The
AM Magazine
ISSN 0974-7133 ISSUE 29 NOVEMBER 2015
The Magazine for 3D Printing and Additive Manufacturing Technologies
Sch端le foundry partners with ExOne to deliver fast and ?exible solutions for the auto industry and beyond
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Professor Deon de Beer Vaal University of Technology, South Africa Dr. Wan Abdul Rahman Standard and Industrial Research Institute of Malaysia (SIRIM), Malaysia Professor Khalid Abdel Ghany Director of CAD/CAE and Rapid Prototyping and Manufacturing Lab. Central Metallurgical Research and Development Institute (CMRDI), Cairo, Egypt
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French Rapid Prototyping Association
Central Metallurgical Research & Development Institute
ADVERTISING/OPERATIONS Jyothish Kumar RAPITECH Solutions Inc. jyothish@rapitech.co.in Mob: +91 9901033712 Standard and Industrial Research Institute of Malaysia
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Professor Alain Bernard IRCCyN, Ecole Centrale de Nantes, France Associate Professor Chua Chee Kai Nanyang Technological University, Singapore
3D Systems, USA Voxeljet Technology Gmbh, Gmbh
ExOne, GmbH
Dr Gurunathan Saravana Kumar Department of Engineering Design, Indian Institute of Technology Madras Professor David W. Rosen Rapid Prototyping and Manufacturing Institute (RPMI) Georgia Institute of Technology, Atlanta USA
Nikon Metrology
Optomec Inc. USA
Arcam AB, Sweden
Professor Bopaya Bidanda University of Pittsburg, USA Associate Professor Yonghua Chen The University of Hong Kong, Hong Kong
EOS Gmbh, Germany
Schultheiss Gmbh, Germany
Layerwise, Belgium
Professor Manoj Kumar Tiwari Indian Institute of Technology, Kharagpur Professor Grier Lin International Leadership Institute, South Australia
EFESTO LLC, USA
FARO, USA
Stratasys Inc, USA
Professor David L. Bourall University of Texas at Austin, USA Dr Allan E. W. Rennie Lancaster Product Development Unit, Lancaster University
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The AM Magazine
AM - 14/15 Vol.05 Issue 29
CONTENTS
Latest Updates
Regulars
15 Press Release - EOS GmbH Marks Its 25th Anniversary with a move into a new new technology and Customer Centre at its Headquarters in Krailling
04 Editorial
16 Press Release - ZERO – G PRINTER - A Historic Revolution in Space Access -– The Sky is no longer the limit – “The Machine Shop for Space”
07 Defence & Space Case study – Aerospace Company Airbus Defence and Space Uses Additive Manufacturing for the Production of Satellite Parts
17 Press Release - Reconstructing cylinder heads for Porsche legends
Upcoming event 3D Printing and Additive Manufacturing Applications Symposium, Bangalore, INDIA
05 Special Article - The metal foundry uses ExOne 3D Printing processess
10 Unmanned Vehicle System – Advanced Aerials removes the mystery from Unmanned Vehicle System development with an assist from Quickparts® 12 Biomedical Applications of 3D Printing – Saving a newborn with the support of 3D Printing 14 3D Printing of Sand Moulds
AM Magazine online www.ammagazine.in http://issuu.com/rpdmag
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Editorial
3D Sand Printing – A Milestone for the Pump Industry Pumps being the basic equipment for every sphere of the national economy Pumps are the vital elements in an enormous range of fluid handling applications & range from small household pumps to immense units utilized in the water, chemical and energy industries. Pump performance requirements and duties vary considerably in terms of material of construction, wide range of temperature, pressure, viscosity, density etc. For many years pump industry have been using traditional manufacturing methods for fulfilling the demands of market and in th is large demand from various sectors it is not easy to cater all the industry fastly and with consistent improving quality. In such a high demanding and competitive environment it is required to move to new advanced fast manufacturing methods and ‘3D Printing is one of them’. 3D printing is an ideal tool for volute shapes like impeller casings etc. For the pump industry, ExO ne offers digital part materialization for patternless, digital production of sand molds and cores. Regardless of size or complexity, ExOne provides the fastest and most cost-effective way to produce cores for prototyping, replacements parts, and low volume production using foundry materials. Various other additional benefits of 3D printing technology are impeller Core Accuracy up to +/- 0.3mm, Superior Blade Registration, Better Hydraulic Performance, Ease of Dynamic Balance etc. All these features of this 3D printing technology make it a versatile tool for Pump Industry. This will enhance the dependability of OEM’s on suppliers for better quality and fast deliveries. In coming future this technology is going to lead the whole pumping industry and will prov e itself a milestone. - GlobalAxis(PartnertoExOneGmbH) NewDelhi,India
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SPECIAL ARTICLE
“Schüle foundry partners with ExOne to deliver fast and flexible solutions” “The main advantage is definitely the time savings,” says Ronald Spranger, Head of Sales and Project at Schüle GmbH.
The metal foundry uses the 3D Printing process The German based foundry company cooperates with threedimensional (“3D”) printing specialist ExOne to supply automotive sector customers as well as other business areas with success. Automotive manufacturers are faced with the challenge to produce parts more efficiently and at a lower cost. Meanwhile, the demand for more complex parts in increasing and development cycles are decreasing. Automotive manufacturers must keep an eye on every production step to keep up with this ever-changing industry. The advantages of the 3D printing process are apparent to automotive manufacturers as they assess these changes. ExOne, based in Gersthofen, specializes in the additive 3D printing technique, which applies consecutive thin layers of sand to a working platform. The sand is bonded by inorganic or chemical binders and results in casting molds made without time-consuming and cost-intensive tool production directly from a CAD-file. This method is especially suitable for two application fields: to produce new products via rapid prototyping or low volume production and to avoid storage whenever possible. Therefore the ExOne™ technology provides an excellent complement to the portfolio of Schüle.
intensive parts. Amongst them are ambitious parts, such as gearboxes or engine blocks, for more than 200 customers in different locations. About half of the parts being produced by the Schüle foundry are prototypes. The foundry employs 80 people and uses 500 tons of aluminum per year. As a mid-sized company, Schüle can react flexibly to the needs of the customers. Their company offers, depending on the customer requirements, a fully automatic core package molding line down to a furan hand molding line with optimal results. They also provide pre- and post-processing steps such as modeling and casting construction, in addition to comprehensive quality testing. “Our customers have different requirements," says Schüle. “When it comes to serial production, the delivery reliability is most important. What counts in this field, are feasibility and short lead time solutions. Prototypes should still have all the relevant characteristics of a production part.”
The aluminum sand casting foundry specializes in complex, core-
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SPECIAL ARTICLE
3D printing suitable for rapid prototyping and small scale production Designers are completely free to develop an experimental design without any concerns related to casting production. In fact, the more complex design of the core, the better it is to 3D print the part. For example, a highly complex casting such as a twelve bore cylinder block, where the water jack core often needs to be produced in various sections, can be 3D printed as one complete part. The cooperation with ExOne started just three years ago when the company was looking for a foundry to cast samples with their sand cores. Since then, Schüle orders more and more cores from ExOne, 30 to 50 pieces per month currently. Most of them are special molds for complicated and core-intensive casting parts like engine blocks, gearboxes, compressor housings and heat exchangers. They are mainly used in pilot tests in the automotive branch and during the initial prototype assemblies in machine and industrial plant installations. In this case, Schüle uses ExOne’s so called “Production Service Center“(PSC). The PSC is part of their core business in addition to the manufacturing of 3D sand printers. ExOne has offered the production of parts since the year 2000 and maintains several PSCs worldwide. ExOne is growing their PSCs to reduce delivery time and be closer to the customers.
Rainer Höchsmann is General Manager of ExOne Europa and Chief Development Officer of ExOne The unprinted sand, which contains an activator, can be recycled for further use. In general, Mr.Schüle has come to the conclusion that, “The cooperation is very good, thanks to the knowledge of ExOne, who are world leaders in their field.” Rainer Höchsmann has developed his expertise since 1999, when he co-founded the company Generis, the predecessor of ExOne. He is now the General Manager of ExOne Europe and the Chief Development Officer. Generis developed world’s first 3D printer for sand molds that has been in use since 2001 in the automotive industry. To date, ExOne has installed more than 100 printers and has become the market leader of 3D sand printing. It offers a large variety of materials which meet the requirements of various casting materials, such as aluminum, magnesium, iron and steel. The company developed furan, phenolic and silicate binder systems which can be used in conjunction with silica or ceramic sand. In this year’s exhibition in Hannover, the Europe premiere of the MFLEX 3D metal printer took place. In addition to the production of the 3D printers, ExOne also offers print services in its product portfolio. Schüle has considered buying its own printer. 3D printing is mainly utilized for prototyping, but the technique has been growing in use for serial production too. One attractive application is the use of conventional methods for the production of the relatively simple mold halves and 3D printing of complex cores that would be expensive to produce by conventional techniques. “We have already gained positive experiences,” confirms Schüle. “And the printing of molds and parts will establish itself more and more and become an inherent part of the foundry business.” One thing that will not change: The know-how and experience of the casting experts will still be required even though the design of the molds/cores will play a key role in future production.
Schüle can react quick and flexible to customer inquiries The integration of 3D printing into Schüle’s established casting processes was simple and without problems. “The cores and/or mold packages which are delivered by ExOne are very similar to conventionally produced parts” said Mr Spranger, “This means: The workflow is comparable and extensive changes were not necessary.” It is also valid for the materials used.
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CUSTOMER CASE STUDY DEFENCE & SPACE
Facts Challenge Cost-effective production of optimized retaining brackets for the connection of components in telecommunication satellites . Solution Faster production of thermally highly stressed components by using Additive Manufacturing technology for metal parts offered by EOS. Results •
• • •
Robust: temperature resist- ance meets highdemand of permanent space missions Economic: production costs reduced by more than 20% Light: weight reduction of the retaining brackets is about 300 g Paving the way: lighthouse project as the pioneering role for other applications in space
Short profile Airbus Defence and Space is a division of Airbus Group formed by combining the business activities of Cassidian, Astrium and Airbus Military. The new division is Europe’s number one defence and space enterprise, the second largest space business worldwide. Address Airbus Defence and Space Avda. Aragón
Telecommunicationsatellite:thethreeadditive manufacturedbracketseasilywithstandatemperature rangeof330°Candmeetthehighdemandofpermanent spacemissions(Source:AirbusDefenceandSpace).
Advanced Manufacturing Process by EOS Optimizes Satellite Technology
Aerospace Company Airbus Defence and Space Uses Additive Manufacturing for the Production of Satellite Parts The literal translation of the word satellite (companion) does not come close to explaining how complex these technical devices are and what they do for our daily lives. Their tasks range from weather forecast to message transport and navigation information. The Airbus Defence and Space division is one of the world‘s leading suppliers of satellite and space transport technology. Its Spanish subsidiary is part of the satellite business and the largest aerospace company in its home market.
The portfolio ranges from satellite systems to components for the International Space Station ISS. A competence centre for composite materials is also located at the headquarters in Madrid – because innovative materials and production methods play an important role in the a erospace industry. The requirements for the devices are particularly high because of the tremendous temperature differences and external forces involved. To achieve the best results in component manufacturing, Airbus Defence and Space relies, among other t hings, on Additive Manufacturing technology by the German company EOS.
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CUSTOMER CASE STUDY DEFENCE & SPACE
Challenge
Solution
The current generation of satel- lites includes specific brackets that serve as a link between the body of the satellite and the reflectors and feeder facilities mounted at its upper end. The engineers at Airbus Defence and Space faced two key challenges with regards to the construction of these retaining brackets: on the one hand, the brackets must
The choice fell to the Additive Manufacturing technology for metal parts offered by EOS. This meant that titanium was still usa- ble as a tried and tested material. It also allowed the design of the components to be adapted easily. As Otilia Castro Matías, who is responsible for the area of antennae at Airbus Defence and Space, explains: ”The solution now found by us has two advanta- ges. For once we were able to optimize production itself. In addition, we have improved the design, so the entire workpiece can be manufactured in a single step. Hewn from a single block so to speak, even though technically speaking it is the opposite of this traditional technique.“
fix the securely to the body. On the other hand, however, the task of the brackets is to mitigate the extreme temperature fluctuations in space. The brackets are very important as a layer of insulation: the temperature ranges from –180 to +150 °C, so the stress on the material is extremely high. Very few materials are able to meet these requirements. As so often in the aviation and aero- space industry, titanium turned out to be the appropriate cho ice. In addition to its wellknown advantages with regards to weight and thermal conductivity, it offers an acceptable density. After all, every kilogram to be carried into space costs many thousand dollars; the exact amount depends on factors such as the carrier system and the orbit to be reached. However, sixfigure sums and higher are not uncommon.
After the design was established, the well established process followed: the engineers loaded the 3D construction plans from the CAD software into the pro- duction machine – an EOSINT M 280 – and started the manu- facturing process: a laser beam precisely melts and hardens the deposited metal powder layer by layer, so when the precision- made workpiece is complete, no excess material remains except for re-useable raw material. Results
The brackets manufactured in the conventional way and especially their connection with the carbon components of the satellite – a function subject to high thermal stress – did not meet the expecta- tions of Airbus Defence and Space. In addition, subsequent installati- on on the satellite component was very time-consuming so costs needed to be reduced. The engineers therefore began looking for alternatives. Special attention was paid to the fact that the design of future components could be optimized accordingly.
The new devices meet all expect - ations of the experts involved. Most important of all is the improved temperature resistance of the entire structure, which now can easily and permanently withstand a margin of 330 °C under a force of 20 kN. In addition to this, the Spanish aerospace experts were able to reduce production time of the brackets during assembly of feed and sub reflector units by five days. Production time of the three brackets required for each satellite is now less than a month. ”These improvements signifi- cantly reduce thermally induced failure during the qualification test campaign. The cost of space activities is relatively high, so it is even more important to protect any hardware from possible failures,“ adds Castro Matías. ”The Additive Manufacturing method brought measurable benefits to critical aspects of the project, without requiring cuts to be made elsewhere. No compromises - this is something engineers like to hear, but don’t get to hear very often.“ In addition to the technical advantages, targeted cost reductions were achieved: savings in production alone amount to more than 20%. What is more, the engineers success - fully put the part on a diet: the weight advantage is about 300 g, which means nearly one kilo per satellite. Incidentally, European Space Agency (ESA) supported this program. Its successful completion it allows further use of this efficient production technology in the aerospace field.
Therobusttitaniumbracketsweremanufacturedusing anEOSINTM280.Theyeasilyandpermanently withstandthehightemperaturesandexternalforcesin space(source:AirbusDefenceandSpace).
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CUSTOMER CASE STUDY DEFENCE & SPACE
”The use of titanium as the material for the retaining brackets of our satellites has proven highly effective. The main weakness, however, was the connection of the brackets with the carbon panel of feed and reflector assembly because here the thermal stress was negative factor. Thanks to Additive Manu- facturing, we were able to redesign the bracket and eliminate this vulnerability. There were other benefits, too, such as shorter, more cost-effective and more lightweight production.“
- Otilia Castro Matías, COC Antennae at Airbus Defence and Space
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UNMANNED VEHICLE SYSTEM
Advanced Aerials removes the mystery from Unmanned Vehicle System development with an assist from
In an industry typically shut off by red “Top Secret” stamps and closed-door meetings, Advanced Aerials is doing things a little differently. They’ve put a welcome mat on their door in an effort to not only supply Unmanned Vehicle Systems (UVS) but to perfect their designs and innovate through open-source collaboration. Think of Advanced Aerials’ work as the launching point for creating affordable UVS designs that fulfill the exact requirements of users from military intelligence units to first responders SLSpartsfortheMSEV
“There’s a lot of forcing of designs that aren’t fully baked. We don’t want to force technology because it inevitably falls short,” says Advanced Aerials founder Bert Wagner. “We’re crowd sourcing UVS design by sending prototypes to end users so they can collaborate and build something that fits a need perfectly. We want to solve problems, not sell products.” Wagner, a former professional photographer, taught himself CAD and vehicle design in order to make drones for aerial photos. Over the years, that side project morphed into Advanced Aerials. For a homegrown business like this, it’s sometimes difficult to fulfill manufacturing requirements: tooling and injection molding are far too expensive and owning a 3D printer would be cost prohibitive at this point. At the same time, the advantages of 3D printing fit perfectly with Wagner’s needs. “I had to focus on design intent and less on how to provide enough clearance for a given tool. I didn’t want to worry about a machinist.”
Above,BertWagnerassemblestheMSEVBelow,MSEVparts madewithDuraform®EXBlack Take the Miniature Surveillance Expendable Vehicle (MSEV), for instance, a UAV made largely of SLS components from Quickparts and being developed for one of Advanced Aerials’ DoD customers. MSEV, a deployable, four -rotor vehicle, will eventually aid in situational awareness. Other Advanced Aerials vehicles will support short-range, short- duration counter IED operations. The company is also supporting software and vehicles that would allow users
What Wagner needed was his own 3 D printing manufacturing unit, a way to produce parts quickly and iterate design without equipment and labor overhead. That’s where Quickparts—the on-demand printing service by 3D Systems—came in. Ten years later, Wagner still uses Quickparts, which produces Advanced Aerials’ ready-touse vehicle components using 3D Systems’ Selective Laser Sintering (SLS®) technology.
to operate UVSs in environments where external guidance signals, e.g., GPS or RF, are weak, unavailable or actively jammed. These could drastically improve the safety of soldiers and first responders as they inspect buildings or other dangerous enclosed areas. And that’s a huge goal for Advanced Aerials —improving safety and saving lives.
“We use Quickparts for anywhere between $3,000 and $10,000 worth of parts per year,” says Wagner. “The beauty is that if I’m in a rush, I can get parts in a couple of days. You can’t beat that.”
As Wagner puts it, “We want our vehicles to go from A to B in some pretty brutal environments.” But there’s so much more to it; they’re democratizing UVS development, and using the speed and affordability of Quickparts SLS manufacturing to do it.
Bear in mind, these are not concept model parts or casting patterns, as is sometimes the case with robotics developers. Instead, they are characteristically tough SLS parts, made in Duraform® and Duraform Flex materials, that Advanced Aerials installs onto their UVSs for direct field use. “Our parts have held up under crashes. We’re real happy with that,” says Wagner.
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UNMANNED VEHICLE SYSTEM
UVSs don’t have to cost so much or be so shrouded in red tape to be effective, and Advanced Aerials is proving it. Down the road, they even see educational opportunities brought about by their open-source model, giving students the opportunity to discover, explore and contribute to the emerging science of robotics. All in all, that’s how you build a better UVS: accept ideas from all around, appeal to the next generation of engineers, and find the perfect partner to help you make it.
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BIOMEDICAL APPLICATIONS OF 3D PRINTING
Saving a newborn with the support of 3D Printing Finding out that you are going to have a baby may be one of the happiest days of your life. Sadly for one family in Ne York, the joy quickly turned to fear and uncertainty when they found out their baby would be born with a complex form of congenital heart disease. Having already diagnosed the condition in the womb, the doctors at NewYorkPresbyterian/Morgan Stanley Children’s Hospital had time to plan how they would save the baby’s life before it even began with the support of 3D printing and Materialise’s Mimics Innovation Suite of software.
Supporting an Unprecedented Procedure
In July, a baby boy was born with a complex form of congenital heart disease in which both the aorta and pulmonary arteries arise from the right ventricle. Also present was a large hole in the heart called a ventricular septal defect (VSD). On the first day of his life, an extremely low dose chest CT scan was acquired to better understand the complex 3D relationships of the heart and defects. From the images alone it was difficult for the doctors to formulate the optimal surgical plan, especially considerin g that the baby’s heart was no bigger than a walnut! They turned to the 3D printing experts at Materialise for a solution. Starting with the baby’s image data, Todd Pietila, Cardiovascular Business Development Manager at Materialise, created a 3D model of his heart using Mimics Innovation Suite of software. The team at NewYorkPresbyterian/Morgan Stanley Children’s Hospital worked closely with Mr. Pietila to achieve an accurate reconstruction of the heart, which would allow the surgical team to best visualize the complex defect. The result was a 3D representation of the heart with the small details of the congenital defects captured accurately. The file was then 3D printed at the medical production facil ity at Materialise’s U.S. headquarters in Plymouth, Michigan. Only 2 days after receiving the data, a replica of the baby’s heart was delivered to the hospital!
The Power of Holding the Tiny 3D -Printed Heart The complex 3D relationships of the newborn’s defects were not apparent from the ultrasound and scan data alone. Fortunately, with the 3D-printed model in hand, the team of clinicians at NewYork -Presbyterian/Morgan Stanley Children’s Hospital found an ideal solution for repairing all of the defects during one procedure, instead of three or four surgeries.
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BIOMEDICAL APPLICATIONS OF 3D PRINTING
“The baby’s heart had holes, which are not uncommon with CHD, but the heart chambers were also in an unusual formation, rather like a maze,” said Dr. Emile Bacha, a congenital heart surgeon and Director of Congenital and Pediatric Cardiac Surgery at NewYor k-Presbyterian/Morgan Stanley Children’s Hospital. “In the past we had to stop the heart and look inside to decide what to do. With this technique [using a 3D printed model], it was like we had a road map to guide us.” Dr. Emile Bacha performed the surgery when the week-old baby weighed just over 7 lbs. His single procedure approach allowed the baby to avoid the typical series of palliative operations which can be life threatening. The clinical outcome was ideal and the baby is on his way to a healthy life. The 3D printed heart model also allowed the surgeons’ to explain the baby’s condition and their plan to the worried parents. By seeing the model and understanding what needed to be done, the parents became as confident as the surgi cal team. The baby’s father commented, "In discussing the necessary surgery with the doctors it was unclear how it would be performed and if it would be accomplished with one or two surgeries. We were told that they are working on getting a 3D-printed model of our son’s heart, which the team hoped would clarify the surgical plan. Upon receiving the model, everything changed. After studying the model, the surgeon got a clearer picture of what needed to be done and was very optimistic that he could do the repair in one surgery. Our baby was saved from subsequent surgeries and interventions and all the side effects and developmental delays that come with it. This is truly an amazing advancement in surgical planning and outcome. We are so thankful!"
The Future Looks Bright The 3D printed HeartPrint® model proved to be so valuable that the clinicians at NewYork -Presbyterian/Morgan Stanley Children’s Hospital are already working with Materialise on additional cases. Dr. Bacha added, “After the success of this surgery, it’s hard to imagine entering an o perating room for another complex case without the aid of a 3D printed model. It’s definitely going to be standard of care in the future and we’re happy to be leading the way.”
The Standard in ‘Engineering on Anatomy TM’ The Mimics Innovation Suite turns 3D image data into high -quality digital models in an accurate and efficient way. Starting from optical scan, CT or MRI data, the Mimics Innovation Suite offers the most advanced image segmentation, the broadest anatomical measurement options, powerf ul CAD tools for Engineering on Anatomy and 3D Printing, and accurate model preparation for FEA and CFD.
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3D PRINTING OF SAND MOULDS
Project description: The car must be faster, and also lighter. Also in the formula student projects is the focus on the weight optimization of the new racing cars. In this case, a magnesium and an aluminum wheel carrier were compared. • Purpose: Prototyping • Challenge: Production of complex wheel carrier in a few weeks • Solution: Production of 2 sand casting molds for the aluminium and magnesium castings
CAD-file of the wheel carrier
Sand casting form of the wheel carrier
SandMoulds
Race Tech in action
Mounted wheel carrier
Castings
Totalsize(mm)
697x523x353
Totalsize(mm)
520x205x390
Weight(kg)
1.2
Weight(kg)
3.4
1
Material
AIuminium
Material
Sand
Leadtime(weeks)
3
Layerthickness (mm)
0.3
Leadtime(days)
5
Buildtime(hours)
3.5
Individualparts
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.
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PRESS RELEASE
EOS GmbH Marks Its 25th Anniversary with a move into a new new technology and Customer Centre at its Headquarters in Krailling EOS Additive manufacturing (AM) now allows industrial applications in series production
Dr.HansJ.Langer,founderandCEOEOS
Krailling, 17 July 2014 – EOS, the technological and market leaders in design-driven, integrated e-manufacturing solutions in the field of Additive manufacturing (AM), has now moved into its new Technology and Customer Centre in the Krailling Innovation Mile (KIM). Dr. Hans J. Langer, founder and CEO of EOS comments: "This new building represents a further milestone for EOS and is an expression of our company's growth and success story over the last twenty-five years. We operate in a market that is high ly dynamic and which offers a huge potential. In the past we almost exclusively served the area of Rapid Prototyping, whereas now, Additive Manufacturing enables industrial applications in series production." And he adds: "This new building gives us more space in which to grow, allowing EOS to continually adapt to new market conditions and customer segments. Moreover, the new customer centre gives us the spatial flexibility we need to allow us to jointly develop current and future application solutions in Additive Manufacturing together with our customers."
A few facts about the new building With the construction of this new building, EOS underlines its loyalty to its location in the west of Munich. Christian Kirner, the company's COO, stresses: "With a floor space of 17,000m², the building is able to accommodate an additional 300 employees, while its design follows specific architectural, spatial and workplace concepts. The architectural concept renders the three key principles of the company's business strategy – innovation, quality and sustainability – both visible and tangible. The facility operates on the basis of an integral, sustainable energy concept." He continues: "In line with our corporate objectives, right from the start the emphasis was placed on the building's functional and ecological efficiency. Both its construction and operation were conceived with all due consideration for the efficient use of resources and energy-efficient building. In this way, the EOS building concept already complies with the requirements of tomorrow – apt reflection of the nature of the technology offered Customers and long-term companions over the last 25 years congratulate the company on its anniversary: •
NewEOSTechnologyandCustomerCentrein Krailling
Christoph Weiss, Managing Partner of the BEGO Group: "We have enjoyed a good and close partnership with EOS since 2008. Their systems represent the current benchmark in selective laser-melting system engineering in the dental market and have facilitated our great success over three continents – Europe, Asia and America. contact that we have to the developers in Finland.
•
Thanks to the sophisticated EOS technology and our BEGO processes and alloys, we are able to restore the smiles to the faces of patients worldwide – and it is this that drives us on every single day."
•
Bart Van Der Schueren, Executive Vice President Materialise: “We want to congratulate EOS with their 25th anniversary. We have been successfully collaborating with EOS over their entire history, both as a software partner and as a user of their technology. Looking back over these 25 years it is without saying that EOS has had a huge impact on the industry. Thanks to the effort of EOS, production is changing in a fundamental way and is giving unseen new opportunities for new produc ts and businesses.”
•
Terry Wohlers, Wohlers Associates: “ EOS has played an important role in the history of Additive Manufacturing and industrial 3D printing worldwide. Without the company, the landscape of the industry would be much different today. We expect laser sintering to serve a wide spectrum of organizations in the future, especially as they uncover the vast potential of the technology.”
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PRESS RELEASE
ZERO – G PRINTER - A Historic Revolution in Space Access -– The Sky is no longer the limit – “The Machine Shop for Space”
Zero-GPrinter The Zero-G Printer is the first 3D printer designed to operate in zero gravity. Launched into orbit on September 21, 2014, the printer was built under a joint partnership between NASA MSFC and Made In Space. Contracted as the “3D Printing in Zero-G Experiment,” this first version of the Zero-G printer will usher in the era of off-world manufacturing.
alternative to launching items from Earth. “Everything that has ever been built for space has been built on the ground. Tremendous amounts of money and time have been spent to place even the simplest of items in space to aid exploration and development,” said Aaron Kemmer, Chief Executive Officer of Made In Space. “This new capability will fundamentally change how the supply and development of space missions is looked at.”
This initial version of the Zero-G Printer will serve as a test bed for understanding the long-term effects of microgravity on 3D printing, and how it can enable the future of space exploration. It is a culmination of contracts and development dating back to 2010 including microgravity tests with NASA’s Flight Opportunities Program, R&D contracts under NASA’s SBIR Programs, and development contracts with NASA MSFC.
Following delivery to ISS, the 3D printer is scheduled to be installed in the Microgravity Science Glovebox (MSG) to conduct its series of prints. The printer will create a series of test coupons, parts, tools, use case examples and even STEM project designs by students as part of the 3D Printing in Zero-G Experiment. This experiment, intended to demonstrate additive manufacturing capabilities in space, was developed through a partnership between Made In Space and NASA MSFC. Made In Space is working with busin ess partners to formulate additional use case examples to demonstrate printer capabilities.
This “machine shop for space” will mark the first time that a multi-purpose manufacturing device will be utilized offworld to create parts, tools and emergency solutions. Developed by Made In Space, Inc., under a contract with NASA Marshall Space Flight Center (MSFC), the 3D printer is part of a technology demonstration intended to show that on-site, on-demand manufacturing is a viable www.madeinspace.us
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PRESS RELEASE
Reconstructing cylinder heads for Porsche legends Anyone who owns a legendary Porsche 550 Spider, 904 or 356 Carrera can count himself lucky. These cars have experienced an enormous increase in value over the last few years. Unfortunately special parts like cylinder heads are no longer available. In the event of damage, the only remedy is through customized parts reconstruction or reverse engineering, and 3-D printing turned out to be the cheapest way.
Reconstructing complex components is a challenge for e very design engineer, because drawings are not available in most cases and they are not provided by the OEM-manufacturers. In this particular case, the reconstruction of a Carrera cylinder head made of aluminum started with measuring and scanning of the defective head.
CylinderHeads Valve guides, seat rings, camshaft bearing, intake and exhaust ducts, cylinder head screws etc. had to be set up as 3D base bodies in a meticulous detailed process. The next step was the transfer to superordinate functional models and the adding of design features from casting technology like site measuring, bevels and fillets.
has many years of experience in project of this kind. Thanks to the excellent printing quality of the voxeljet printer, it was also possible to outline the thin-walled cooling rib measuring 2 mm without additional supporting structure in the inner and outer cores. The molding was made by the foundry Rauleder & Rudolf based in Schwäbisch Gmünd, which specializes in constructing unique components. The hot isostatic pressing (HIP) treatment led to a tremendous improvement of the mechanical properties, as well as a reduction of pores.
Affordable sand cores from the 3D printer After the geometric reconstruction made by the company CAD Support from Mössingen, Germany, the production of the sand cores was the next item on the agenda. The project implementation with conventional cores based on core-making tools was impossible for cost reasons. The only solution was creating the cores in a 3D printer.
The final T6 heat treatment provided the ultimate strength of the cylinder head. The finishing of the components was made on the basis of the 3D CAD files in a 5-axis machining center. After completion, the aluminum cylinder head was ready for assembly.
The order for printing the entire core packa ge with eleven cores in total went to the voxeljet service center in Friedberg which
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EOS e- Manufacturing Solutions
EOS Additive Manufacturing: Fuel Injector & Swirler, Material: CobaltChrome MP1 (Source: Morris Technologies)
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