Materials for Additive Manufacturing

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1 Evonik. Power to create. Materials for Additive Manufacturing 3D-Additive Manufacturing Herstellungstechnologie der Zukunft Hessisches Ministerium für Wirtschaft, Energie, Verkehr und Landesentwicklung Sylvia Monsheimer September, 23th, 2014

2 Agenda Short Introduction Evonik 3DP a hype Materials for AM Implications of a new product/technology/design options 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 2

3 Evonik Industries AG Key figures 2013 Sales 12.9 billion Adjusted EBITDA 2.0 billion Profitability (adjusted EBITDA margin) 15.6% Return on capital employed (ROCE) 14.5% Employees as of Dec. 31, ,650 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 3

4 Evonik Industries AG Marl Site 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 4

5 Evonik Industries AG A modern Structure Evonik 2013 Segments Consumer, Health & Nutrition Resource Efficiency Specialty Materials Services Business Units Consumer Specialties Health & Nutrition Inorganic Materials Coatings & Additives Performance Polymers Advanced Intermediates 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 5

6 Evonik Industries AG BU-PP BL High Performance Polymers = Polymers from Evonik Performance Driven = semifinished products from Evonik High-performance polymers PEI PI PAI PPSU PMI PES PMMI PSU PEEK FPs PPA LCP PPS PA 1012 PA12 PA4.6 PA11 PAR Transp. PA PA 1010 PA612 Engineering polymers PMMA PC PPE PA 610 PET PBT PA6 / PA66 POM PUR Cost Driven Commodity polymers PVC ABS PS SAN amorphous PE PP PE-LD PE-HD crystalline Page 6

7 Evonik Industries AG BL HP Product Portfolio Integration Butadiene Building Blocks & Monomers CDT CDAN CDON DDS LL COD COE VCH TM-CDT DM-COD Polymers PA 12 PA 612 PA 1012 PA 6-3-T CoPA PPA PEEK PMMA PMI PI PVDF Compounds & Powders Semi-finished goods PI fibers PPS fibers PMMA sheets PMMA films PMI foams PI foams PC films PC sheets PPSU films PPSU sheets PMMA - PVDF films 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 7

8 Evonik drives innovation with a global network Global footprint Resources and philosophy Innovation for attractive markets with high growth potential Modern management, strong culture Regional focus of R&D activities are Germany, USA and Asia Key statistics 2012 Major R&D centers R&D spend: 393 m. (~ 3 % of sales) Employees: ~ 2,500 Facilities: ~ 35 >26,000 patents >7,700 trademarks 8

9 Structured R&D approach with high output focus 393m Other 5% 2012 R&D expenditures New/advanced applications 10% New/improved processes 25% New products 40% Strategic research ~20% Business Unit based Corporate based Focus on existing technologies and markets Short to mid term perspective Close customer orientation and strategic partnerships Largest component of portfolio value Dedicated entity Creavis on group level with special organizational units: Growth lines Project Houses (e.g. Light & Electronics, Taiwan) Mid to long term perspective Focus on new markets and/or new technologies and new business models Page 9

10 3DP some words about the HYPE. 3DP 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 10

11 3DP some words about the HYPE. From the historical point of view the expression 3DP changed ist meaning several times : 1. MIT-process (binder is printed onto a powder layer) 2. Office friendly processes (independent from the technology used) 3. In the HYPE now: meaning not quite defined, covers all market segments, or only the fabber segment 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 11

12 3DP some words about the HYPE. From Rapid Prototyping to a more segmented market Concept Modeling Prototyping Additive Manufacturing Fabber Market 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 12

13 Additive Manufacturing Characteristics of Additive Fabrication Processes 3Dresults Arbitrarily shaped Creates a physical model use of numerical data (CAD) Working layerwise Merkmale process is quick additive process process is flexible process is automated Page 13

14 Additive Manufacturing SL MIT/3DP LOM SLS, LS FDM Inkjet Page 14

15 Additive Manufacturing Principle SLS Page 15

16 Additive Manufacturing Important features of the powder based processes: Good mechanical properties no support structures necessary arbitrary complexity of the parts possible big volume usable High potential for real (small) series production Page 16

17 Additive Fabrication: Motivation to use Motivation for the use of toolless fabrication processes Price issue for injection moulding of small series (dependent on the part itself) Individual parts (needs software and handling etc) Impossible to produce by injection moulding (undercuts etc) Integration of several parts to one part (difficult to show)(whole production process) Page 17

18 Technology and Economic Aspects Rapid is no longer important in the sense of Rapid Prototyping The whole production process has to be economically Competition against injection moulding Cost per unit Injection Molding Principle only Dependent on the specific part AM superior over IM AM Small parts have higher break even values Comparison 1:1, without using advantages like integrating functionality, or more freedom of design no. of units 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 18

19 BL High Performance Polymers - Development of Materials for AM Mechanical properties Surface quality Processability 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 19

20 Materials Development The Toolbox and Examples Analytics Standards Committee Polymer Testing Application Tests Reactive Systems Ink Formulation Modification and Fractionation Powder Polymer Monomer Page 20

21 BL High Performance Polymers - New Materials for AM VESTAKEEP AM 9000 E modulus 3720 MPa Elongation at break 2,2 % Tensile strength 72 MPa Melting point 340 C Continuous operating temperature 280 C Easy to process Sharp edges Rough surface O O O Poly Ether Ether Keton = PEEK Inherent flame retardant ; UL94 V-O Low smoke density and no toxic gases High heat temperature resistance, excellent chemical resistance Resistance against X-ray, beta and gamma radiation High strength and flexibility Seite 21

22 BL High Performance Polymers - New Materials for AM Comparison of material properties E modulus standard grade 1700 MPa ( psi) new rubberlike material Vestosint Z MPa ( psi) Elongation at break 15 % >100 % Tensile strength 45 MPa (6.250 psi) 8 MPa (1.160 psi) Notched impact strength 3,5 KJ/m 2 No break Melting point 186 C (366 F) 150 C (302 F) Common refreshing rate 50 % 50 % Shore A 90 Shore D 40 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 22

23 BL High Performance Polymers - New Materials for AM Air Duct With some integrated functionality (heat shield, injection nozzle) New Material Grade Temperature Resistance High Impact Strength Improved Stiffness 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 23

24 RealityTests of a new grade with improved mechanical properties Air Duct had been in the car since 26./27.7. in Hockenheim, 23./24.8. Red Bull Ring in Austria, 6./7. 9. in Dijon Good performance, no failure! 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 24

25 BL High Performance Polymers Biobased SLS material Pilot plant for omega-amino lauric acid (ALS) since beginning of 2013 Alternative to petroleum based laurin lactam Material 100 % bio based Applicable to SLS 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 25

26 BL High Performance Polymers - QA for AM Responsibility validated in 1997 under the EU Eco-Audit (EMAS) regulations. certified according to ISO 14001:2005 The management systemcertified to ISO 9001:2000 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 26

27 BL High Performance Polymers - Where quality control of the powders takes place: 3D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 27

28 Fields of R&D - Value Chain Fundamentals Pre Processing Process Machine Material Post Processing Assembly Application Develop ment Page 28

29 Additive Fabrication Processes Benefit of FEM Modell Variation Volumen (mm³) σ max N/mm²) ε max (%) Auslenkung (mm) hakenvoll 1+5 mm Radius ,2 0,85 15,7 hakenvoll 5 mm dick, 1+5 mm ,1 0,29 3,1 Radius hakenhohl 3+5 mm Radius ,8 0,80 17,7 hakenhohl optimal ,3 0,18 3,2 Tensile stresses and elongations as well as the movement of the tip can be reduced to an amount of 20 % - with the same amount of material used. Page 29

30 The OEM s perspective: GE s plans for AM General Electric (GE) is expanding the uses of 3D printing and expects the technology to be involved in more than half of its manufacturing in 20 years. GE uses less than 10% of 3D printing in its manufacturing processes today, but that share should rise to 20% to 25% in 10 years and 50% or more in 20 years, says Christine Furstoss, GE's technical director of manufacturing and materials technologies in an interview with IBD. Oct D-Additive Manufacturing Hessen Nanotech Evonik Industries Page 30

31 Future Zone - AM Large steps forward need their time!!! Big Bang New upcoming applications in different branches Page 31

32 Contact Information Sylvia Monsheimer Director Additive Manufacturing Performance Polymers Phone Mobile Fax Evonik Industries AG Paul-Baumann-Straße Marl Germany Page 32

33 Page 33

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