Presentation DMRC. Additive Manufacturing

Transcription

1 Presentation DMRC Additive Manufacturing Dr.-Ing. Eric Klemp 1 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 2 1

2 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 3 DMRC Direct Manufacturing Research Center Paderborn Berlin DMRC (Start in 2009): 25 Researchers 9 Chairs at University ~ 80 Students Dr.-Ing. Eric Klemp 4 2

3 The Growth of DMRC First offer Contracts Beginning of operation Start of projects Projects: LS, SLM, FDM, Fatigue, Design Rules, Foresight, Quality Dec 07 June 08 Jan 09 May 09 today Selective Criteria: Scientific expertise Experience in other Research Center Vision und Strategy Commitment for Growth Funding University Paderborn: Expertise in AM-relevant subjects Active Contribution of University and State NRW DMRC as collaborative Enterprise Potential industrial partners as well in neighbourhood Dr.-Ing. Eric Klemp 5 Currently 15 partners in DMRC Science & R&D Materials Equipment & Systems Service Provider Enduser Production AM -System Founding Partners The LEGO Group New Partners Dr.-Ing. Eric Klemp 6 3

4 The Direct Manufacturing Research Center - DMRC Technology driven projects Fused Polymer Metal Deposition Laser Laser Modeling Sintering Melting The LEGO Group Cross cutting projects Dr.-Ing. Eric Klemp 7 Involved Institutes Dr.-Ing. Eric Klemp 8 4

5 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 9 Technical Equipment EOS EOSINT P 395 Stratasys FDM Fortus 400 mc SLM 250 HL & 280 HL Source: EOS, Stratasys Inc., SLM Solutions Dr.-Ing. Eric Klemp 10 5

6 Technology CAD AM-Anlage Produkte individual complex Source: EOS, SLM Solutions, Stratasys quick & functionell Source: EOS, SLM Solutions Dr.-Ing. Eric Klemp 11 Different parts CAD LS part FDM part SLM part Source: DMRC Dr.-Ing. Eric Klemp 12 6

7 CAD- Design Dr.-Ing. Eric Klemp 13 Movie Design Dr.-Ing. Eric Klemp 14 7

8 Movie Design Dr.-Ing. Eric Klemp 15 Polymer Laser Sinter Verfahren sliced information lowering of platform coating of one powder layer heating CAD data scanning of each layer by laser (sintering process) final part Dr.-Ing. Eric Klemp 16 8

9 Laser Sintering CO 2 -laser scanner infrared heating storage container powder bed overflow tank parts building platform storage container re-coater overflow tank Dr.-Ing. Eric Klemp 17 Movie LS Dr.-Ing. Eric Klemp 18 9

10 Application: Mixer LS Dr.-Ing. Eric Klemp 19 Applications in LS Properties: Design different shapes Inner structures Flexibility Form follows function Design follows demand Various applications Limitations: Mechanical properties Surface properties Remaining powder Dr.-Ing. Eric Klemp 20 10

11 Design Application: Isolation Channel Isolation by internal structures Properties: Saves weight Hollow structure Isolation follows structure Increasing mechanical properties Flexibility No additional assembly For LS and FDM Limits: Need of support (FDM) Remaining Powder (LS) Dr.-Ing. Eric Klemp 21 Design Application: Isolation Channel Dr.-Ing. Eric Klemp 22 11

12 Design Application: Isolation Channel Dr.-Ing. Eric Klemp 23 Design Application Dr.-Ing. Eric Klemp 24 12

13 Design Application: Robot System Multiple in use Movable platform Measurement of load-turning Position of load (photoelectric sensor) All electronic parts are included Single application (low volume) Flexibility Dr.-Ing. Eric Klemp 25 Laser melting process sliced information coating of one powder layer lowering of building platform CAD data Local scanning of each layer by laser (melting process) final part Dr.-Ing. Eric Klemp 26 13

14 Laser melting ytterbium-laser scanning system storage container powder bed overflow tank part support structure re-coater overflow tank building platform Dr.-Ing. Eric Klemp 27 Movie SLM Dr.-Ing. Eric Klemp 28 14

15 Dreifachmischer Laserschmelzen SLM Bauteil Dr.-Ing. Eric Klemp 29 Applications in SLM Properties: Metal structures Saves weight Hollow structure Inner structures Form follows function Design follows demand Various applications Limitations: Support Source: EOS, SLM Solutions Dr.-Ing. Eric Klemp 30 15

16 Dr.-Ing. Eric Klemp 31 Fused Deposition Modeling process sliced information deposition of one new layer CAD data lowering of building platform finished part Dr.-Ing. Eric Klemp 32 16

17 Fused Deposition Modeling model material filament support material filament FDM head part extrusion tip support structure build sheet build platform Dr.-Ing. Eric Klemp 33 Movie FDM Dr.-Ing. Eric Klemp 34 17

18 Fused Deposition Modeling model material filament support material filament FDM head part extrusion tip support structure build sheet build platform Dr.-Ing. Eric Klemp 35 Dreifachmischer FDM Dr.-Ing. Eric Klemp 36 18

19 Applications in FDM Properties: Design different shapes Hollow structure Inner structures Flexibility Material Ultem 9085 Limitations: Support Mechanical properties Surface properties Dr.-Ing. Eric Klemp 37 FDM Ultem Bauteil Dr.-Ing. Eric Klemp 38 19

20 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 39 The Direct Manufacturing Research Center - DMRC Technology driven projects Fused Polymer Metal Deposition Laser Laser Modeling Sintering Melting The LEGO Group Cross cutting projects Dr.-Ing. Eric Klemp 40 20

21 Research-projects Technology Fused Polymer Metal specific Deposition Laser Laser Projects Modeling Sintering Melting Cross - Cutting Projects Dr.-Ing. Eric Klemp 41 Technology specific projects Determination of Material Properties by references to a Real Product, optimized for Laser Sintering Surface Topography Analysis and Enhancement of Laser Sintered Parts (STEP) Advanced Additive Manufacturing Material & Part Properties (AMP²) FDM part quality manufactured with Ultem*9085 Ageing effect on FDM parts made of Ultem*9085 Improvement of the FDM Process Quality Surface Treatment Methods for FDM Parts Analysis of the FDM Part Quality manufactured with ABS M30 with the focus on the toy industry Dr.-Ing. Eric Klemp 42 21

22 Technology specific projects Product Optimization for SLM-Process Characterization and comparison of mechanical properties of SLM materials with regard to process cycle time improvement Optimization of lattice structures manufactured by Selective Laser Melting Light-weight construction: Robust simulation of complex loaded cellular structures Fatigue Life Manipulation High temperature fatigue behavior of Ni-base superalloys processed by SLM Innovative SLM materials Dr.-Ing. Eric Klemp 43 Research-projects Technology Fused Polymer Metal specific Deposition Laser Laser Projects Modeling Sintering Melting Cross - Cutting Projects Dr.-Ing. Eric Klemp 44 22

23 Cross cutting projects Direct Manufacturing Design Rules Future RepAIR and Maintenance for Aerospace industry Research Strategies for Additive Manufacturing Opportunities and Barriers of Direct Manufacturing Technologies QM-System for AM Processes in DMRC New Structure: Direct Manufacturing of Structure Elements for the Next Generation Platform Co2AMPLy: Costing Analysis for Additive Manufacturing during Product Lifecycle Dr.-Ing. Eric Klemp 45 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 46 23

24 The Hype of 3D printing Source: Gartner (August 2014) Dr.-Ing. Eric Klemp 47 Relevant Industries Dr.-Ing. Eric Klemp 48 24

25 Advantages of AM Buy to fly ratio High complex parts Low quantity parts AM optimised parts Dr.-Ing. Eric Klemp 49 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 50 25

26 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 51 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 52 26

27 Beispiel: individualisiertes Interieur Dr.-Ing. Eric Klemp 53 Dr.-Ing. Eric Klemp 54 Beispiel: Klimaanlage 27

28 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 55 Lattice Structures Advantages AM / SLM Tool less highes flexibility Complex structures / geometries Light-weight potential Efficiences in ressources Currently drawbacks High cooling rate while process residual stress deformation a Low productivity Small size of building chamber HIGH potential for customer specific and load optimised parts Approach: Lightweight design by use of cellular structures Optimisation of specific load capacity by modification of lattice structure for mechanical properties Investigation of local deformation Dr.-Ing. Eric Klemp 56 28

29 Light-weight structures Approach: Light-weight design by application of cellular structures Optimization of specific loading capacity through local modification of stiffness and strength Local deformation mechanisms have to be taken into account Dr.-Ing. Eric Klemp 57 Light-weight structures Uni-axial tensile testing Ti-6Al-4V high influence of post-process heat treatment on deformation behavior immanent structural weakness in 45 axis with respect to loading direction Dr.-Ing. Eric Klemp 58 29

30 Tailoring mechanical properties 316L 400 W laser 1000 W: lower yield strenght lower Young s modulus higher elongation at fracture 1 kw laser clear differences in mechanical behavior effect on high temperatur creep in Ni-base alloys? Dr.-Ing. Eric Klemp 59 Teil Energieabsportion Mechanisches Verhalten Druckprüfung Ti-6Al-4V Wärmebehandlung 1050 C, 2h führt zu: Leichte Reduzierung der Zugfestigkeit Höhere Duktilität Mikrostrukturelle Gründe: Feineres martensitisches Gefüge führt nach der Prozess zu hoher Festigkeit und geringer Duktilität Verbesserte Duktilität durch Wärmebehandlung Anwendung: Verbesserung der Energie - Absorption Dr.-Ing. Eric Klemp 60 30

31 local failures as-processed Ti-6Al-4V ε = 0.5 % Heat processing (1050 C, 2h) ε = 2.5 % ε = 4 % ε = 2 % ε = 8.5 % Design of lattice structures Dr.-Ing. Eric Klemp 61 Dynamical behaviour Mechanical behaviour at dynamic load Ti-6Al-4V as-processed : Fehler bei etwa Lastspielen Nach Wärmebehandlung: konstanter Verlauf Verdoppelung der Lastpielzahlen Nachbearbeitung von SLM Ti-6Al-4V - Proben hat eine hohe Relevanz bei zellulären Strukturen Dr.-Ing. Eric Klemp 62 31

32 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 63 Example: inner structures Dr.-Ing. Eric Klemp 64 32

33 AM application: oil-filter case Dr.-Ing. Eric Klemp 65 AM application: oil-filter case Dr.-Ing. Eric Klemp 66 33

34 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 67 application: product protection against product piracy Source: UPBracing Dr.-Ing. Eric Klemp 68 34

35 product protection against product piracy weight reduction Weight reduction by 515 g auf 305 g (40%) Original weight ca. 16 kg 15,5 kg waste AM weight = 720 g Cost- reduction from to 400 (60%) i Singular design! Copies only with same production system and knowledge of process-parameters Dr.-Ing. Eric Klemp 69 Relevance of AM flexible production integration of functions supply chain management individualisation time-to-market freedom of design fast changemanagement no tools protection against product piracy Dr.-Ing. Eric Klemp 70 35

36 Design for additive manufacturing Key aspects Design for manufacturing Design rules that show design potentials show design restrictions show design differences of AM-processes are universally applicable are function independent Design for function To gain benefits aspire function integration use design potentials use process properties Design for tolerances Dimensional deviations occur due to physical manufacturing Must be considered Must be limited due to tolerances Dr.-Ing. Eric Klemp 71 Design for manufacturing Example: Island height Regular description Specific description Unsuitable design Suitable design LS LM FDM Island heights should be as small as possible. X Fused Deposition Modeling Islands must be supported Support structure manufacturing requires tip switches in each layer Increasing island heights increase number of required tip switches Manufacturing time increases [AZ13a] t [min] Fused Deposition Modeling h Isl [mm] Dr.-Ing. Eric Klemp 72 36

37 Summary Challenges Capability Speed Reliability Repeatability Automatisation & Logistic Software Material Costs Industry-Standards Continuous Improvement Field of Actions Process technologies Design of machinery Control technology Software Design of parts Material properties Quality control Standards Education The DMRC is a proactive collaboration of key technology stakeholders who have the common interest in advancing Additive Manufacturing technology into dependable, production rugged Direct Manufacturing technology. Dr.-Ing. Eric Klemp 73 Agenda DMRC Technology Lasersintering Selective Laser Melting Fused Deposition Modelling Research Projects Fields of interest and Industries Integration into Industry 4.0 Partner und Links Dr.-Ing. Eric Klemp 74 37

38 Direct Manufacturing Research Center Partners The LEGO Group Dr.-Ing. Eric Klemp 75 Downloadlinks Yearly report of DMRC: Studies: Direct Manufacturing Design Rules Dr.-Ing. Eric Klemp 76 38