Additive manufacturing met metaal Trends & ontwikkelingen en de kansen voor de maakindustrie

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1 Additive manufacturing met metaal Trends & ontwikkelingen en de kansen voor de maakindustrie Bert Thuis Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR

2 Overview What is Additive manufacturing ref.: Additive Manufacturing: A game changer for the manufacturing industry?, Roland Berger, Strategy Consultants, München, nov Materials (Metals) for Additive Manufacturing programme Conclusies 2

3 What is Additive Manufacturing 3

4 3D printing Fabricate a product directly from a 3D-CAD file On a local or remote printer. 4

5 Additive manufacturing is a step up from rapid prototyping MRL differs by application 5

6 6

7 Using AM, geometrically complex shapes with increased functional performance can be manufactured at virtually no additional cost 7

8 Powder Bed Fusion is the most frequently used technique for printing metal objects 8

9 Direct Energy Deposition for metal AM is less widespread, primarily due to lower accuracy and required postprocessing 9

10 Laser Powder Bed fusion is the dominant technology for metal AM due to higher accuracy, surface quality and freed om of design 10

11 It is not all perfect 11

12 Application metal AM is growing Many companies invest in Additive Manufacturing technology ESA, DLR, EADS, GKN Aerospace, Boeing, GE, Avio S.p.A., Rolls-Royce, ESA,... 12

13 3D printing initiatives USA 4 National Additive Manufacturing Innovation Institutes, $ 30 million federal investment, matched by Industry 11 more to be established Europe UK: National Centre for Additive Manufacturing 30 million matched by Industry Much work done in GBR, GER and BEL Singapore NTU Addtive Manufacturing Centre Netherlands NATO Harmonisation Industry and knowledge centers UT/NWO; Sintas en TUDelft AMSMART Several industries: Addlab Fontys STO: Additive manufacturing for military hardware 13

14 NLR Additive Manufacturing activities in the past Research for Dutch Defence into mechanical properties & applicability of SLM parts Research for Dutch Defence into application for production and repair of motor components Development hinge for solar panels Parts for wind tunnel models Development of components based on SLM for cooling of electronic components in space Development of light weight micropumping system to be produced with SLM A survey among stakeholders of NLR showed that the majority had an interest in Laser Powder Bed Fusion as technology and facility to support research and high TRL developments 14

15 Laser powder bed fusion (SLM) facility at NLR SLM 280 HL Build Chamber in 280 x280 x 350 mm (x/y/z) Laser Power dual 400/1000 W, YLR-Fibre-Laser laser system Build Speed Maximum ±35 cm 3 /h (depending on material, geometry,...) Common for Ti6Al4V= 5-8 cm 3 /hr Pract. Layer thickness Min. Scan Line / Wall Thickness Operational Beam Focus variable Scan Speed Powder bed heating Quality control 20 μm μm 180 μm 100 μm -700 μm 15 m/s 200 C 500 C Automated powder layer inspection system 15

16 Added value of NLR in respect to SLM Metal Additive Manufacturing Technology Centre 16 16

17 NLR programme on Selective Laser Melting 17

18 Selective Laser Melting SLM Workflow Design Build preparation Design rules Development design tools Optimise use of design freedom Take SLM limitations into account Prediction residual stresses Production Post treatments X 18

19 Selective Laser Melting SLM Workflow Design Build preparation Production Optimum orientation Minimum support structures Optimise support design Slicing & Hatching: Develop methods for parameter optimisation Post treatments 19

20 NLR programme on SLM SLM Workflow Design Build preparation Production Post treatments Optimise process parameters Different materials/alloys Different criteria (fast, large, accurate, low residual stresses,...) Scanning strategies Influence of powder bed preheating Optimise gas flow 20

21 Selective Laser Melting SLM Workflow Design Build preparation Production Post treatments Powder removal methods Heat treatments Removal from substrate plate Fast removal of supports Surface treatments 21

22 Draft Work Plan for the AM Programme 15 mei

23 Approach of the Materials (Metals) for Additive manufacturing Programme Programme will be a Public Private Partnership (PPP) and formulated in a Samenwerkingsovereenkomst between participants in order to apply for TKI-Toeslag Detailed proposal of the four years Materials for AM Programme with a clear description of the activities, deliverables and planning will be an appendix to the PPP Samenwerkingsovereenkomst Private and Public entities can join this PPP The private contribution will qualify as a foundation for the TKItoeslag according to the Regulation TKI-toeslag. NLR and TNO intend to apply the TKI-toeslag for this project according to the prevailing Regulation TKI-toeslag. PPP is a condition for additional TTI funding that can become available from the Rijksdienst voor Ondernemend Nederland 15 mei

24 It s not only technology Lower non recurring costs Printing on demand No need for batch production No need for stock Quicker introduction of new products World wide local production Less transport cost Mobile part hospital 24

25 It s not only technology Automated process Less influence of human error Differently skilled personnel required Less raw materials Sell the design instead of the product Protect the design Scan and print Security Hacking the design Hacking the printer Not yet an alternative for mass production 25

26 Summary Metal AM components already in production 3D printing has huge (additional) potential Design freedom Multi material and integrated structures Quicker from design to product Manufacturing on demand Manufacture where needed Smaller footprint Let s make it happen 26

27 27

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