beam Melting (EBM) and Selective Laser Melting (SLM) are the key metal printing technologies.
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Additive Manufacturing 2018
The aerospace, automotive and healthcare sectors are the fastest adopters of metal AM. Advances in software, materials, colour and printing techniques are spurring these industries’ appetite for material resilience, technical precision and structural engineering. By integrating AM into production strategy, manufacturing time and the cost of low-volume complicated parts can potentially be reduced up to an order of magnitude, in some cases. Prototype parts can be made through 3D printing for initial testing, and innovation cycles can be exponentially sped up. In the aerospace industry, air ducts, wing spare components, hinges and complicated jet engine parts are some of the key components manufactured through 3D printing. Singapore’s Metal AM Landscape Singapore possesses a comprehensive ecosystem of AM companies along different parts of the value chain, which encompasses 3D scanning and AM design, printing, post processing, testing and certification. 3D printing service bureaus include UCT (one of the largest AM service bureaus in the region), 3D Printing Studios, Forefront Additive Manufacturing (which focuses on medical applications), 3D Matters, Creatz3D and Singapore Technologies Engineering – one of Asia’s largest integrated engineering groups – which in addition to offering AM as a service, is adopting the technology in-house as part of its drive to digitise and adopt advanced technology. Entry Barriers & Funding To companies who wish to enter the market in Singapore, the barriers to entry are not for the faint of heart. Industry-grade 3D printers typically cost above half a million dollars and run into the millions, depending on the complexity of the system. New research and technological breakthroughs are also emerging regularly. Technical expertise is in short supply, and getting design, fabrication and testing experts may make labour costs run high. Facilities to house the machines also add to the overall fixed costs.
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METAL AM SME CASE STUDY 1: FOREFRONT ADDITIVE MANUFACTURING Forefront Additive Manufacturing specialises in using 3D printing to produce lowvolume high-complexity parts used in conformal cooling channel inserts for the plastics tooling industries, and precision parts for OEM customers. Because of their complexity, these parts are impossible or very difficult to be manufactured by traditional subtractive manufacturing methods. The use of AM efficiently and effectively enables them to do business at competitive prices with shorter delivery times.
A showcase of the home-grown company’s high precision parts made using 3D printing
To avoid printing rejected parts because of heat distortion, Forefront AM boasts expert care and knowledge required to position the printed parts correctly. Engineers analyse the design and construction of the parts, and ensure there is enough post-machining allowance on critical areas before embarking on the actual printing. To adopt AM technology, it is suggested that starting by selecting a few suitable parts that have the potential to simplify, improve or reduce the lead-time of existing manufacturing processes is a good way to begin. Forefront AM is willing to provide support by early involvement and free consultation in identifying such parts, and to provide immediate availability of AM technology resources and know-how.
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AEROSPACE
AM has yet to reach its full potential, but given existing efforts underway, Singapore is well-positioned to fully harness the benefits of AM across multiple industries. Challenges Ahead & Future Developments As with any new technology, there are challenges. Standardisation and certification are crucial for industry-wide adoption, especially for functional parts that go into critical components and the data sheets that give components the physical strength and chemical properties needed in their application. Once those are established, part development, printing and implementation will be able to advance smoothly. The education gap is another challenge. Due to its newness, AM is widely regarded as an advanced technology that requires in-depth niche expertise. To enable the workforce to transition to this new sector, education is critical. Currently, there are a good number of researchers but a lack of talent at the technician and tool operator level. Ultimately, the goal is to develop consistently high-quality workers relevant to companies’ needs. Having said that, wider AM adoption by various industry verticals such as aviation, marine and offshore, healthcare, automotive and supply chain logistics is expected. In addition to precision components, larger parts would be produced by AM, as the industry leverages on the development of largescale deposition technologies such as cold spray, Wire Arc and direct energy deposition. AM has yet to reach its full potential, but given existing efforts underway, Singapore is well-positioned to fully harness the benefits of AM across multiple industries.
Additive Manufacturing 2018
METAL AM STARTUP CASE STUDY 2: SPARE PARTS 3D Spare Parts 3D uses metal AM to produce spare parts for industrial machineries. It supports manufacturers in improving their after-sales service by increasing the availability of their spare parts, which are produced locally and on-demand thanks to the use of AM. Despite the high cost, the company still believes it makes sense to produce using AM because of the shorter lead-times. This is particularly valuable when customers are short of the spare parts required to repair their equipment. Generally, the opportunity costs due to the equipment down-time are much higher than the cost of the spare part itself.
A 3D printed metal impeller produced using Spare Parts 3D’s unique solution – rapid casting. The impeller is a rotating device used to vary the pressure and the flow of a fluid or gas, mainly produced for marine or power and gas industries.
Directed Energy Deposition (DED) technology – where a nozzle supplying material powder moves along multiple axes and an electron or high power laser beam projector melts the fed powder through directing a high power radiation to produce models and parts of metals and alloys.
To companies thinking of stepping into AM, CEO Paul Guillaumot has this to say, “Start first by looking at what can be done with AM and how much can be saved. At Spare Parts 3D, we do support manufacturers and spare parts users to build up a plan for adoption of AM for their spare parts. We study their list of spare parts and let them know what best technologies can be used. In parallel to that, we help them to structure their objectives and build their business cases related to the use of AM on-demand production of spare parts. Once that is done, they know in which technologies they should invest with an actual ROI plan.”
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TOOLING
Additive Manufacturing 2018
THE ROAD AHEAD:
RAPID PROTOTYPING IN THE AUTOMOTIVE INDUSTRY PACE-SETTING AUTOMOTIVE DESIGN Henry Ford may not have invented the automobile, but his pioneering spirit did transform the way cars were made. His assembly line process drastically reduced costs with standardized parts and greater efficiency which led to lower cost, higher quality and greater reliability. Contributed by Stratasys.
Introduction hat Ford had no way of foreseeing was that sweeping changes to the auto industry in the 21st century would completely reorder sales drivers. While the auto industry was built on innovation, its continued growth depends on it. Electric cars, car sharing and self-driving cars have meant what’s under the hood is becoming less a consideration than how car
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interiors can and will be tailored to the changing needs and wants of consumers. In fact, according to Wards AutoWorld, “Interiors will be the number one differentiator in the age of mobility services, because the interiors will influence why someone picks a particular brand.” To keep pace, car designers will require nimble design and prototyping processes to carry innovation through to applications that will drive customer purchasing.
Futuristic Cars If our cars are going to be driving themselves in the future, then what are we, as drivers, going to be doing? Will cars become entertainment centres, meeting rooms or sleeping pods? The point is that no one should be underestimating the increasingly pivotal nature of car interiors as unique brand differentiators. Short design-cycle iteration is important in any industry, but none more so than the automotive
TOOLING
Additive Manufacturing 2018
validated, quickly. But the constraints inherent in many of the intricate and multi-material and fused parts, especially for interior and exterior parts that call for custom features and complex multimaterial parts with separate elements, mean the demand for prototypes often exceeds the capabilities of traditional, multi-step processes. An exploration of how 3D printing for automotive can enable both rapid iteration and facilitate complex design, factors that lead to cost reduction and increased speed, are worth exploring. Road-Blocks To Design Car interiors are complex places. The elements of form, fit and function all play an important role in how user-friendly and aesthetically pleasing customers find a particular design. And, while anyone over the age of 16 can probably point to a particular car that just “felt” great, chances are that same buyer sat in many interiors that “didn’t feel right.” Devices like cup-holders have long been a point of contention to consumers: which work, which don’t, which vehicles have enough, which don’t. But with the advent of driverless and electric cars and a proliferation of the sharing culture, interior design is going to take on a new level of importance. These intangibles undeniably contribute to a great or not-so-great userexperience and will necessitate a growing attention to morphing demands of the automotive industry. arena. So what does this mean for the auto industry? It highlights the need for shortened design cycles and more seamless product design in order to shorten time-to-market. Low margins, due to the rising cost of development, make automotive a capital-intensive industry with the added challenges of constant innovation, customization and the need to bring designs to life efficiently and cost-effectively in order to stay ahead of the curve. The importance of new design validation cannot be underestimated. The auto industry prototyping market is estimated to hit $5 billion by 2020, driving industry designers and engineers toward new ways to get their designs
An Engine Of Innovation Additive manufacturing allows rapid prototyping labs to quickly produce their designs, providing the ability to efficiently iterate, as well as produce prototypes that resemble the finished product. Cutting-edge 3D printing allows for printing in multiple materials so parts that would require separate production and assembly can be seamlessly printed in one run. These have numerous benefits for automotive manufacturers such as: ● Accelerating the product design phase. ● Allowing for printing in multiple colours. ● Printing with multiple textures.
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● Eliminating time-consuming finishing
steps such as assembly and painting. ● Facilitating a quicker design cycle which means quicker time-tomarket. Driving Efficiencies The use of 3D printing for prototypes has sparked a rapid evolution in design, development and the manufacturing of products in many industries, including automotive. In industries where material weight is of importance, such as automotive, 3D printing has spurred advancements in both lighter weight and more complex designs at a lower cost. The use of 3D printing for prototyping also means designers are able to spot design errors or defects early on in the process, which also contributes to a reduction in both production timetables and overall cost. 3D Printing: How Does It Work 3D printing works by depositing material on a print bed, layer by layer, from the bottom up from a digital file. This “additive” process also contributes to cost savings due to its reduction in overall material waste. Designers and rapid prototyping shops can create products much faster than by traditional methods. Faster, easier production provides more time for refinements before arriving at the optimal design. Having a tool that helps accelerate the product design phase is the main goal of rapid prototyping. Since designs usually take anywhere from a few to hundreds of iterations before arriving at a final design, having a cost-efficient, green, high quality process is invaluable. 3D printing has proved to be such a process for many industries, including automotive. In addition to being able to spot design flaws early on, before expensive tooling or machining comes in, having an actual physical model that is nearly indiscernible from the real thing is also very helpful. Tactile feedback is proven to enhance product decision-making. Currently, rapid prototyping is the largest application for 3D printing in the auto industry.
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TOOLING
Additive Manufacturing 2018
LAAM Printer in 3D Metalforge Additive Manufacturing Centre (AMC)
SIZE MATTERS:
LARGE FORMAT METAL PRINTING FOR HEAVY INDUSTRIES Contributed by Mr Matthew Waterhouse, CEO of 3D Metalforge Pte Ltd and CEO of 3D Matters Pte Ltd.
Background ver the last two to three years, metal printing has rapidly evolved to take the leading role for commercial and industrial additive manufacturing uses. Industries such as automotive and precision engineering industries that have historically been a leading user of polymer 3D printing technologies for rapid prototyping and tooling applications; have now switched gears to use metal printing for R&D and
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end use parts production. Companies in the marine and offshore industry are also looking at leveraging metal additive manufacturing as part of their new growth, cost control or sustainability strategy. In many of these industries, the majority of the parts and components are larger in size compared to other manufacturing sectors. Increasing business costs, shortened lead times
and other economic pressures have compelled companies to leverage on metal additive manufacturing for selected parts. With new developments in the metal printing industry, there are also added benefits over traditional metalworking in terms of being able to re-design the original part for enhanced aesthetics and functionality; or even optimize the original part for material reduction, lightweighting or better performance.
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Additive Manufacturing 2018
LAAM as a game changer for heavy industries One of the challenges 3D Metalforge has found in discussions with clients over the past few years is the limitations of size, speed and the high cost of running traditional powder bed metal sintering or meting printers. The most common size of powder bed printer is around 30cm x 30cm x 30cm – which restricts output prints to a table top size; and a decent sized part can take anywhere up to 40 hours to print. This leads to very high per kg costs of printed parts. Whilst many leading manufacturers have pushed the “size envelope� upwards of 40 or 50cm, the challenge of high costs remain. For 3D Metalforge, one of their most exciting developments was the establishment and commissioning of their LAAM printer (otherwise known as Laser Arc Additive Manufacturing printer) into its suite of printers last year in 2017. Their LAAM is capable of printing at more than 0.5kg per hour at sizes up to 1.5m in a growing range of metals. The 1.5m span, which is some 3 to 4 times larger than the largest available powder bed printers today, is made possible by a high energy laser beam mounted on a free ranging robot arm with a wraparound inert gas curtain that effectively extends the reach of the powder blown printer for material deposition. The company firmly believes that this printer will be a game changer for industries such as oil and gas, marine, engineering, automotive and numerous others that need cost effective large format metal printing due to its speed and cost-effectiveness. As of current figures, manufacturing costs by LAAM can be reduced by about 20-30% compared to selective laser melting if the focus is on achieving large, mid-complex parts. Extensive testing has shown that the quality of LAAM printed parts is as good, if not better, than traditional manufacturing, especially in casting. What are the main uses of LAAM? LAAM technology can be used for across LAAM technology can be used for across a wide range of industrial uses including
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What is also valuable about LAAM is that it can easily repair high value-add components, supports quick retrofitting with production of additional or spare parts, as well as surface modification for current equipment or machinery to add on wear and corrosion resistance properties. aerospace, defence, energy, precision engineering, oil & gas, offshore and automotive. Diverse applications can range from engine components and braking parts to medical implants and impellers, turbine blades and crane hooks. Apart from totally new, end-use parts and components that can be directly printed from scratch, what is also valuable about LAAM is that it can easily repair high value-add components, supports quick retrofitting with production of additional or spare parts, as well as surface modification for current equipment or machinery to add on wear and corrosion resistance properties. To provide some real life examples, 3D Metalforge has used LAAM to print valves, impellers and large-sized antenna mount for naval use; and is also currently in the process of re-optimizing the 3D files of various automotive components for printing on LAAM. Why large format metal printing is the choice for for next-generation end-use parts Another key advantage of LAAM over other direct deposition techniques is the ability to produce components that are close to the finished size and shape, also known as near net shape powder-based additive manufacturing. This means that there is significant reduction in the amount of waste material generated and number of processing steps to speed up production. In fact, forgings that used to take months can now be completed in days with metal printing. The connection to CAD/CAM files and design systems also mean that LAAM allow for intricate and complex
geometries that would otherwise be impossible with traditional metalworking. By being able to support rapid design iterations and ease of part customization, large format metal printing has certainly planted its flag in the world of next-generation end use parts for heavy industries. Apart from ongoing enhancements to their current Laser Aided Additive Manufacturing (LAAM) technology, 3D Metalforge is also collaborating with NAMIC and SUTD on a Hybrid WireArc Additive Manufacturing (H-WAAM) technology that utilizes cutting-edge robotics, plasma and machining technology to deliver an even faster and more cost-effective metal printing solution.
Examples of large format metal prints done at 3D Metalforge AMC
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AUTOMOTIVE
Additive Manufacturing 2018
Prototyping with HP 3D voxel technology
ARTIFICIAL INTELLIGENCE ADVANCES ADDITIVE MANUFACTURING
Additive manufacturing (AM) has been in the market for a while and with its use steadily increasing, there arises the need to develop a process that makes AM a responsible, cost-effective business decision. Alexandre Lalumiere, Director, 3D Printing, Asia Pacific and Japan, Hewlett-Packard, speaks to APMEN on the numerous benefits of AM and the cost savings manufacturers can achieve with additively manufactured parts—over 70 percent in direct savings.
Q WHAT ARE YOUR INSIGHTS ON THE AM TRENDS IN SINGAPORE AND THE REST OF SOUTHEAST ASIA? Alexandre Lalumiere (AL): Singapore is currently at the forefront in the AM market Alex Lalumiere in Southeast Asia. The local government is deeply committed in continuing to develop Industry 4.0 technologies in the country. And there are also significant efforts by the government to ensure its workforce has the opportunity to upscale and go for
industry training that would equip them with skill sets in the AM field. Southeast Asia has a huge amount of potential, especially in the areas of healthcare—due to the sheer amount of people that reside in the region which will contribute to the market. This is especially when the AM market matures and becomes fully ready for mass production of certain parts. And mass customisation in one of the beauties of 3D printing. Every part can therefore be customised to an individual’s body (in healthcare) and their needs.
Q IS AM GOING TO DISPLACE CONVENTIONAL PRODUCTION PROCESSES ALTOGETHER? OR WILL THEY BE INTEGRATED ALONG WITH EXISTING MANUFACTURING PROCESSES? AL: AM complements traditional manufacturing processes. There are certain processes that require the conventional techniques of CNC machining, such as injection moulding. The precision and repeatability when you print the same part numerous times with the exact same accuracy is what 3D printing as an industry has not been able to achieve as yet. It has not reached the stage cost-wise for this to be profitable. We have been working with our open materials platform with multiple industry partners to develop materials to drive down the costs which will increase the adoption of 3D printing. There is also the breakeven point, where we look at the cost of part and the volume of the part produced. So manufacturers have to see which of their parts make more sense to use 3D printing or other conventional methods which might be more suitable in terms of costs. When we look at mass customisation, 3D printing brings a huge benefit as manufacturers will not need to bring in the tools and mould just to produce one part. Whereas when they are producing lowcost products that require just a ‘good enough’ accuracy, then injection moulding might be the better solution for them. These two production methods are definitely working in parallel with each other. Q WILL THE COMPANY LOOK INTO METAL AM IN THE FUTURE? AL: Yes, we have announced recently that we will get into metal AM sometime in the future. We are currently at the research stage. We will announce in the future what our market plans are for this. Our goal is to bring new developments in the technology, just as we are doing with plastic AM now and finding ways to push the boundaries in terms of cost, speed, part quality and reliability. We are trying to emulate the same kind of breakthrough in the metal AM space as well.
AUTOMOTIVE
Additive Manufacturing 2018
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Multi jet fusion 3D printer
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WHAT ARE SOME OF THE CHALLENGES THAT ARE FACING THE AM SECTOR IN SOUTHEAST ASIA? AL: The challenges in this sector are speed, cost, quality and reliability, and these four points are key. With some of our new technology right now, such as the multi jet fusion, we are working on the speed aspect of the technology where the speed is 10 times faster than comparable technologies in the market. On the basis of cost, we are working with other companies to reduce the cost of production and total cost of ownership over time. When manufacturers can print and have a high throughput, it will reduce fixed costs related to the initial depreciation of the initial investment in the machinery and technology. Â Â Q HOW ARE OTHER DISRUPTIVE TECHNOLOGIES SUCH AS THE INDUSTRIAL INTERNET OF THINGS (IIOT) AND INDUSTRY 4.0 AFFECTING AM? AL: These technologies are working together with AM. It is interesting to see AM bringing benefits to areas such as robotics and vice versa. The outer shell of robots is typically plastic and we can print those parts. The tips/fingers of robots that grips parts before moving it along can be customised for the exact motion that is required. 3D printing will bring a lower cost to create customised parts for robots. Likewise, a robot could potentially automate some of the manual steps in the manufacturing process.
We are also able to dispense an agent to dispense the properties of a part. With sensors within the machine, the vibration on the part can be tested and we can find out if the vibrations are too strong for that part or not. We can check if the part is subjected to failure, wear and breakage, and we can then start producing smart parts by leveraging the IIoT technology. Moreover, our printers are fitted with AI in the way that we manage the thermoprocess. This means with our powderbed technology, we are basically applying energy to fuse the powder, layer upon layer. And so the 3D printed keychain with HP logo
control of the thermoprocess is all done automatically with AI, as the machine can adjust itself based on the environmental conditions and ensures the temperature is even throughout the powderbed by looking at the thermal camera, gathering data then adjusting the temperature of the build chamber accordingly; this is a self-learning process which is built inside the machine. All these technologies will really allow us to disrupt manufacturing together, and not just one particular technology or trend will achieve the transformation.
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AUTOMOTIVE
Additive Manufacturing 2018
In the construction the student engineers employed for the first time an Additive Manufacturing (AM) process and the car went on to win the title (Source: Rennteam Uni Stuttgart).
ADDITIVE MANUFACTURING:
THE DRIVER OF THE AUTOMOTIVE INDUSTRY
The invention of the automobile has brought drastic impact to the world. In the past few decades, we saw great innovators like Henry Ford and Taiichi Ohno transform the way cars were made, fundamentally spurring a lucrative environment for automakers alike. Asia will be the third-fastest growing region for vehicle sales, boasting a forecasted growth of 4.7 percent in 2018. The sector is expected to see growth in sales volume across the board, from industry vehicles, high-end and compact cars to motorsport race cars. Nonetheless, what will come next is never easy to predict, but one pervasive technology that will greatly benefit the automotive industry is additive manufacturing (AM). Contributed by Terrence Oh, Senior Vice President (Asia-Pacific), EOS.
Current Uses Of AM For The Automotive Industry oday, automotive original equipment manufacturers (OEMs) leverage AM for a multitude of reasons. These include rapid Terrence Oh prototyping, bespoke fabrication of tooling for the assembly line, reduced dependency on tooling in product design and low-volume production of complex automobile parts.
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AM is also disrupting the supply chain model of the automotive industry. By eliminating the need for tooling, AM cuts the overall manufacturing lead time by directly producing high quality integrated and composite parts. This greatly improves market responsiveness. Additionally, AM offers incremental changes within the supply chain, such as the ability to manufacture products closer to customers, minimizing supply chain complexities and removing extensive capital deployment.
While AM already has brought forth a myriad of benefits to the automotive industry, the technology has the potential to help OEMs achieve a lot more. Automakers are compelled to consistently innovate to stay above the curve in such a highly competitive industry and in time to come, AM will help automakers achieve larger gains in productivity, decision making and innovation they seek.
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Additive Manufacturing 2018
Traditional manufacturing encourages wastage of materials because it requires multiple trial-and-error to produce automotive designs. On the other hand, AM reduces the carbon footprint of automotive manufacturing through eco-friendly procedures. How AM Solves The Challenges Faced By OEMs Today While the automotive industry focuses on being more energy-efficient and environmentally-friendly, there is also a growing need for customer-specific solutions. However, the problem with small-series production and the increasing demand for customization is that traditional tool-based manufacturing processes often cannot be applied profitably. This is where innovative, toolless AM comes in. The technology promises maximum design freedom while allowing the creation of complex yet light components with enhanced rigidity. We see these principles being emulated when AM could potentially be used to develop ergonomicallydesigned car seats. If this materializes, this could facilitate massive weight savings, elevated comfort and levels of integration based on customers’ needs. The premium interior of DS Automobiles’ new DS 3 Dark Side, for instance, aptly demonstrates what EOS AM technology can achieve for OEMs today.
On an economic standpoint, the intense global competition calls for an augmented efficiency to offset a lower margin of profit. With AM, rapid prototyping becomes commonplace. This increases the efficiency of research and developmental processes, thereby enabling OEMs to get their products on the market at an accelerated pace. Sustainability is also a rising concern for consumers, as they are more inclined to pledge loyalty to brands that are seen as more being sustainable. With such added pressures on the automotive industry, it is imperative to ensure that cars are manufactured sustainably. Tr a d i t i o n a l m a n u f a c t u r i n g encourages wastage of materials because it requires multiple trial-anderror to produce automotive designs. On the other hand, AM reduces the carbon footprint of automotive manufacturing through eco-friendly procedures. The technology effectively eliminates trialand-error as designs are electronically created. Furthermore, albeit being an energy-intensive process, AM still utilizes less energy compared to traditional manufacturing.
Thanks to this complex aluminum component, cooling performance was increased by 37%. This achievement was the result of optimized coolant flow and improved heat dissipation
(courtesy of EOS GmbH).
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The technology effectively eliminates trial-and-error as designs are electronically created. Furthermore, albeit being an energy-intensive process, AM still utilizes less energy compared to traditional manufacturing. Future Of AM In The Automotive Industry The process of assembling a car takes around 17 to 18 hours in total, but the time needed to design, develop and test all 30,000 parts under a car’s hood can take up to months. As profitability in the automotive industry is driven by volume, the low production speed of AM inevitably serves as an impediment. This is further compounded against a shrinking automotive manufacturing workforce, where a recent study done by SME revealed that more than half of 300 auto industry experts expect to lose 20% or more of their workforce due to retiring workers. It is therefore vital for the automation levels of AM to grow in step. With heightened levels of automation, along with stringent education for the AM workforce, the technology is poised to reduce the total number of processes and workers required. Even though AM is now only scratching the surface of the automotive industry, more and more OEMs are beginning to realize the benefits that AM brings. By channeling our efforts into growing this technology and with the integration of a broader gamut of materials, AM will soon become a true disruptor in the automotive industry.
Additively manufactured titanium component for DS3 Dark Side limited edition cars: inside door handle covers with a very intricate titanium mesh on the upper side (source: EOS GmbH, Spartacus 3D).
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ADDITIVE TECHNOLOGY:
USES AND BENEFITS In additive manufacturing, components are created from nothing more than powder and laser light. On the basis of a 3D model, the laser constructs the component layer by layer. As such, additive methods contrast with ablation and forming methods, which have predominated in industrial production until now. The paradigm shift toward additive manufacturing carries the promise of producing geometrically complex objects which could not be produced using traditional methods – all without using any tools. One great benefit here is the freedom to design any desired shapes. Contributed by Trumpf.
Laser metal deposition he laser is the key element in additive manufacturing. It melts on the metal powder and solidifies it to produce a high-quality workpiece. There are different versions of additive manufacturing for metals: laser metal fusion and laser metal deposition. With laser metal fusion, the laser creates new workpieces by building up layers from powder. This method has proven particularly advantageous when producing prototypes, unique pieces, and small series. With laser metal deposition, the laser generates a weld pool on the component surface. A metal filler material powder is then continuously added and melted on this pool. This creates beads that are welded to one another, which then form structures on existing base bodies or entire components. You can also use this method for coating and repair work. Laser metal deposition is a generative manufacturing technique
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for metals. Laser metal deposition (LMD) is the most common term for the technique, though some refer to “direct metal deposition” (DMD) or “direct energy deposition” (DED). The principle is simple: A laser beam is used to generate a molten bed, to which additional material is added. The laser then fuses the surface of the component with the additional material. As a result the coating and the component or existing coating are fused with a metallurgical bond. The metal powder is added to the base material, layer by layer, and fuses with the substrate so that the final product is nonporous and crack-free. What is special is that you can use the technique to systematically build up multiple similar or even non-similar metal coatings. Laser metal deposition can be used for coating and repair purposes, to generate entire components, and for joining processes such as bridging gaps. In the field of additive manufacturing, it is also ideal for generating entire components and combining different manufacturing methods. As such, a conventionally cast or formed base body can be offered in a range of versions cost-effectively by using the additive method. You can also combine the LMD method with laser welding and cutting. Advantages of Laser Metal Deposition In comparison to other generative processes, the build-up rates and therefore, the process speed are high. Several powder containers can be used for Laser Metal Deposition, which enables you to develop custom alloys to suit your requirements. Sandwich structures can be created by combining different materials. You can choose from a wide variety of materials in powder form, including steels, base alloys made from nickel(Ni), cobalt (Co), aluminum (AI), copper (Cu) and titanium (Ti), as well as WC or TiC embedded in metal matrixes. Generative laser metal deposition is used in Industries including aviation and aerospace, energy, petrochemicals, automotive and medical technology.
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Laser metal deposition can be used for coating and repair purposes, to generate entire components, and for joining processes such as bridging gaps. In the field of additive manufacturing, it is also ideal for generating entire components and combining different manufacturing methods.
LMF Intro Laser metal fusion is often referred to as metal 3D printing, powder bed fusion or selective laser melting. The laser builds up the workpiece from a powder bed, layer by layer. A CAD model provides the plan for doing so, and no tools are required. The powder is added to build a platform and the laser beam accurately melts on the
powder according to the CAD data and joins defined points to the layer underneath. The laser then repeats this process until the metal part is finished. The workpiece has the same properties as the metal powder which was used. A large variety of metal materials in powder form can be used, such as steel, aluminum and titanium.
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Advantages of Laser Metal Fusion As a supplement to conventional production methods, the LMF method offers a number of advantages. There are virtually no limits on the design freedom, which enables complex forms and custom components to be produced quickly, cost – effectively and with flexibility. When conventional production methods reach their limits, LMF can provide the answer. It enables cost – effective production, even for small lot sizes. TRUMPF has expanded its technology and product range in additive manufacturing continuously over the last years. Introducing latest solutions in laser metal fusion (LMF), and developments in laser metal deposition (LMD), a technology TRUMPF established fifteen years ago.
Geometric complexity
Weight reduction
Maximum freedom in geometric design with 3 major advantages: • New geometries that cannot be produced with other methods • Integration of functionalities • Monolithic design
Robust lightweight construction through hollow spaces, grid structures or bionic design
Speed Reduction of process steps (e.g. tool-free production)
Cost reduction Cost-effective production of small and mid-sized components, starting with lot size 1. Especially for complex structures (“complexity for free”) e.g. small series and prototyping
Sustainability Protection of resources through low material and energy consumption – in both the production and in operation of the finished parts
TRUMPF is the world’s only manufacturer to have all the pertinent laser technologies for industrial 3D printing. TRUMPF offers customers the complete package – the laser beam source, machine, powder, services and application consulting – from a single source.
INDUSTRIAL APPLICATIONS
AEROSPACE: TITANIUM MOUNTING BRACKET ● Topology optimization, material accumulation solely along force flow lines (bionics) ● 90% reduction of the material removal ● 30% weight savings ADVANTAGES Part costs independent of quantity and complexity ● Cost reduction through material and weight savings ●
AEROSPACE: TITANIUM TURBO RADIAL BLOWER ● Complex structure with hollow interior ● Higher number of revolutions due to lower weight ● Simple structure, being one piece ● Optimized material usage ADVANTAGES Geometric freedom ● Resource efficiency ● Weight reduction ● Fast prototyping ● Fewer parts within assemblies ● Reduction of production steps
DENTAL: CUSTOMIZED DENTAL CROWNS AND BRIDGES FROM COBALT - CHROME ● Simple fabrication of retention structures on the surfaces for adhesion of plastics and ceramics ● High output und little post processing, since roughness increases the adhesiveness ● Use of bio-compatible material
MEDICAL: TITANIUM HEAT SOCKET ● Patient-specific with high level of customization ● Biologic functionality integration (e.g. structures that facilitate tissue integration) ● Simple data preparation through a CT Scan ● Quick availability and reduction of surgery time because of high accuracy
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ADVANTAGES High fitting accuracy ● Little need for post processing ● Comparably fast production for larger quantities of unique pieces ●
ADVANTAGES Efficient fabrication of unique parts ● Bio compatibility ● Complexity and individualization ●
EOS Singapore Pte Ltd 2 Woodlands Sector 1 #05-09 Woodlands Spectrum 1 Singapore 738068 info-ap@eos.info | +65 6430 0463
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Additive Manufacturing 2018
From left to right: ARTC, Jack Zhang (Design Engineer); ARTC, Lim Jia Hao (Technical Lead); Tru-Marine, Tiong Yih Loong (Technical Manager)
TRANSLATING RESEARCH INTO APPLICATION Asia Pacific Metalworking Equipment News is pleased to conduct an interview with Lim Jia Hao, Development Engineer, Additive Manufacturing at the Advanced Remanufacturing and Technology Centre (ARTC), Agency for Science, Technology and Research (A*STAR).
Q
WHAT PARTS DO YOU MANUFACTURE AT THE MOMENT? Lim Jia H ao ( L J H): ARTC is an advanced research centre based on a contemporary business model of public-private partnership. We develop advanced technology for the manufacturing of high value components such as: ● Aerospace parts including hinges,
brackets, complex fuel nozzles, jet engine parts and replacement parts ● Tooling and moulds with conformal cooling channels for thermal management and performance Q DO YOU USE AM TO MANUFACTURE THESE PARTS? IF SO, WHY? LJH: Yes. Our Additive Manufacturing Industrialisation team aims to
deliver complete solution from preto-post additive manufacturing processes, enabling test bedding of the manufactured components and translation into products. The focus is to identify current limitations on part geometry and performance using traditional manufacturing methods and explore opportunities for product improvement
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Additive Manufacturing 2018
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Cover Ring Reclamation
Q&A WITH TRU-MARINE WHAT ARE THE MOST IMPORTANT IMPROVEMENTS THAT CAN BE DERIVED FROM IMPLEMENTING AM IN THE MAINTENANCE AND REPAIR PROCESSES OF TURBOCHARGERS? Our current MRO operations are labour intensive. Serving time-critical industries, job fulfilment is dependent on repair lead times and the availability of spare parts. AM has enabled us to achieve productivity gains through the reconstruction of worn out components, or building them brand new from scratch, within a fraction of the time required by commonplace repair methods. By building them back to “as new” condition, we extend the service life of useful components instead of replacing them prematurely. With AM, we are able to optimise and elevate our repair processes in achieving consistent quality output, regardless of material composition and component size. ANY POSSIBILITY WITH AM TECHNOLOGY THAT YOU EXPECT TO BE DEVELOPED IN THE NEAR FUTURE? We look forward to sustainable manufacturing capabilities that advocate zero material wastage, conservation and safety consciousness.
Laser Powder Bed (EOS M290) Fabrication
and functionality using additive manufacturing. Q
HOW DO YOU SELECT WHICH PARTS TO AM? LJH: Not all parts are suitable for AM. Design and cost analysis are required to identify how AM can bring about the most technological and economic benefits. Typical considerations include functional integration, need for customisation, potential materials and cost savings, and operational efficiency. These are some questions that can be asked when selecting parts to AM: ● Can the sub-components be merged into a one without compromising its performance? ● What is the typical batch size? ● D o e s t h e p a r t r e q u i r e customisation? How much design variation is expected each time?
● Can weight reduction or topology
optimisation help to improve performance or provide cost savings? ● Can the operating cost be lowered? Can the productivity be increased? Can lead time be reduced? Q WHAT ARE YOUR FUTURE PLANS FOR AM? L J H : Current AM systems i.e. laser powder bed machines have sensors and capabilities to monitor current machine state i.e. layering irregularities or defects and meltpool properties. The next stage is to develop a feedback control or closed loop systems to prevent or repair common problems during the processing. This will provide industries with more confidence in terms of quality assurance and help to accelerate the adoption of AM.
WHAT ARE THE BIGGEST HURDLES SMES FACE WHEN IT COMES TO LEVERAGING THE POTENTIAL OF AM? SMEs need relatively more assistance in capacity and capabilities building. As a marine SME, we face daily challenges to ensure that our business operations are resilient and viable. Due to the lack of time and resources, we will need to prioritise investments that will significantly enrich and extend our product and service lines. In addition to the hardware, due care must be given to upskill our workforce to operate advanced machinery. AS FAR AS DISRUPTIVE TECHNOLOGY GOES, WHAT IS TRU-MARINE STRIVING TO ACHIEVE IN THE NEXT FEW YEARS? Digitalisation and automation for us go hand in hand. For years, we have introduced highly specialised technological repair processes using automation and robotics, operating largely on a customised, piece-rate basis. In the recent months, we have just started with our warehousing cell to process digital vs manual orders, operating solely via computers “humanhands off”. It is also in the plans for digitalisation to integrate separate processes and machines into one, and this requires upskilling just one operator to operate multiple machinery vs deploying one operator for every machine.
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Additive Manufacturing 2018
Sodick
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ACCURACY IN COMPLEX 3D PRINTING
APMEN interviews Wu Yong Lin, Managing Director of Forefront Additive Manufacturing Pte Ltd, a user of Sodick addictive manufacturing solutions, on achieving accuracies in 3D printing complex parts.
Q What parts do you manufacture at the moment? Forefront Additive Manufacturing focuses in supplying products such as medical device (orthoses); conformal cooling channel inserts for tooling systems; high-precision parts; prototypes; jigs and fixtures.
Q Do you use AM to manufacture these parts? If so, why? Yes, we mainly used AM/3D printing machines to manufacture all our products. This is because these parts are usually complex in shapes and with internal cooling channels that followed the profile of the products. These
EV Connector
features are very complex and may even be impossible to be made by the subtractive manufacturing methods. Q How do you select which parts to AM? Selection of the right part to be printed is very important and usually requires
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Additive Manufacturing 2018
good precision engineering and 3D printing knowledge in order to make the right decision. Selection criteria are based on the following: ● Material availability: The right powder material should be available and able to be printed with good quality. ● Complexity of the shapes: The more complex the shape of the part the more it is suitable and cost effective to print. ● Design: Design must be 3D printing friendly to avoid excessive support structures. ● Accuracy: As AM/3D is one of the processes in manufacturing, selection of the right part to be printed and able to perform further post-printing machining to achieve the required accuracies and tolerances become the most important factor.
All machining can be performed by a single process on the OPM250L, including the many ribs arranged around the perimeter
Q
What types of AM machines do you have in your facility? We have three types of printing machines: ● Direct metal laser sintering (DMLS), ● Hybrid metal printer (Printing/ CNC milling), and ● Polymer printer. Q What type of staff skills did you need to develop for successful AM? Engineers must be trained in AM/3D technologies and good precision engineering knowhow. They must be competent in using CAD and CAM software as well as metallurgy and the ability to interpret geometrical and dimensions tolerancing on the drawings. Q What are your future plans for incorporating additive technology into EDM machining? In making conforming cooling channel inserts for the tooling system nearly all inserts after AM/3D printing require to finish by EDM. For Forefront AM, we have EDM machines and capabilities with one of our consortium partners.
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Additive Manufacturing 2018
Image credit: OrthoStreams
A PERFECTLY FITTING METAL 3D IMPLANT WITH EXCELLENT SURGICAL RESULTS Benefits Of Am Printed Implants edical and dental implants are inherently complex in their physical form and do not easily lend themselves to a traditional manufacturing process where higher volumes are required to make the process viable. In the case of medical part manufacturing it is less a case of mass production as mass customization, AM is highly suitable to build complex features and accurate parts in both cobalt chrome and titanium. In traditional manufacturing, making metal objects can be a wasteful process. Plenty of chunky parts are produced and surplus material used. Subtractive manufacturing removes unwanted material; in contrast additive
M
manufacturing or 3D printing adds only the material required, resulting in a far more efficient use of material and a more predictable manufacturing cost with high level of customization. Finished 3D printed products can be up to 60% lighter than their machined counterparts. This gives manufacturers the opportunity to take advantage of higher efficiency and flexibility. 3D Printed Orbital Floor Recover Eyesight A young mother Shashi Kala Rai in Nepal had sustained an orbital floor and medial wall fracture in a road traffic collision. She had previously funded her own corrective bone graft surgery in India but was left with unequal eyes. The left eye was lower, sunken-in and scarring
Image credit: Renishaw
From complex reconstructive facial surgery to orthopedic and trauma surgery, additive manufacturing advancements have inspired a growing number of progressive surgeons to use metal 3D printed implants for excellent surgical results. Contributed by Shaun Lim, Strategic Business Development Manager, Renishaw, ASEAN.
Alignment before the surgery
had reduced its size. Her left eyelids needed to be revised laterally and the eye supported and re-aligned. Alignment before the surgery Orbital implant procedures always carry the risks of causing blindness or double vision, because of the position of the optical nerve. In this case, there were the added risks from being a secondary
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Additive Manufacturing 2018
Metal 3D printed orbital floor
Rai finally received groundbreaking surgery of at the expert hands of consultant Oral and Maxillofacial Surgeon Shakir Mustafa who chairs the Norman Rowe International Education Foundation (NRIEF), a subcommittee of The British Association of Oral and Maxillofacial Surgeons’ (BAOMS). Scrutinising hard copies of Rai’s CT scans, Mustafa could see that the bone graft was incorrectly placed and lying partly in the maxillary sinus and only partly in the orbit. Mustafa began planning the operation and collaborated with a team of experts in 3D design and printing who had a track record of supporting predictable results in complex facial reconstructive surgery. Renishaw was enlisted in the project as the metal 3D printing supplier which also contributed its precision measurement skills to produce the complex geometries needed to help the implant fit perfectly, first time. Mustafa worked with Morriston Hospital’s Maxillofacial Prosthetics Laboratory in Swansea to design the implant in computer-aided design (CAD), with the plates to be visualised and edited in a 3D virtual environment using a haptic arm. Mustafa suggested clinical design modifications, using the
In traditional manufacturing, making metal objects can be a wasteful process. Plenty of chunky parts are produced and surplus material used. Subtractive manufacturing removes unwanted material; in contrast additive manufacturing or 3D printing adds only the material required, resulting in a far more efficient use of material and a more predictable manufacturing cost with high level of customization. flexibility of the process to compensate for the defects from Rai’s first operation, where scar tissue and an ill-fitting bone graft could potentially undermine the plate’s chances of a good fit.
Image credit: Renishaw
Image credit: Renishaw
reconstruction procedure, with earlier incisions and scars jeopardising his ability to restore full form and function. Despite these challenges, this would be an operation where a customized, metal 3D printed orbital floor implant would make a world of difference and support a predictable outcome with reduced risks.
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The plate needed to cover the existing orbital floor and medial wall defects. The team also made adjustments on screen to increase the venting holes, thus aiding drainage. They reduced the extension to the rear of the plate to avoid the optic nerve and reduced the extension of the plate up the medial wall to make surgical placement easier and more predictable. The earlier fracture had allowed some orbital fat to herniate down in to the maxillary sinus resulting in a sunken eye appearance. To compensate, an exaggerated curvature was added to the plate to recreate the retrobulbar bulge of the eye socket and give added aesthetic benefit.
Proven Titanium Implant By Renishaw The .stl files were sent to Renishaw where an metal 3D implant was made on Renishaw’s AM250 machines. Renishaw applies metal powder bed fusion technology to the series of AM systems. AM250 uses a highpowered ytterbium fibre laser to fuse fine metallic powders together creating functional 3-dimensional parts with high durability. Renishaw’s digital workflow ensured the company was able to deliver the implant printed in the proven titanium Ti MG1 material which is tested to ISO 10993 part 1. 3D printed titanium is the strongest material that commonly used in the dental and medical fields, specifically for medical implants due to its nontoxicity, light weight and resistance to corrosion. The operation was a success as Mustafa applied his guiding belief system in “planning to perfection”. This operation is believed to have been a first in many ways in Nepal: the first customised maxillofacial operation and the first 3D printed orbital implant surgery of any kind. By the time Mustafa left Nepal, Rai was still slightly swollen from her operation, but once the sutures were removed, she had normal visual acuity, no double vision, good eye and eyelid movement and the correct eye position had been restored. She made a full recovery and was delighted with the results.
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Additive Manufacturing 2018
THE CHALLENGE OF VERIFICATION IN ADDITIVE MANUFACTURING
3D printing processes—also known interchangeably as additive manufacturing— are becoming increasingly a part of the industrial production chain. Medical technology, aerospace, and automotive industries are leading the innovation and implementation of additive manufacturing. The greatest challenge lies here in the verification of the 3D printed parts’ absolute reliability. Contributed by Zeiss.
Z
eiss 3D ManuFACT offers the perfect inspection verification. Using this unique holistic inspection process for 3D manufacturing the concentrated competence of all Zeiss technologies is applied. This integrated process brings the most reliable knowledge and thus certainty about the reliability of 3D parts. This unique holistic inspection solution for additive manufacturing focuses on: ● Material Composition Analysis ● Powder Analysis ● Post-build Analysis Including Heat Treatment, Part Removal, and Cleaning ● Metallographic Analysis ● Defect Analysis ● Surface Metrology – External and Internal ● Dimensional Metrology – External and Internal
ZEISS Additive Manufacturing Solutions Improving Yield with Holistic Quality Inspection and Correlation
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Additive Manufacturing 2018
This integrated process brings the most reliable knowledge and, thus, certainty about the reliability of 3D printed parts.
Zeiss 3D ManuFACT offers the perfect inspection verification. Using this unique holistic inspection process for 3D manufacturing the concentrated competence of all Zeiss technologies is applied. This integrated process brings the most reliable knowledge and thus certainty about the reliability of 3D parts. On Additive Manufacturing “We assume that an increasing number of critical components will be manufactured with 3D printing. Efficiency depends largely on how well companies understand and monitor the additive manufacturing process chain,” says Dr. Claus Hermannstädter, who is responsible for Strategy and Business Development at the Zeiss Industrial Metrology business group. “Laying the foundation for the necessary process expertise generally requires years of investment.” In Hermannstädter’s experience, detailed analyses of materials and processes can significantly reduce the number of iteration loops.
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THE PROCESS FROM POWDER TO RELIABLE PARTS
POWDER AND MATERIAL CHARACTERIZATION
Powder is the building block of additively manufactured parts. Size distribution of individual powder particles influences how the powder is compacted and affects the density of the build and the possibility of defects visible later in the process. Light microscopy (LM), Scanning Electron Microscopy (SEM) and X-ray Computed Tomography (CT) help to define the powder quality.
POST-PRINT HEAT TREATMENT AND PART REMOVAL
Successful build requires various post-processing treatments to ensure dimensional accuracy and optimal material properties. After printing, the part is still attached to the build plate. It is then heattreated and removed with wire EDM. To better understand the influence of those processes on final quality, a CMM or optical 3D scanner can be used.
DEFECT AND INNER STRUCTURE INSPECTION
POST-PRINT MATERIAL QUALITY INSPECTION
DIMENSIONAL AND SURFACE QUALITY INSPECTION
PROCESS DATA STATISTICS AND ANALYTICS
The quality of powder and how it is spread during the build process might cause voids or material impurity to form in the structure. Inspecting the quality of the build with LM or internal structures with high-resolution X-ray CT helps to determine process parameters influence and faster define a possible path to achieve optimal settings.
Dimensional accuracy and surface finish are critical to ensure proper assembly and consistent mating across multiple parts. The surface finish can be analysed with optical methods, and the internal surface is examined with X-ray CT. Dimensional accuracy of the final part can be validated either with CMM, optical 3D Scanning or with X-ray CT.
The additive manufacturing process, unlike classic manufacturing methods, requires powders to be melted during the build. Melt temperatures and process parameters greatly affect the crystallographic composition and, as a consequence, part properties.
Collection and analysis of data across the entire process chain with Zeiss PiWeb provides a deep understanding of how process changes might correlate with different dimensional and material properties. Clear visual representation and correlation of results across all process steps help to quickly and more efficiently develop printing strategies while increasing yield.
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Additive Manufacturing 2018
SIEMENS’ ADDITIVE MANUFACTURING TOUR, HANNOVER MESSE 2018 Kicking off the series of presentations at Hannover Messe 2018, Andreas Saar, Vice President, Manufacturing Solutions and Additive Manufacturing (AM) Programme Lead at Siemens, asserted that in order to unlock the value of AM, a shift in mindset is imperative. Contributed by Jessminder Kaur
something. It is much bigger than that. There are different pillars, as stated below, to additive manufacturing that determine its success, which Siemens has a very serious approach to. ● End-to-end software ● Consultative services which Siemens is in the process of building ● Defining your business model and how much training is needed
● The ability to deal with automation
Having said that, the company finds itself in a unique position to revolutionise industrial additive manufacturing. The Potential Closer To Home From an Asia Pacific viewpoint, I couldn’t help but wonder how receptive industries have been with regards to the potential of additive manufacturing. I had the
Siemens
A
s a newcomer to this arena, one of the first lessons I was imparted with was that engineers need to be empowered with the confidence to transition into AM because it is important to unlearn conventional methods and re-educate an organisation in its entirety, and not think of it as simply redefining manufacturing or merely printing
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Additive Manufacturing 2018
opportunity to speak to Zvi Feuer, senior vice president, manufacturing engineering software, Siemens PLM and gain his perceptions on the Asian landscape. Zvi: In my opinion, Japan and Korea are moving ahead very fast both by building their own machines and by adopting technologies and by learning gradually. It’s a journey and it does not happen in one day. Vendors and customers, even some that we do not know of, are starting to deploy this technology. In China, there is the ‘Made in China 2025’ strategy and they are investing in robotics and additive manufacturing and this is part of their agenda. I have also noticed that in some of the technical universities, they are putting a lot of effort into AM, in the form of studies and training. I did meet in Pune, India some young companies that have some radical ideas about additive manufacturing, start-ups with varying business models, building their own machines and renting them out. What becomes of this innovative approach, we do not know as of yet. At the moment, there is a lot of knowledge that needs to be accumulated, changes within an organisation that needs to happen to be successful. Q As complexity pervades the present landscape, Siemens PLM software has been announcing new AM initiatives to help visualise processes. What are customer thoughts and feedback in catching up with this kind of technology? Zvi: To customers, at first, it looks like it is very innovative. They read about with interest and feel they need to adopt it quickly but then they ask: Which machine should I buy? How do I train my people? Where do I position this machine? Because they eventually find out that if they put the machine in a particular corner, it prints differently from if it were placed in a different corner, due to conditions surrounding humidity and temperature that have a great impact. How then does one calibrate the machine and get the results they are
after? Another thing to ponder about is where do I get the software to help me redesign the parts because most of the parts of today are designed with CNC machines in mind. So it is not just a question of how do I buy, install and print with the machine, but knowing what to print and if the parts are available to me. It involves an entire chain of design, testing, analysing and making sure the parts are physically functional after they have been re-manufactured and can immediately be put into an aircraft, for example. To further elaborate on the influence of AM from an Asia vantage point, I asked Bob Jones, Executive Vice President of Global Sales, Marketing and Services on what Siemens foresees in the future for on-demand AM. Bob: Right now, we think it’s going to be significant which is one the reasons we built the AM network, because we think there’s going to be a large community for on-demand to support a couple of things. Mostly, it’s the spare parts industries. There will be a lot of need where you need to build a part in a certain region, such as Asia and it’s easier to use an on demand print servers opposed to having your own facility that may only print those parts a few times a year. The other thing is if you think about the ability for a start-up company to disrupt a large traditional industry with today’s digitalisation technology and with additive manufacturing, suddenly now, I as an individual, can take on the largest manufacturing companies in the world because I have access to design technology, simulation technology, and with the print services that are available or will be available, I now have manufacturing available to me. Fast-Tracking Hackrod, Inc’s Vision for Automotive Design One of the highlights of my tour with Siemens was the opportunity to meet and listen to a presentation by Hackrod Inc.’s Chief Executive Officer, Mouse McCoy, a man of many talents whose career has encompassed professional
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Mouse McCoy, CEO of Hackrod Inc./ Photo by Rickett & Sones
motorcycle racing, stunts, and now, filmmaking. If engineering design and manufacturing were to be democratised, allowing the consumer to turn creator in the automotive space, I believe this is arguably a huge milestone in the arena of disruptive innovation in terms of deep customisation and radical creativity. Partnering with Siemens, Mr McCoy shared how his team will create the world’s first car designed in virtual reality, engineered to full size with AI, and 3D printed in structural alloy. Hackrod’s factory of the future leverages the Siemens Digital Innovation Platform, affording individuals and small enterprises a never-seen-before ability to yield a product as easily as playing a video game. With multiple tools from Siemens PLM software including NX software, and the new cloud based collaboration software Solid Edge Portal, Hackrod is developing a platform to give a chance for truly bespoke aesthetic design to prevail with guaranteed
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engineering solutions. The products of this partnership will illustrate the impact this team will create with access to world class digital design, engineering, visualisation, manufacturing and inspection power. Adoption Challenges We had the privilege of being hosted by Toolcraft GmbH, a manufacturing facility in Georgensgmünd, where Christoph Hauck, one of three managing directors in the company briefed us on how Toolcraft faced the uphill task of developing internal quality control standards to ensure a danger-free environment to operate in. Mr Hauck also stated that in many cases additive jobs involving AM require more meticulous work with their customers, very frequently, for the optimisation of design, and sometimes
Additive Manufacturing 2018
they would attempt to not implement AM at all. Final Thoughts From what I have gathered, the road to embracing AM is still a rocky one for many companies because they lack the experience internally to do so confidently. In light of the understandable trepidation, it was heartening for me learn that the issue of awareness is being addressed through a consulting group that Karsten Heuser, Siemens’ Vice President of Additive Manufacturing, is responsible for because it’s not enough just to have the technology. There should be heavy investment in helping drive awareness and education which Siemens recognises is a very critical component in its journey towards AM success.
In many cases additive jobs involving AM require more meticulous work with their customers, very frequently, for the optimisation of design, and sometimes they would attempt to not implement AM at all.
A COMPELLING EXPLORATION OF SIEMENS AM TECHNOLOGY Gas turbine burner showcased at the Siemens booth in Hannover Messe The left picture shows the conventional burner comprising 13 components, 18 welds and a thermal barrier coating requiring 26 weeks of lead-time. The right image is of the redesigned part using EOS powder bed fusion technology: a single integrated part with no need for thermal barrier coating and manufacturing lead-time of only three weeks.
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❑ No ❑ No ❑ No
❑ 300 CNC Machining
❑ 321 EDM/ECM
❑ 313 Forging
❑ 308 Broaching
❑ 303 Milling
❑ 324 Inspection/Measuring/Testing
❑ 316 Rolling
❑ 311 Plastic Moulding
❑ 306 Gear Cutting
❑ 301 Design with CAD/CAM
❑ 319 Die Casting
❑ 314 Pressworking
❑ 309 Grinding
❑ 304 Drilling/Boring
❑ 322 Welding
❑ 317 Automated Assembly
❑ 315 Stamping
❑ 307 Tapping/Threading
❑ 302 Turning
❑ 320 Beading
❑ 318 Shearing
❑ 310 Lapping/Honing
❑ 305 Coil Forming
❑ 323 Electroplating
❑ 350 OTHERS (Please specify)
YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 Basic Metal/Foundaries/Mills
❑ 123 Shipbuilding
❑ 150 Electrical & Electronics production
❑ 160 Design & Consultancy Services
❑ 222 Telecommunications Equipment Manufacturing ❑ 180 Govt bodies, Trade Assns, Exhibitions Cos. ❑ 120 Aircraft maintenance/components mfg.
❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories
❑ 223 Dies & Moulds mfg.
❑ 224 Mechanical, Fabrication and all other metal engineering works
❑ 122 Motor Vehicles Parts
❑ 027 OTHERS (Please specify)
JOB FUNCTION (Please be specific)
❑ 021 Senior & Middle Management ❑ 028 Testing & Inspection
❑ 022 Production Engineering
❑ 026 Design Engineering
❑ 023 Maintenance Engineering
❑ 030 Sales & Marketing
❑ 024 Quality Control/Assurance
❑ 029 Purchasing/Sourcing
❑ 025 Research & Devt
❑ 027 OTHERS (Please specify)
SIZE OF COMPANY
❑ 001 (1 – 10)
❑ 002 (11 – 30)
❑ 003 (31 – 50)
❑ 004 (51 – 100)
❑ 005 (101+)
TruPrint 3000:
Flexible LMF solution for industrial production The TruPrint 3000 is a universal medium - format machine with industrial part and powder management, designed for flexible series production of complex, metal components using 3D printing. It is ideally suited to general industry applications. Components can be arranged with utmost flexibility in the large build area of Ă˜ 300 x 400 mm. The TruPrint 3000 is ideal for use in job shops when combined with the industrial part and powder management.
www.trumpf.com