The
AM Magazine The Magazine for 3D Printing and Additive Manufacturing Technologies
ISSN 0974-7133 ISSUE 31 | MAY 2015
The AM Magazine RAPITECH Solutions Inc. # 42, BSK 3rd Stage, 3rd Block, 3rd Phase, 9th Cross, Banagalore-560085, INDIA
EDITORIAL Publisher RAPITECH Solutions Inc. INDIA
The AM Magazine will introduce and update the latest developments in layer manufacturing and Rapid Product Development technologies. The focus of the magzine is to serve the Design and Manufacturing professionals, Research and Development organisations and Educational Institutions who are particularly seeking to adopt layer manufacturing and rapid product development technologies.
Chief Editors
Endorsed by
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
Additive Manufacturing Society of India
French Rapid Prototyping Association
Central Metallurgical Research & Development Institute
Global Alliance of Addtive Manufacring Association
Standard and Industrial Research Institute of Malaysia
Portugese Rapid Prototyping Association
ADVERTISING/OPERATIONS Jyothish Kumar RAPITECH Solutions Inc. jyothish@rapitech.co.in Mob: +91 9901033712
EDITORIAL ADVISORY BOARD Professor P.Bartolo Department of Mechanial Engineering, School of Technology and Management Leira, Portugal Assitant Professor Bahram Asiabanpour, Ph.D Manufacturing Engineering Ingram School of Engineering Texas State University- USA
The AM Magazine is also endorsed by the following associations and organisations as a leading resource for information on the latest development of Rapid Product Development Technologies
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
Publisher
Associate Professor Salih Akour University of Jordan, Amman Dr Rajesh Ranganathan Department of Mechanical Engineering, Coimbatore Institute of Technology Dr Pulak M Pandey Indian Institute of Technology, Delhi
RAPITECH Solutions Inc., is a leading edge service provider in Rapid
Rob Snoejis, Layerwise, Belgium
Prototyping (SLA/ SLS/ FDM /3D Printing), Rapid Tooling (Vaccum Casting), Rapid Metal Casting and Reverse Engineering. RAPITECH Solutions Inc., aims to disseminate the research and development work in the field of Additive Manufacturing Technologies. The Objectives areTo undertake and support Additive Manufacturing research projects. To disseminate knowledge on state-of the–art Additive Manufacturing technology through training courses, organising seminars, symposia and workshops.
SUBSCRIPTIONS Annual Subscriptions Rs. 5,000/The AM Magazine is published bi-monthly by RAPITECH Solutions Inc. * All payments are to be made by DD drawn in favor of “ RAPITECH Solutions Inc.,Bangalore”
To network and tie up with best the Additive Manufacturing institutions/ Organisations in the world to tap best ideas and transfer best practices from around the world. Interact and collaborate with international Additive Manufacturing institutions and organisations to pursue research projects.
www.rapitech.co.in
The AM Magazine
AM - 15/16 Vol.06 Issue 31
CONTENTS
557 WORLD'S LARGEST ARGON CHAMBER PROFESSIONAL GRADE PRODUCTION PROVEN COMMERCIALLY AVAILABLE
POWDER FED LASER METAL DEPOSITION TECHNOLOGY SYSTEM Manufactured in the USA by RPM Innovations Inc.
Regulars
Latest Updates
04. Editorial
News Release:
05. ExOne Case Study – 3D Metal Printing Technology
18. ExOne Unveils Innovent™ 3D Printing System for Research and Education Customers
06. White Paper – Five Best Practices: How Innovative Universities are Incorporating 3D Printing into the class room 11. Direct Metal Printing – Metal Technology forges new path with metal 3D printing and English Racing 14. Case Study: Laser Cladding Technology to Repair forging
15. Metal Laser Melting(LaserCUSING) in Medical Technology
AM Magazine online www.ammagazine.in http://issuu.com/rpdmag
19. Stratasys Additive Manufacturing Solutions Selected by AIRBUS to produce 3D Printed Flight Parts for its A350 XWB Aircraft 17. 5th International Conference on Additive Manufacturing Technologies - AM 2015 - Global Additive Manufacturing Summit”, 7 - 8th September 2015, Bangalore, INDIA
WAVE OF FUTURE: 3D PRINTING TECHNOLOGY 3D printing long ago moved from being theoretically to a reality. 3D printing or additive manufacturing is a process of making three-dimensional solid objects from a digital file. In an additive process an object is created by laying down successive layers of material until the entire object is created. Each of these layers can be seen as thinly sliced horizontal cross-section of the eventual object. Additive manufacturing's earliest applications have been on the tool room end of the manufacturing spectrum. For example, rapid prototyping was one of the earliest additive variants and its mission was to reduce the lead time and cost of developing prototypes of new parts and services, which was earlier done with subtractive tool room methods which are typically slow and expensive. However, as the years go by and technology continuously advances, additive methods are moving ever further into the production end of manufacturing. Parts that formerly were the sole province of subtractive methods can now in some cases be made more profitably via additive ones. 3D printing is an enabling technology that encourages and drives innovation with unprecedented design freedom. Components can be designed specifically to avoid assembly requirements with intricate geometry and complex features created at no extra cost. 3D printing is also emerging as an energy-efficient technology that can provide environmental efficiencies in terms of both the manufacturing process itself. 3D printers capable of producing in multiple materials already exist and will continue to improve to a point where functional products will be able to be output. With effects on energy use, waste reduction, customization, product availability, medicine, art, construction and sciences, 3D printing will change the manufacturing world as we know it. Technologies have made our lives better in many ways, opened up new avenues and possibilities, but usually it takes time, sometimes even decades, before the truly disruptive nature of the technology becomes apparent.
- Global Axis (Partner to ExOne GmbH) New Delhi India
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CASE STUDY: LASER CLADDING TECHNOLOGY TO REPAIR FORGING
Repair of Ti-6Al-4V Forging RPM Innovations received a Ti-6Al-4V drive plate forging that needed repair. The forging was undersized. Material needed to be added to the part to build it up so it could be machined to the proper fit. The drive plate is for an atomizer wheel used in a Flue Gas Desulfurization system. All of the parts in the atomizer wheel rotate up to 15,000 RPM. For this system, it is important that the part be precisely machined and that the material used be resistant to wear. Titanium is used to minimize the weight of the part while maintaining the hardness and strength needed for the application. Using Laser Repair Technology (LRT), material was added to the part. Once the material was added, the strong metallurgical bond allowed the material to be machined off to the proper fit while maintaining the required strength and hardness for the application. The low heat input of the LRT process ensured that the part did not change its shape or material properties.
路 Ti-6Al-4V atomizer drive plate. 路 Part rotates up to 15,000 rpm. 路 Forgings were undersized. 路 Used Laser Repair Technology (LRT) for building up material.
Forging As Received
Forging During Deposition
Forging After Deposition
Source: RPM Innovations USA.
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Forging After Final Finish
METAL LASER MELTING (LaserCUSING) IN MEDICAL TECHNOLOGY
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METAL LASER MELTING (LaserCUSING) IN MEDICAL TECHNOLOGY
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METAL LASER MELTING (LaserCUSING) IN MEDICAL TECHNOLOGY
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2015
5 INTERNATIONAL CONFERENCE & EXHIBITION ON ADDITIVE MANUFACTURING TECHNOLOGIES “Global Additive Manufacturing Summit” - 2015 September 7 - 8, 2015 Nimhans Convention Centre, Bangalore, INDIA
”Aerospace, Defence, Space, Automotive, Tooling Die & Mould, Bio Medical, Academia, R & D ” www.amsi.org.in 17
PRESS RELEASE: ExOne
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ExOne Systems & Services materialise sandcasting cores, moulds & functional metal parts with less cost and increased efficiency for prototype or production use. 速