1
2
The
AM
AM –14/15 Vol.05 Issue 27
Magazine
Website: www.ammagazine.in
On the cover: ‘3D Printing Sand Moulds and Cores by ExOne’
regulars: 4.Editorial Insight 5. White Paper: New Mindset in Product Design
latest updates: 20.
Press Release: RAPID.TECH 2014: EOS launches the EOS M 290 metal system to succeed the established EOSINT M 280 system
21. Press Release: SLM Solutions: New order intake in H1 2014 underpins positive expectations
22.
Press Release: Efesto and RPM Innovations announce global strategic partnership in Metal 3D Printing, launch premium suite of Metal 3D Printing equipment, repair & free form fabrication services
09. Case study: Direct Digital Manufacturing Takes Flight - Stratasys
11. Case Study: Boeing Sees Growing Value & Versatility in SLS System and DuraForm Materials
13. ExOne – The New Standard for Pump Manufacturing
15. Case Study: Medical– US Regulator FDA Awards First Approval for Customised 3D-Printed Polymeric Cranial Implants
A 17. Intake manifold: 3D Printing of sand Moulds: Voxeljet
18.The World’s Largest Argon Chamber Industrially Hardened LMD System : Efesto LLC, USA
3
Editorial:
“3D printing--Shaping the future of Indian Foundry industry” The foundry industry in India has been growing steadily over the past several years despite economic slowdown dented its demand from the end user industry i.e. engineering and auto component sectors. The Indian foundry industry is producing various grades of Castings as per International standards.
ExOne’s S-Max with a job box size of 1.8x1.0x.07m is playing a promising role-- just design the CAD data and print the mold package eliminating the need for patterns and tooling. Now dependency on the tool and pattern makers is minimized. 3D is currently entering the mainstream to great fanfare.
The various types of castings which are produced are ferrous, non ferrous, Aluminium Alloy, graded cast iron, ductile iron, Steel etc for application in Automobiles, Railways, Pumps Compressors & Valves, Diesel Engines, Cement/Electrical/Textile Machinery, Aero & Sanitary pipes & Fittings etc & Castings for special applications.
The technology is at its tipping point right now allowing companies to build larger components and achieve greater precision and finer resolution at higher speeds. This in turn transforms overall manufacturing by slashing product-development cycle times, eliminating tooling costs and simplifying production runs—which makes creation of complex shapes & structures that weren’t feasible before. Moreover, it would help companies improve the productivity of materials by eliminating waste that accrues in traditional manufacturing.
To get a casting done in a foundry through conventional process we go through various processes-- we develop cad part file, design pattern and core box, manufacture a pattern and a core box, produce and assemble cores, produce cope and drag mold, then we assemble the mold package and finally produce the casting. This conventional process is very cumbersome and time-taking. As well, the first prototype is never the finished product and prototypes need to be redesigned numerous times. The slow nature and high cost of traditional prototype design do not allow organizations to fully utilize their expertise and abilities. Also many times we come across a better way to design our product, but due to the costs and time involved to make these changes, we can't implement the changes to our design. To unfold and eliminate the monotonous and the cumbersome conventional method, ExOne Gmbh, after spending a lot of time and money in research and development, has successfully been able to provide a paradigm shift from conventional manufacturing to 3D printing. It has brought a new life to the foundry industry. Intricate parts with undercuts, draft angles can be created in a matter of hours and the design changes can be made numerous times giving designers the flexibility to design a product.
- Global Axis (Partner to ExOne GmbH) New Delhi, India
4
India has not yet caught on the 3D printing wave like the US and Europe have, but as competitive pressures in the market increase, various technology patents lapse, vendors eager to fulfill interest and demand, falling prices will make printers more affordable for more consumers. Expiring of 3D printing patents this year will likely to open new avenues in 3D printing revolution which in turn can also bring down the cost. Others argue that the only thing holding 3D printing back is the technology itself––printers are either too slow, too cumbersome or incapable of printing objects that people actually want, partly due to limitations in materials. Despite these, it would be a positive move for the industry and may translate into 3D printing taking off in a big way in India. Three-D printing, no doubt will make the world a very different place-- and, with the right strategies, a better one too.
White Paper: A new Mindset in Product Design
3D PRINTING CAN HELP BRING BETTER PRODUCTS TO MARKET FASTER
By Stratasys, Inc. The terms “3D printing” and “additive manufacturing” refer to processes that automatically build objects layer by layer from computer data. The technology is already well-used in many sectors including transportation, health care, military and education. Uses include building concept models, functional prototypes, factory tooling (such as molds and robot-arm ends), and even finished goods (such as aircraft internal components). The aerospace and medical industries in particular have developed advanced applications for 3D printing. 3D printing is sometimes referred to as “rapid prototyping,” but this term does not encompass all current uses for the technology. Materials used in 3D printing include resins, plastics and, in some cases, metal. The earliest method, stereolithography, has been around since the late 1980s, but adoption was limited because of the toxic chemicals it required and the fragility of its models. Other technologies have evolved since then, including Fused Deposition Modeling (FDM®). FDM, introduced in the early 1990s, lays down super-thin layers of production-grade thermoplastic, yielding comparatively durable models. Since 3D printing’s inception, system reliability and model quality have increased, resulting in diverse applications. At the same time, prices have gone down to the point where some systems are affordable even for small businesses.
In a 2011 report, Wohlers Associates predicted that worldwide annual sales of additive manufacturing systems will reach 15,000 units by 2015 — more than double the 2010 rate. Lower-priced professional systems will drive most of this growth. In FDM TechnologyTM, printer software on the user’s Windows network or workstation accepts computer-aided design (CAD) data in .stl format. The software works like a paper printer’s driver, sending data to the 3D printer as a job and telling the print head where to lay down material. Filaments of plastic modeling material and soluble support material are heated to a semi-liquid state, forced through an extrusion tip and precisely deposited in extremely fine layers. (FDM layer thickness ranges from 0.005 inch [.127 mm] to 0.013 inch [.330 mm], depending on the system.) The print head moves in X-Y coordinates, and the modeling base moves down the Z axis as the model and its support material are built from the bottom up. The soluble support material (brown in the example photo on this page) holds up overhanging portions while the model is being built, and allows for complex models — even nested structures and multipart assemblies with moving parts — to be 3D printed. When the print job is complete, the support material washes away and the model is ready to be used or, if desired, finished with paint or another process. Some 3D printers are small enough and clean enough to function as office equipment inside a department or even an individual cubicle. By comparison, large rapid prototyping systems often must be centrally located and run by a dedicated staff of experts. The very cheapest class of 3D printers comprises home-use devices now on the market for hobbyists. While fascinating for enthusiasts, these machines differ from small professional systems in that the resulting models often have poor resolution, are dimensionally inaccurate and unstable, and lack durability. Trends toward affordability and ease of use are bringing professional 3D printing technology in-house for many designers and engineers. The growing expectation that a CAD drawing can become a real threedimensional object in a matter of hours is altering how companies see the design process. 3D-printed models are shown with soluble support material (brown) intact, and after removal.
5
White Paper: A new Mindset in Product Design
Some 3D printers are small enough and clean enough to function as office equipment inside a department or even an individual cubicle. By comparison, large rapid prototyping systems often must be centrally located and run by a dedicated staff of experts. The very cheapest class of 3D printers comprises home-use devices now on the market for hobbyists. While fascinating for enthusiasts, these machines differ from small professional systems in that the resulting models often have poor resolution, are dimensionally inaccurate and unstable, and lack durability.
Trends toward affordability and ease of use are bringing professional 3D printing technology in-house for many designers and engineers. The growing expectation that a CAD drawing can become a real three-dimensional object in a matter of hours is altering how companies see the design process. It can be faster, more effective, and less costly.
USING 3D PRINTING TO ACCELERATE DESIGN hurdles. Analysis of new product development by Greg Stevens and James Burley in their oft-cited study “3,000 Raw Ideas = 1 Commercial Success� found that in addition to 3,000 raw ideas, a single successful innovation also requires 125 small projects, four major developments and 1.7 product launches.3 3D printing capabilities can speed the process by which companies determine whether concepts are worthy of development resources.
The longer a product stays in the design cycle, the longer it takes to get to market, meaning less potential profit for the company. Time-to-market considerations were identified as the most critical daily issue facing respondents of a 2008 Product Design & Development readership poll. This group also said prototyping itself presented a time-to-market obstacle in 17 percent of product launches. With increasing pressure to get products to market quickly, companies are compelled to make quick yet accurate decisions during the conceptual stage of design. These decisions can affect the majority of total cost factors by establishing material selection, manufacturing techniques and design longevity. 3D printing can optimize design processes for greatest potential profit by speeding iterations through product testing.
While outsourcing 3D printing might result in models equal in quality to those 3D printed in-house, the Graco example illustrates the benefits of investing in your own machine. A highly iterative process can only happen in a feasible time frame when engineers can see quick feedback on design changes. In-house 3D printing eliminates shipping delays and reduces administrative slowdowns that can accompany sourcing prototypes from external services. With some systems z one in-house model per month justifies the cost of a printer versus money spent outsourcing.
For example, Graco Inc. makes paint spraying and texturing equipment for professional use. Its engineers used a 3D printer to experiment with various paint gun and nozzle combinations to create the perfect spray pattern and volume. The resulting new spray-texture gun was based on functional prototypes 3D printed in ABS plastic. Graco estimates that 3D printing helped reduce development time by as much as 75 percent. The journey from brilliant idea to successful product is fraught with
Time Saved prototyping with in-house 3D printing vs. other methods Industry
Old Method
Time Savings
Industrial Design
Clay models
96%
Education
Outsourced machining
87%
Aerospace
2D Laser Cutting
75%
Automotive
Aluminium Tooling
67%
Aerospace
Injection molding and CNC tooling
43%
Each example is based on a real customer experience.
6
WhitePaper: Paper: A new Design White new Mindset MindsetininProduct Product Design
MORE EFFECTIVE DESIGN THROUGH3D PRINTING 3D printing can increase the chances of a successful product launch by enabling more thorough design evaluations and a more iterative process. At Henk and I, an industrial design firm in Johannesburg, South Africa, designers created and extensively tested a new kind of pool-cleaner motor that works well with low-flow, energy-saving filters. The high-torque design was the result of an iterative refinement process using the office 3D printer. In the functional testing stage, 30 3D-printed prototypes cleaned pools in various regions worldwide. The result was a new pool cleaner model, the MX 8, for the firm’s client, Zodiac. According to Henk van derMeijden of Henk and I, the motor innovation would have been impossible without 3D printing.
strength to withstand rigorous testing, designers can be more confident in their work. Additionally, data integrity and security is paramount in a competitive environment. While sharing confidential STL files with trusted vendors is generally safe, having a 3D printer in-house removes any worry that might stem from sending intellectual property offsite. Making needed changes as early as possible saves money and time. 3D-printed models can give designers and engineers a thorough understanding of potential products earlier in the design process than other methods, minimizing the risk that problems will go unnoticed until it’s too late. Acist Medical Systems designs and manufactures contrast injection devices for cardiologists and radiologists. The company uses 3D printed parts in functional testing, fixtures and end-use parts. In complex assemblies, Acist uses 3D printing to design plastic parts as efficiently as possible around machined parts, circuit boards and integrated circuits. In one display unit, Acist reduced part count from 15 to seven because of 3D printing’s ability to help evaluate complex geometries. The company even tests functional 3D-printed units in customer settings, working out design problems and incorporating real customer feedback before committing to large-scale tooling.
Successful product design requires review and input from many sources. With in-house 3D printers, design teams can review concepts earlier with others who may provide feedback. Fast collaboration with engineering, marketing and quality assurance can empower designers to make adjustments throughout the design process and follow-up testing. Faster turnaround is the only way to enable iterative discovery without lengthening the design process. 3D printing users in aerospace, automotive, industrial design and education have reported improvements of 43 to 96 percent in prototyping speed when switching from traditional methods to 3D printing. Traditional prototyping methods include injection molding, CNC machining, metal machining and 2D laser cutting. In some cases, lead time required by a machine shop had been a major factor in slowing prototype creation. As the trend toward affordable 3D printing continues to result in more decentralized machines, for example in departments or individual cubicles, opportunities to speed the design cycle are multiplying. An optimized design process with more prototype iterations can help minimize risk of product failure. Because 3D printers can produce models with fine feature details and the
At Acist Medical Systems, medical-device designers test ideas with 3DPrinted prototypes and low quantities of end-use parts.
ADOPTING 3D PRINTING TO REDUCE PRODUCT-DESIGN COSTS The acquisition cost of a professional 3D printing system can be as little as $10,000 (USD), which may surprise engineers and designers who’ve priced larger 3D production systems. Annual operating costs are generally lower too, partly because 3D printers require no dedicated facility or special expertise to run. Leasing options can mitigate the cost barriers that may have restricted adoption of 3D printing technology in the past. Other costs to consider are printer maintenance and material costs, which vary depending on use. When evaluating 3D printing systems, consider facilities requirements; expertise needed to run the system; accuracy, durability and size of models; available materials; speed; and, of course, cost.
Your desired application will help you determine the best system for you, but keep in mind that many users report discovering diverse uses after acquiring a 3D printing system. For example, a system purchased for functional prototypes might prove useful for building manufacturing tools. At Leptron, a developer of remotely piloted helicopters for law enforcement, military and civilian use, engineers used a 3D printer to design, test and build a tiny surveillance drone. The RDASS 4 has eight modular fuselage components that can combine for various uses. Designing the complex drone and testing it to withstand crash landings required an iterative
7
White Paper: A new Mindset in Product Design
approach involving 200 design changes, including structural reinforcements and aerodynamic improvements. In-house 3D printing cut product development costs for the RDASS 4 by 60 percent over injection molding. Further, the project may not have been commercially feasible without the 6-month head start that 3D printing offered in getting the drone to market.
significantly improve production costs and time to market. This can create a distinct competitive advantage for those companies who include 3D printing as an integral part of their design process. Lower costs will continue to expand the 3D printing market, especially in small to medium-sized businesses and schools. The speed, consistency, accuracy and low cost of these printers will help companies reduce time-to-market and maintain a competitive edge.
3D printing provides a highly cost-efficient means of producing numerous design iterations and gaining immediate feedback throughout the critical beginning stages of the development process. The ability to refine form, fit and function quickly can
8
Direct Digital Manufacturing Takes Flight - Stratasys
FDM Direct Digital Manufacturing Saves $800,000 and Three Years Development Time Over FourYear Period “FDM has saved the government over $3.8 million to date with an expected 10-to-15-year savings of over $15 million. “ - Mitchell Weatherly, Sheppard AFB, Chief, Trainer Development Flight For the Department of Defense, the TDF designs and builds “trainers” and “training aids” such as UAV replicas to train students.
Based at Sheppard Air Force Base, Wichita Falls, Texas, the Trainer Development Flight (TDF) is a facility that designs, develops, and manufactures trainers and training aids for the Air Force and all branches of the Department of Defense (DoD) as required. These items are used in numerous training environments, including avionics, weapons and fuel systems, medical readiness, HVAC, and telecommunications systems.
applications, it’s more economical to train students on replicas, instead of the often extremely expensive equipment. The TDF uses direct digital manufacturing to fabricate a wide majority of its training products. To do so, it employs four FDM additive fabrication machines in a centralized location with AFSO 21 (Lean) processes incorporated into the overall process.
The trainers and training aids may be either original products or replicas of existing ones, depending on the training need. Some devices are not required to be working units, so it usually isn’t cost-efficient to purchase the actual item. For most training
How Did FDM Compare to Traditional Methods for Sheppard AFB over a four-year period? Estimated Part Cost Savings $800,000
Estimated Time Savings 3 years
Real Challenge Before adding direct digital manufacturing to its processes, the TDF used conventional manufacturing methods to make its products. Conventional manufacturing typically requires longer lead times because there is often multiple steps, such as machining, lathe work, welding, sheet metal bending and
cutting. A similar difficulty occurs when producing tooling to mold a part. “Because most of our projects are either one-of-a-kind or very low volume, conventional methods become very expensive,” says Mitchell Weatherly, Chief of the TDF. “Only about 10 percent of our work is for prototyping, and 90 percent is production.”
Real Solution Before settling on FDM, the TDF considered “a multitude” of the other additive processes, says Weatherly. “With FDM, the investment is up front, not ongoing,” he says. “The parts are durable, and they have the high level of detail we require. In addition, the process is environmentally safe and 100% ‘green’ with zero waste.” The TDF is responsible for designing and manufacturing an exact replica of an unmanned aerial vehicle (UAV) or “drone” for training repair technicians. It has built a variety of internal and external components using its FDM machines. The components included most of the body components as well as several cowlings, propellers, and antennas. They also purchased a number of real UAV components from the OEM. Real Benefits Just for producing the UAV’s large antenna alone, using the FDM machines did the job in about one-tenth the time it would normally have taken with conventional methods, and it delivered an ROI of over $12,000. The savings go beyond time, though. For the antenna, it would have taken an outsourced machine shop up to 20 days to produce the part, where it took
only two days using FDM — but only 15 to 20 minutes of labor. For the entire UAV project there was a total time saved of more than 3 years in some areas. This project, along with other trainer savings has been very impressive with an $800,000 cost avoidance over the last four years.
9
Direct Digital Manufacturing Takes Flight - Stratasys
“Major advantages to the FDM system include its speed over other processes or alternative build methods, the versatility of FDM versus injection molding, and the ability to run multiple parts simultaneously through the system,” says Weatherly. Benefits include ease of maintenance, as well as the availability to use multiple materials for a variety of purposes. “Additional capabilities include the ability to design based on function needs instead of manufacturing constraints, and the ability to implement design changes immediately and at minimal costs. The versatility to manufacture any item coupled with zero hazardous waste is one of the greatest advantages to the Air Force,” says Weatherly. “The FDM-based machines have been used for a number of trainer projects which have tight budgets. We have also utilized the FDM process for research and
development for our airmen and soldiers to be able to train like we fight.” “For our first FDM machine purchase, we projected ROI in 4 years, but it took only 18 months,” Weatherly says. “For our second FDM machine purchase we saw ROI in only 9 months. You will never get away from conventional methods and highly skilled technicians, but you can give them the proper tools and new technology that can make their job easier and competitive. I believe FDM is one of the technologically advanced premier manufacturing methods available. Since 2004, when we purchased our first of four machines, the FDM process has saved the government over $3.8 million to date with an expected 10-to-15-year savings of over $15 million.”
The TDF often reverse engineers UAV replica fuselage and wings, Antenna and other components being With direct digital manufacturing, components to make the replicas. manufactured with the FDM process. Manufactured by a Fortus machine. The TDF can produce batches of components.
10
Boeing Sees Growing Value & Versatility in SLS System and DuraForm Materials – 3D Systems
Sector: Aerospace Technology: SLS® system / DuraForm® material Boeing creates prototypes and manufactures parts for the AH-64D Apache Longbow helicopter using DuraForm material on the SLS system from 3D Systems. When most companies consider an equipment purchase, a big concern is how quickly the equipment will pay for itself. Fortunately, when The Boeing Company’s air vehicle design division in Mesa, Ariz., estimated the return on investment on its SLS system, it found reason to celebrate. The system had paid for itself in less than a year. “If I were to add up all the tooling costs we’ve eliminated, all the secondary rework we didn’t have to perform, all the post-processing steps we’ve eliminated, all the parts we’ve made, and all the man hours we’ve saved by using our SLS system to create prototypes and parts, I could easily say we’ve saved enough to pay for the system—and potentially even a second machine,” says Jerry Clark, manager of the Air Vehicle Configuration Design, Integration and Rapid Development Department of The Boeing Company in Mesa. In the span of five months, Clark’s department built more than 400 parts on its SLS system. Most were made with DuraForm Polyamide (PA) material. DuraForm is filling many of the prototyping and direct manufacturing needs Boeing has in Mesa as the company works to design, test and produce a variety of air vehicle products, including the AH-64D Apache Longbow helicopter.
“DuraForm material is flexible and durable,” notes Clark. “We’ve noticed that it has outstanding characteristics coming out of the machine. We’ve also seen the results other Boeing locations are getting with the material.” Why the SLS system became a “high priority” “We were looking at ways we could potentially reduce cycle times, build tools more quickly, and in some cases, eliminate the need for tooling and other post-processing steps altogether. Plus, we saw areas where the SLS system could help us with research,” says Clark. “That’s what prompted us to purchase our own system. We saw it as an opportunity to significantly reduce cycle time.” Clark notes, “We chose the SLS machine because of its flexibility, the variety of materials it can use, its potential usage in research, and its increasing potential with metals.”
“If a picture is worth a thousand words, then a physical 3-D mockup is worth 10,000 words.” Jerry Clark, The Boeing Company Many of the DuraForm parts Boeing makes on its SLS system in Mesa go directly on prototype aircraft, vehicles and mock-ups. Clark notes that “DuraForm works well in areas where we have to make functional parts for the secondary structure, such as ducts, fairings and other non-load carrying components and parts.” Boeing also is looking into using DuraForm to create load-carrying components and parts. These parts usually undergo a variety of tests, including those measuring tensile strength, heat resistance, fatigue, material consistency and resistance to moisture and various fungi. The combination of tests performed depends on how and where the parts are used, what conditions and hazards they may be subjected to, whether humans will be in contact with them, and many other factors. Minimizing potential for human error Boeing’s ability to make DuraForm prototype parts directly on its SLS system has minimized or eliminated the long and often tedious processes of generating part drawings, creating prototype tooling, producing prototype parts and performing post secondary fabrication steps. As a result, Boeing saves time, reduces costs and lessens the likelihood of repeating the many types of human errors that can occur in the various stages of development. “It could be rather painful to go through the process of having prototype tooling and parts made, only to find out they don’t fit or work right. In contrast, with our SLS system, we often go directly from computer data to prototype
11
Boeing Sees Growing Value & Versatility in SLS System and DuraForm Materials – 3D Systems
part to installation on the aircraft. It’s another type of paperless system. If a picture is worth a thousand words, then a physical 3-D mockup is worth 10,000 words,” says Clark. Digital manufacturing small quantities Boeing Mesa also is exploring the use of DuraForm parts to fill orders for limited-production part quantities. This solution has great potential at Boeing. Clark explains, “Our primary customer is the U.S. Army, but we sell to foreign defense forces as well. Foreign customers may want the same aircraft or vehicle that the U.S. military uses, but they may have special requirements and requests for customization or changes.” For example, customers may want to add their own avionics equipment onto the vehicle. “Therefore, we may need a different cooling system configuration and associated ducting arrangement,” says Clark. “If our customers purchase 40 or 50 aircraft a year, and Boeing has to make only three or four cooling ducts per aircraft, it doesn’t make sense to spend the time or money producing expensive tooling and performing the multiple lay up steps,” says Clark. “Here, we can produce the DuraForm parts the customer needs directly on our SLS system. Later, if there is greater demand for more parts, we can go forward with production tooling by building the tooling itself with our SLS system.” Clark adds, “The key here is the ability to customize a baseline quickly and rapidly and produce the parts per the customer’s needs without adding in a lot of tooling time or costs to the process.” Clark notes that Boeing has used DuraForm parts and prototypes for a long and growing list of applications, including creating visualization samples for suppliers; providing quotes; producing samples of existing parts that could not be produced any other way except through dissection of a complex assembly; conducting internal design review and technical review sessions with upper management; performance reviews (with customers’ sample parts provided); and producing scale models for testing. “Another benefit we are seeing is improved communication with our suppliers and team members and also among colleagues.” “This is particularly true when technical staff members are explaining a part to non-technical staff members,” says Clark. “When you get people to understand each other and communicate, it definitely helps the projects run more smoothly.” “Probably one of our greatest challenges here is getting our people to understand that our SLS system is not just a machine for making pretty models,” Clark says. “Sure you can do that, but right now we are using it for actual parts, functional parts, rapid prototyping, rapid tool development and rapid manufacturing.” Clark adds, “We want more people within the corporation to know this and to understand and see the potential applications and uses.”
12
ExOne – The New Standard for Pump Manufacturing
For years, the pump industry has relied on traditional processes to create the molds for pumps and parts, which, because of the necessary man-hours, often result in work stoppages and slowdowns. But now the industry is in the midst of an overhaul as additive manufacturing – think 3D printing for the industrial sector – led by ExOne offers the promise of a fast and cost-effective way to build the sand molds for castings. ExOne, a publicly traded leader in the additive manufacturing space, provides 3D printing machines, 3D printed products and related services to industrial customers in several segments, including pumps, automotive, aerospace, medical and energy. The ExOne process gives traditional manufacturers an opportunity to reduce costs, lower the risk of trial and error and create opportunities for design innovation. ExOne delivers functional parts – primarily in stainless steel and foundry silica sand – which can be used for both prototyping and realworld production applications. Manufacturers that use ExOne’s additive manufacturing process see significant, strategic advantages over traditional methods. The ability to expand creativity and flexibility with virtually unlimited design complexity, without the need for draft angles, enables product designs previously unattainable. Additionally, the opportunity for rapid production of castings and prototypes in turn reduces lead times significantly, and gets new products to the market faster.
Fig 1: Standard Alloys’ 3D printed core
Fig 2: Standard Alloys’ finished casting
Fig 3: Andritz Ritz CAD rendering
In the pumps industry, ExOne has dramatically improved hydraulic balancing of impeller castings and produced quick turnaround times for one-off castings. Concurrent iterations can be achieved in a matter of weeks. Additive manufacturing is also the ideal application for reverse engineering of legacy pump components and reduces the need for physical warehouse space for patterns, since data files can be stored on a hard drive. The ExOne process helps customers in the pumping industry produce castings for prototyping, replacement impellers, volute shapes and rotating parts, by printing entire mold packages or as part of a “hybrid” approach to print just the cores. By creating these types of molds and cores through an additive process, ExOne significantly reduces the time and cost required to rapidly produce castings. When compared to traditional pattern manufacturing process, delivery of mold packages to the foundry is measured in days versus months. In addition, customers have experienced parts that have shown to yield additional benefits, such as improved impeller core accuracy, superior blade registration, better hydraulic performance and ease of dynamic balance. Several leading pumps manufacturers around the world, including Flowserve and Hydro Parts Solutions Inc., have seen significant value in working with ExOne to integrate multi-piece assemblies and enhance product functionality. ExOne’s work with Standard Alloys began with a challenge to create a 57-inch impeller casting within critical lead time requirements. Using digital part materialization and 3D sand printing technology, ExOne produced Standard Alloys’ largest RCT core to date – from concept to completion in less than eight weeks. Andritz Ritz one of the largest manufacturers of Pumps also sought out ExOne’s process to fast-track complex prototype and spare part production to meet tight production schedules while driving down costs. ExOne’s successful solution was to print several cores and shells for a complete mold package as well as using a hybrid approach with traditional methods to create prototype step pump housings and impellers. It’s no secret that additive manufacturing/3D printing continues to explode, with major companies like Ford, Apple, Samsung and GE publicly announcing the integration of the technology into their production processes. In fact, a report recently published by Research and
13
ExOne – The New Standard for Pump Manufacturing
Markets claims the 3D printing/additive manufacturing industry will be worth $4 billion by 2025. To meet the unique needs of specific customers, ExOne has made significant investments in its material qualification research and testing with the opening of a new material characterization and testing facility in St. Clairsville, Ohio in April 2013. ExOne has firmly positioned itself as the leader in the industrial market, and over the past year has made significant strides to further solidify that position. The company continues to develop machines that increase print speeds and reduce lead time in an effort to continually lower the cost curve for industrial customers. ExOne’s S-Max 3Dsand printer creates complex sand casting cores and molds directly from CAD data, in about 24 – 30 hours - without hard tooling, which significantly reduces lead time, increases design freedom, and improves the entire casting process chain.
14
Customer Case Study Medical - EOS: US Regulator FDA Awards First Approval for Customised 3DPrinted Polymeric Cranial Implants
Facts Short Profile: Since 2000, Oxford Performance Materials (OPM) has built its business solely on PEKK material. Headquartered in South Windsor, Connecticut (USA) the company has produced a number of bony void replacements as well as developing a variety of biomedical and industrial materials The Challenge: Production and FDA approval of patient-specific polymeric cranial implants based on CT or MRI scans Solution: Speedy manufacturing of individual cranial implants made of PEKK on an EOSINT P 800 by EOS. Results: • Customised: Fewer side effects due to patient specific manufacturing • Osteoconductive: bone cells grow in to PEKK implant and increase its long term stability • Economic: better treatment outcome at reduced costs • Integrated: self-contained production and supply chain
Oxford Performance Materials (OPM) made medical history when they received the first Food and Drug Administration (FDA) 510(k) clearance for their polymer additive manufactured OsteoFab™ Patient Specific Cranial Device (OPSCD). The customizable implant made of the plastic material PEKK is designed to restore voids in the skull caused by trauma or disease. Manufactured in a matter of hours with Additive Manufacturing (AM) technology by EOS, the implant saw its first use just a few days later when the device was successfully implanted in a patient missing a significant portion of cranial bone. Challenge However, PEKK has a high melting point relative to other polymers. And the EOSINT P 800 is the only industrial 3D-printing system in the world which can process the high-temperature polymer via additive layer manufacturing. But it wasn’t just a matter of buying the system one day and making a product the next. Scott DeFelice, President and CEO of OPM, explains the arduous path to commercialization of patient specific implants: “For starters, you need an ISO 13485 compliant facility that has design controls and an appropriate clean manufacturing environment. Furthermore you need to be compliant with CFR 21 cGMP (current Good Manufacturing Practices). Add to that a completely validated process and ISO 10993 biocompatibility data on your finished parts. In short, you need a lot of stuff in your bucket.” Solution The high-temperature plastic has a number of mechanical and thermal qualities that make it highly suitable for cranial reconstruction. It has a density and stiffness similar to bone, it is lighter than traditional implant material such as titanium and stainless steel, it hardly reacts with other substances and it is radiolucent so as not to interfere with diagnostic imaging equipment.
Perhaps its most exciting attribute is bone’s affinity to the material. “Based on research studies, it is osteoconductive,” says DeFelice. In some implants, the surrounding bone pulls away from the site over time and you have to rely on screws to hold everything in place forever. “Since PEKK has shown osteoconductive properties, long-term implant stability may be easier to achieve than with other materials. And given the correct implant design, results are getting even better. You can obtain a multiplying effect by increasing surface area and achieving intimate contact between the implant and native tissues,” explains DeFelice.
Patient specific medical care: this model of a skull demonstrates how an implant is customized to fit the cranial opening (courtesy of Fred Smith Associates).
Self-contained production and supply chain: the patient specific cranial implants made of high-temperature polymer PEKK can be delivered in less than two weeks (courtesy of Fred Smith Associates).
production processes often have substantial limitations in terms of tolerance and geometry, such as draft angles in moulding and corner design for CNC tooling,” explains DeFelice. In addition, AM doesn’t require the upfront costs of tooling and moulding and doesn’t generate the level of waste that subtractive cutting and milling do.
Patient specific medical care is becoming increasingly important. So OPM also faces the challenge of producing lowvolume parts with complex shapes that are adapted to a person’s anatomy. That’s why Additive Manufacturing technology by EOS was a logical choice. “From a practical perspective, traditional
15
Customer Case Study Medical - EOS: US Regulator FDA Awards First Approval for Customised 3DPrinted Polymeric Cranial Implants
After an intense navigation of regulatory hurdles, it was possible to start creating of a patient specific cranial implant. DeFelice sets the scene: “Based on a CT or MRI scan of the injured area, a slice file is generated which divides the data into cross-sectional layers. After review by a physician, it is sent to OPM. Using 3D design software, a team of design engineers create an implant based on the file to precisely fit that patient’s anatomy. Once you have that, you get approval of the implant design from the surgeon, and then print the part.”
When that layer is done, the build platform lowers, the system distributes a new powder layer on top of the old one, and the laser melts the next cross section. The process is repeated until the entire implant is built. Once the implant has been removed from the powder cake, it’s ready for quality inspection. “In addition to mechanical and analytical testing, we use a structured light scanner run 100 percent line-of-sight metrology inspection to certify the dimensional accuracy of the final product,” DeFelice says. The implant is then shipped to the hospital. The total process takes less than two weeks from the time the data is received to the time the implant is shipped.
The manufacturing is entirely automatic. The EOSINT P 800 lays down a thin layer of powder on its build platform. Guided by the lowest slice of the implant design file, a hightemperature laser melts a cross section of the implant design. Results This self-contained production and supply chain are good news for the patient. The right implant shortens the duration of surgery, the patient recovers more quickly and the risk of infection is reduced.
“EOS technology is capable of producing practically any shape geometry to match the precise needs of an individual patient. It lifts manufacturability restrictions. There is no region of the human skeletal anatomy that won’t be touched by this technology. When the patient is on the operating table and the part shows up and doesn’t fit, you’re putting someone’s life at risk. The first implant case was very large, measuring nearly six inches across, and large areas of critical tissue had to be exposed during surgery. So it was critical that the implant should fit perfectly. Every second is critical in that situation,” explains Scott DeFelice. Medical engineering has very high standards: it demands the right material, the right process, the right quality system, and the right metrology. Together these elements are life-savers.
Hospitals benefit and typical operating room rates run upwards of $60 per minute, so pressure is high to manage the costs of patient care. Scott DeFelice adds: “The new medical paradigm is about improving outcomes while reducing costs. That’s what AM technology helps us accomplish.” After having successfully created and obtained FDA approval for their cranial implant, OPM is making plans to explore other implant opportunities throughout the body. DeFelice states:
An OPM technician sets up a batch of implants for production. The EOSINT P 800 system is capable of running multiple, varying designs in a single build
Shown is a 3D digital model of a cranial Shown is a 3D digital model of a cranial implant (Courtesy Fred Smith Associates).
The completed part is cleaned of any residue powder
Using patient-specific 3D digital data, the cranial implant is additively manufactured with an EOSINT P 800 high-temperature plastic laser-sintering system (Courtesy Fred Smith Associates).
Shown is the OPM production team in front of the EOSINT P 800 (Courtesy Fred Smith Associates).
16
Clutch case - 3D printing of sand moulds: Voxeljet
Project description: The manufacture of sand moulds for cast parts with such thin layers (0.15 mm) presents a great challenge for the construction of sand moulds. Even experts are surprised by the fact that this process can be completed in a fully automated manner and without the use of tools on the basis of 3D CAD data. With conventional methods, model and mould builders would require several weeks to complete this process. The aluminium clutch case is used for the prototype of a vehicle clutch.
Purpose: Produce clutch case in less than 5 days Challenge: Thin castings without tools Solution: Easy mould assembly with 3D printing and 3 mould parts with series-identical properties
CAD-file of the Clutch
Housing Sand mould
Casting in G-Al Si8Cu3
Clutch housing with series-identical properties
Technical data: Sand Moulds
Castings
Total size (mm)
697x523x353
Total size (mm)
520x205x390
Weight (kg)
145
Weight (kg)
48.3
3
Material
AISI8CU3
Material
GS-14
Lead time (weeks)
3
Layer thickness (mm)
0.3
Lead time (days)
5
Build time(hours)
10
Individual parts
Sandcasting: fast, patternless, close-to production voxeljet produces moulds for casting from dataset. Through implementing the Generis Sand Process the user benefits from crucial time and cost savings. Based on 3D CAD data the moulds are made fully automatically without tools using the layer building method in the required mould material. The laborious and costly route to the otherwise necessary mould set-up is dispensed with. Our ability to produce moulds with dimensions of 4 x 2 x 1 meters is unique worldwide.
17
Efesto LLC, USA - The World’s Largest Argon Chamber Industrially Hardened LMD System
18
Efesto LLC, USA - The World’s Largest Argon Chamber Industrially Hardened LMD System
19
Press Release: EOS M 290 Metal System
RAPID.TECH 2014: EOS launches the EOS M 290 metal system to succeed the established EOSINT M 280 system
Erfurt, 14 May 2014 – EOS, the technology and market leader in design-driven, integrated e-manufacturing solutions in the field of Additive Manufacturing (AM), will be exhibiting its products at its stand at this year‘s Rapid.Tech, on 14-15 May in Erfurt. At stand 2-301 in Hall 2, the company will be displaying its brand-new EOS M 290 system, the successor to the established and market-leading EOSINT M 280, designed for the tool-free production of high-quality serial components, spare parts and prototypes. With a build volume of 250 mm x 250 mm x 325 mm, the EOS M 290 permits flexible and economic manufacturing of metal components. The system is available now to purchase. EOS M 290 Metal Additive Manufacturing system (source: EOS)
Dr. Adrian Keppler, CMO at EOS stresses, “EOS has incorporated proven elements from the M 280 system generation in the new EOS M 290, but at the same time, the EOS M 290 also allows us to set new standards in Additive Manufacturing while expanding our product portfolio for metal applications and extending our innovation leadership in terms of quality management and monitoring. This new system is designed to serve the requirements of our serial-production customers. At the same time, we have also created new optimisation potential in terms of build quality for customers from the prototyping space.” Despite all the innovations that have been incorporated in the EOS M 290, its central processing elements have been retained: process chamber, gas stream, process parameters, etc. This ensures constant process behaviour and in turn consistent component quality beyond the EOSINT M 280 and EOS M 290. Extensive quality management, expanded monitoring functions, EOSTATE The new EOS M 290 offers extensive monitoring functions both for the system itself and for monitoring the build process. This adds even more extensive quality assurance to the field of Additive Manufacturing. In particular, it makes the system attractive for industrial applications in the aerospace industry as well for medical applications. With the aid of EOSTATE PowderBed, a camera built into the process chamber monitors the powder bed, following powder deposition and exposure, by means of still images. EOSTATE Base ensures the consistent monitoring of a range of parameters, including the position of the Z axis or scanner, laser power, air humidity, temperature and pressure. Finally, EOSTATE Laser Monitoring measures the laser power throughout the entire build period. Flexible components and extensive accessories The system is equipped with a 400 Watt laser, which is characterised by its high radiation quality and stability of performance. The EOS M 290 can be operated under an inert (nitrogen) atmosphere or under argon, which permits processing of a great breadth of materials. These include light alloys, stainless and tool-grade steels, and superalloys. The EOS parameter sets ensure that parts can be manufactured with standardised property profiles, resulting in a broad spectrum of applications. As with the previous model, EOS also supplies its EOS M 290 customers with the EOS ParameterEditor, to allow them to modify a range of exposure parameters for themselves. The tool enables customers to develop their own parameters for specific applications on the basis of the EOS parameter sets. These include laser power and exposure speed or strategy. A new version of the Parameter Editor is currently under development, which will also allow modification of layer thickness, inert gas stream, build platform temperature, and skip layers. High level of user friendliness, optimised process gas management, intuitive software The EOS M 290 has been rendered even more user friendly thanks to the new EOSYSTEM machine software, which allows intuitive and task-oriented operation of the system via a graphic user interface, which was developed especially for production environments. In addition, an operator assistant is included which guides the user through the program. The new EOSPRINT Desktop Software allows jobs to be prepared and computed directly at the workplace, separately from the build process. The job file can then be transferred through the network to the system, which can then concentrate fully on building the part. Thanks to the availability of offline job preparation, complex parts with large job files can be processed quickly. This in turn improves the flexibility of the application development process. Process gas management has also been optimised. The EOS M 290 is fitted with an air circulation filter which itself is equipped with an automatic self-cleaning function. This considerably increases the filters operating life, with the result that they require less frequent replacement. It also reduces filter costs. The solution portfolio for the EOS M 290 also includes data preparation software, component handling devices, and extensive services. www.eos.info.
20
Press Release: SLM Solutions: New order intake in H1 2014 underpins positive expectations
Luebeck, July 2, 2014 – SLM Solutions Group AG, a leading provider of metal-based additive manufacturing technology (also referred to as “3D printing”), sees the positive trend in new order intake as of the end of the first half of the year as confirmation of its optimistic expectation for the current 2014 financial year. The uptrend in SLM Solutions' order book position continued during the first six months of 2014, as expected: New order intake was boosted to a total of 19 machines – almost double last year's 10 machines. These orders include two orders for the SLM 500HL flagship product, currently the most productive laser melting system on the market. This shift towards high-value systems boosts the total value of the machines that have been ordered, the most important driver of corporate sales revenues. Uwe Bögershausen, CFO of SLM Solutions Group AG, expressed his satisfaction: "Since the start of the year, we have observed a positive trend in our new order intake, and consequently regard this as a confirmation of our expectation for the full year. Internationally operating industrial companies are currently making a transition to deploying laser melting systems also for the direct component manufacturing. This is affecting components as varied as hip implants and dental prostheses, complex tooling applications, and aerospace components. The attractive market segment for metal-based 3D printing is about to pass the inflection point, and is now experiencing a growth boom from which SLM Solutions, in particular, will benefit as one of the technology leaders." About the company: SLM Solutions Group AG, headquartered in Luebeck, Germany, is a leading provider of metal-based additive manufacturing technology (also commonly referred to as “3D printing”). SLM Solutions focuses on the development, assembly and sales of machines and integrated system solutions in the field of selective laser melting, vacuum and metal casting. SLM Solutions currently employs over 80 people in Germany and the USA. The products are used worldwide by customers in particular from the aerospace, energy, healthcare and automotive industries. SLM Solutions stands for technologically advanced, innovative and highly efficient integrated system solutions. Contact: Mark Appoh, cometis AG Unter den Eichen 7, 65195 Wiesbaden Telephone: +49 (611) 205855-21 Email: appoh@cometis.de
21
Press Release: Efesto and RPM Innovation announce global strategic partnership
EFESTO AND RPM INNOVATIONS ANNOUNCE GLOBAL STRATEGIC PARTNERSHIP IN METAL 3D PRINTING, LAUNCH PREMIUM SUITE OF METAL 3D PRINTING EQUIPMENT, REPAIR & FREE-FORM FABRICATION SERVICES Superior Township, MI – June 8, 2014. EFESTO and RPM Innovations, both rapidly growing and leading enterprises specializing in Metal 3D Printing technology and applications, today announced a long term global strategic partnership to offer a comprehensive range of professional grade, industrially hardened, and production proven Laser Metal Deposition (LMD) equipment and services for Metal Additive Manufacturing. (LMD is also known as “Powder Fed”, “Blown Powder”, “Directed Energy Deposition”, “Laser Deposition Technology”...). This partnership brings immediate benefit to potential and existing users of Metal 3D Printing by making available a comprehensive line of premium, robust and production proven LMD machines and the highest quality contract services, supported by more than 50,000 hours of expertise in advanced LMD applications. Ashok Varma, CEO of EFESTO, said: “We met hundreds of potential and existing industrial users, and identified a large global opportunity to satisfy a glaring unmet need - the significant gap between demand and availability of truly industrial grade LMD systems and the practical experience required to ensure good results and economic viability. Most currently installed systems are in laboratories or light industrial applications, many idle or under-utilized, with few suppliers and users having the practical experience to optimally utilize this technology and reduce “time to value”. Metal 3D Printing grew 75% in 2013 over 2012, twice the growth of overall 3D Printing. We believe this trend will accelerate, further expanding the gap between supply and demand. Together with RPMI, we bring a holistic set of solutions, experience, and capability to the global industrial marketplace. Our primary mission is to delight our customers, and to make a profound, enduring and positive impact on this emerging industry.” The companies together will offer the following solutions and services: • Metal 3D Printing Equipment: Premium, Industrially hardened, production proven, Argon chamber, and standard laser build envelope from (XYZ) 600mm x 600mm x 600mm to 1500mm x 1500mm x 2100mm. • Metal 3D Printing Contract Services: Free form fabrication, repair and reclamation, hybrid manufacturing, small lot production, R&D, process validation pilots, “design for Additive” engineering support. • Metal 3D Printing Service Bureaus: Turnkey, Joint Venture, and Build Operate Transfer (BOT) – business case, design engineering, equipment, process development, training, support, management. • Custom Engineering: Larger systems, work piece handling, inter-changeable laser heads for surface treatment, custom nozzles, custom “process recipes”, advanced process monitoring and control … • Global Turnkey Support: Delivery, Installation, Commissioning, Operator/Expert Training, Maintenance Contracts, Extended Warranties, Tele-Service, Rapid Response, Certified Powders/Consumables. Robert Mudge, CEO of RPM Innovations and RPM & Associates, said: “We originally purchased our first LMD machine from an outside manufacturer in 2004. By 2007 we realized this system was not large enough or robust enough for our growing operations. We began investigating existing laser system integrators that could build us a larger premium system so we could meet our customer needs. We were not able to “find” a suitable solution so we decided to design and built our own laser deposition system (RPMI557), which we commissioned in 2009. To date, we have added a total of three additional RPMI 557 systems as we continue to serve our customers in the defense, aerospace, energy, mining and heavy industries. Typically, we deposit more than 15,000 pounds of Titanium, Stainless Steel, Cobalt and Nickel Based Super Alloys annually, and are experiencing exceptional growth in our core LMD services business.” EFESTO and RPMI have partnered to commercialize RPMI’s 557 system for third party use, as well as a full range of smaller systems to address less demanding requirements. All systems retain the core design principles of the industrially hardened 557 platform. The two companies will continue to serve their existing respective markets and customers, and jointly provide application expertise and customer support worldwide. Collectively, this partnership creates the leading specialized entity for revenues in metal 3D Printing with Laser Metal Deposition, deploying more than 40 dedicated engineering, applications and business development specialists operating in the Americas, Europe and Asia, and a rapidly growing sales pipeline already in excess of $ 50 million.
22
Press Release: Efesto and RPM Innovation announce global strategic partnership
Robert Mudge added: “After several years of in-house development and thousands of hours of operation, we recently decided to offer our systems for sale into the 3D printing market. Teaming with EFESTO and their global vision and sales network, we expect our synergy will create exceptional value and opportunity for the 3D printing industry. RPMI will continue to service its existing customer base in North America and parts of Europe while EFESTO will service other selected global markets. We are very pleased to be teamed with EFESTO and anticipate exponential mutual growth as additive manufacturing matures.” Ashok Varma added: “Partnering with RPMI was a straightforward and logical decision. RPMI has seen increasing customer requests to purchase RPMI built LMD systems, and EFESTO required a comprehensive line of industrial grade and production proven systems to satisfy its customer requirements. RPMI’s historical focus has primarily been in North America while EFESTO operates globally. RPMI perfected the service bureau quality and business model, and EFESTO has several requirements to establish 3D Printing service bureaus across the globe. This is going to be an intensely exciting time for both companies.” EFESTO LLC is a rapidly growing global enterprise committed to engineering an industrial revolution in the field of metal 3D Printing.EFESTO has a hybrid business model, offering equipment, services, and establishing fully equipped service bureaus in strategic locations around the world. EFESTO’s vision and mission is to exponentially increase the awareness and acceptance of metal 3D Printing. Target markets include aerospace, defense, energy, marine, tooling/die & mold, mining and construction. Focus applications include repair, free-form fabrication, hybrid manufacturing and advanced R&D. EFESTO teams operate in the Americas, East and West Europe, and Asia. RPM Innovations, Inc. is the leading Laser Metal Deposition services provider in North America and possibly in the world, specializing infreeform fabrication, hybrid manufacturing and repair applications for the aerospace, defense, oil & gas, power, mining and heavy industries. RPMI has successfully manufactured some of the industry’s largest metal 3D Printed components using Titanium and Nickel Super Alloys in their own RPMI 557 laser systems. RPMI has manufactured its premium industrial grade RPMI 557 laser systems for inhouse use since 2009 and currently operates a total of 4 machines in continuous production. RPMI is now offering four sizes (222, 434, 535, 557) of their systems for sale to third party users. RPMI was the recipient of the Gold Boeing Performance Excellence Award in 2010 and Silver Boeing Performance Excellence Award in 2013.
EFESTO Media Contact: Albert Sellas albert.sellas@efesto.us www.efesto.us RPMI Media Contact: Nick Wald nick.wald@RPM-innovations.com www.RPM-innovations.com
23
24
25
26
27