Prof. D.Sc. M.Sc. Gideon N. Levy Additive Manufacturing and Electro Physical & Chemical Processes

Transcription

1 Additive Manufacturing in Manufacturing: A future oriented technology with high degree of innovation potentials- are we ready? Challenges and Chances to handle Prof. D.Sc. M.Sc. Gideon N. Levy Additive Manufacturing and Electro Physical & Chemical Processes 18th edition of the AEPR forum June 2013 at Ecole Centrale Paris Motivation 1

2 How to 3D print your brain Jun.23, 2013 Once you have an MRI image of your head, you can then convert it to a 3D model. intirb uses software FreeSurfer to process the MRI brain scans to obtain the grey matter boundary of brain, intirb suggests to use MeshLab to simplify your.stl file AM is Hot published D printing that has the potential to revolutionize the way we make almost everything President Obama 2

3 We are approaching our target Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation 3

4 Agenda II 6. Pre- /Post Processing Upstream Processes Downstream Processes 7. Business Model Key users: Experimental validation and certification Mainstream users: Service Bureaus Modern users: E- Shopping (online / on site) 8. Conclusions What are Nontraditional Manufacturing processes? 4

5 More than 25 years ago Patent FDM and EBM

6 Patents of SLM and 3DP Why do have AM a great potential? Abstract Real 5 Senses Perception Thinking Speaking Writing Printing Painting Crafting Art, Music Virtual reality Software Film TV Simulation Modelling Science: Rules and equations Physics, Chemistry Mathematics Everything we have And more. 6

7 AM is an Enabling Multidisciplinary Technology Application dedicated Automation Part and powder handling Batch to continues.. System / Process Adaptive control Closed loop Productivity Repeatability Design for AM 3DP design tool Part finishing Coating Modifications Up stream/ Down stream Materials Polymers Metals Ceramics Composite Biologic Medical devices Scaffolds Organ printing.. Applications Industry Aviation Automotive Jewelry Sirmione Lago di Garda, Italy (Was layer by layer nature inspired?) 7

8 Terminology - Process Categories I (2012) 1. Vat Photopolymerization Process Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon C Liquid Photopolymers, Ceramic or Metal filled photopolymers T 2. Material Jetting Process Multiple nozzles Single nozzles C Thermoplastics, Wax or Photopolymers, Metals, Optical materials, Electronic materials 3. Binder Jetting process a liquid bonding agent is selectively deposited C to join powder materials. Polymer, Metal, Ceramic powders T 4. Material Extrusion Process FDM Polymers, composite T C Chemical T Thermal T Thermal post processing Terminology - Process Categories II (2012) 5. Powder Bed Fusion Process SLS, SLM, EBM T Polymers, metals & ceramics powder 6. Sheet Lamination Process Bonding, hot melt, glue, US welding C Paper, Metal, Polymers T 7. Directed Energy Deposition Process focused thermal energy is used to fuse materials by melting as they are T being deposited Metal, polymers, powder, wire C Chemical T Thermal T Thermal post processing 8

9 Scientific push and industrial pull Disillusionment Standardisation Oversell Commercialisation PhD Develompment & modification Evaluation ACCEPTANCE Need Pioneers Scientific push Evolution Industrial pull Gartner Hype July

10 3DP resourcing (and open sources!) 9 3D Printer Kits manufacturer 35 3D Printer Kits Models available 34 3D Printer Fully Assembled Models / 3Doodler: The World's First 3D Printing Pen The pen: The 3Doodler pen is 180mm by 24mm. The pen weighs less than 200 grams Fun Fact: The average 1kg spool of 3mm ABS contains approximately feet of plastic. That's approximately 3,960-4,070 feet of 3Doodling, or 3 Empire State Buildings with enough to spare for several more weeks of doodling 10

11 Rapid Tech Erfurt CM Equipment sales trend CM Units/ year 3'000 2'500 2'000 1'910 2'450 1'500 1'032 1'

12 Additive Manufacturing Machine Tools FDM 3DP (DoB) EBM SLM SLS Metal SLA The value chain in product creation CONCEPT MODELING RAPID PROTOTYPING Pre-SERIE / BRIDGING The Trend CONFORMAL COOLING / TOOLING REVERSE ENGINEERING ADDITIVE MANUFACTURING 12

13 US Patents on RP/AM in steady state trend- maturity growth? Source: AM market growth Additive Manufactured parts Systems and Services Materials 13

14 Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation AM Manufacturing and SM (subtractive manufacturing) are comparable tasks with new features Additive manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. (ASTM standard F ) Manufacturing is the use of = machines, tools and labor to make things for use or sale. The term is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers". 14

15 Manufacturing Implemented Scientific Management (Taylorism) Scientific management is a theory of management that analyzes and synthesizes workflows, with the objective of improving labor productivity. Source: Total Quality Management (or TQM) is a management concept coined by W. Edwards Deming. The basis of TQM is to reduce the errors produced during the manufacturing or service process, increase customer satisfaction, streamline supply chain management, aim for modernization of equipment and ensure workers have the highest level of training Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Management philosophy derived mostly from the Toyota Production System (TPS) Implement scientific manufacturing management (Tylorism) Applications Applications Applications Applications Standards TQM Automation Productivity Process, System, Materials Plant integration Upstream processes Downstream processing business process or business method Production integration The first level of industrial usability was reached Numerous applications of AM are success business cases Modeling, permanent continuous performance advances are required Applications Applications 15

16 Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation Part prices (AM vs. Injection) in function of complexity $ / part Traditional Manufacturing complexity for free Additive Manufacturing complexity for free Traditional DFM (Design for manufacturing) AM Design DFF (Design for Functionality) Source: inspire - irpd Complexity 16

17 Economics behind conceivable future volumes built with AM Technology (SLS). Example Part: Cost [T ] Only 20% of the material is in the parts Motorcycle accessory: Lifetime: 5 years Volume: Manual finishing required to bring surfaces up to standard for a visible part Number of parts TQM a must for results and confidence in AM 17

18 Fact is that for AM the results depend on: Process / Technology dependent Material dependent Geometry dependent Application dependent System maturity and Equipment maintenance dependent Age and equipment generation dependent Operator skills and experience AM is reproducible and reliable only under equal well controlled standardized conditions The bottlenecks in AM are the challenges RP RM AM USE Design Materials Finish Components 18

19 The AM Field and Research Opportunities and Efforts Part type have different primary requirements and standards! Decorative surface structure Functional accuracy Structural properties Source Road Map ALM 2009 D. Bourell et al. Medical biocompatible The wide ranging applications and requirement is a great challenge for manufacturing. Can a universal systems cover it? Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation 19

20 Applications arrays divide and focus consequently on different quality issues and standards Positioning for plastic part AM manufacturing Quantity high Complexity XXL XL IM L medium IM M IM cutting LM AM S cutting LM AM MI low XS low medium high Size Positioning for plastic part manufacturing: AM - Addetive Manufacturing; MI - Micro Injection; IM - Injection Moulding (Source: Levy G.N.iRPD) 20

21 AM direct metal components production relative to usual options PM - Sintering Die Casting MIM Quantity Cutting Investment Casting Layer Addtive Manufacturing 10 0 Low Medium High Geometric Complexity (Source: Meyer E.B., Levy G.N.) Global Adoption Of The Technology - Application Presentation Models 7.8% ( 8.1%) Education/Re search 7% (5.4%) Tooling Components 2.7% (3.1%) Other 1.8% (2.9%) Direct Part Production 19.2% (14.9%) Patterns For Metal Casting 8.9% (8.6%) Visual Aids 10.1% (12.0%) Functional Models 18.4% (19.3%) Fit And Assembly 12.1% (13.3%) Patterns For Prototype Tooling 12.2% (12.3%) Source Wohlers Report

22 Art and Interior FOC 22

23 3DP made Consumer goods will it be successful? 23

24 Various SLS Ducting, Panels and Covers for F/A-18E/F Manufactured by ODM Boeing Dreamliner SLS manufactured Polyimide air ducts (FR 106) Functional design Easy to maintain 24

25 No-Tool production plastic - small parts Series: Material: 520 parts/year PA12 SLS made glass pearls blasting Pries: EUR / 520 part Delivery: 3 days ( from Data) AM PA12 case Conformal cooling systems and heat exchanger A great chance is coming up in moulds! 55 25

26 AMZ Silverstone Racing July 2010 ( with 21 flying SLM parts) Segmented impeller Source :irpd 26

27 Medical device advanced complexity Topology of Bio- Device Manufacturing Patient specific? Patient matched Use in operation theater Use outside operation theater Non-degradable Degradable Non-degradable Degradable Medical and biomedical application Body External (non-clinical) Body internal Temporary (clinical) Body internal Permanent (clinical) Op Theater Instruments Surgical forceps Surgical guides Scalpels OP support Jigs Prosthesis Systems Reconstructive prosthetic Dental crown bridges application Scaffolds Clinical suture Degradable screws and plates Drug delivery systems Hip implant Knee implant Inter verbal spacer Cardiac pacemaker Retinal implants Dental implants Non-degradable Non-degradable Degradable Non-degradable 27

28 Customization patient matched SLS made cutting template My Knee Supporting SLM made Implants (Stainless or Titan) Source :irpd SLM Parts 28

29 DENTAL (orthodontic, alignments, copings, bridges, implants) Data AM User 3DP SLA SLS SLM ALIGN TECHNOLOGY INC. SLA parts per day 29

30 Medical and Life Science a promising future MCP Dr. Anthony Atala (USA) : 3D Printing of Body Parts Institute for Regenerative Medicine in North Carolina 30

31 Technology accomplished allows to build implantable body parts 8 th July Logistics and supply chain mangment Production on Demand 31

32 AM options in lightweight structures Lightweight functional steel part Additive SLS and Composite: no-tool forming Composites Busch SLS Micro Parts also as actuators SMA (shape memory alloy) and ceramics 32

33 The impact of the DirectSpare concept Warehouses stacked with spare parts... Ordered spare parts transported around the globe... Millions of unused spare parts being reduced to scrap... Obsolete equipment because of unavailability of spare parts becomes useful Bio inspired AM fabricated systems 33

34 Added Value: Translate process characterization into specific applications Freedom of Design Lightweight structures (hollow) No-Tool production Assemblies, integrated design Anatomical personalized Ergonometric design Customization individualization Conformal cooling Gradual materials (on the way) Medical scaffolds (on the way) Bio Materials (on the way) Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation 34

35 Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation EBM Arcam MultiBeam 35

36 Up-and-coming Production AM Systems The 80`s trends in machining is repeating for AM Production oriented design Automation starting point, load unload ease Removable transportable work areas (cylinder, vat etc) Resin regeneration and recycling Production oriented control More process and system control in modern SLS, SLA and SLM equipment Adaptive control, on-line calibration Closed loop position controls Closed loop laser power controls Closed loop temperature control Reporting Search for efficiency and productivity [Watch e.g. PRO & EOS System, Prometal S systems, Conceplaser M3] Continuous Additive Manufacturing 36

37 3DP Continuous Additive Manufacturing SLM - Machine size categories Very large > 100 Mid range Small dedicated <1 37

38 Das Bild kann zurzeit nicht angezeigt werden. China 2013 $80 million investment in AM An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China. Courtesy of Guancha Zhe. AM scaffold manufacturing in tissue engineering Cell seeded scaffolds A scaffold in tissue engineering serves as a temporary skeleton to accommodate and stimulate new tissue growth Allow cell attachment, proliferation and differentiation; Deliver and retain cells and growth factors; Enable diffusion of cell nutrients and oxygen; Enable an appropriate mechanical and biological environment for tissue regeneration in an organised way 38

39 Bio-M dedicated equipment - Biocell Printing all in one system implementation Scaffold printing stage Scaffold sterilisation chamber Scaffold bioreactor PhD Work of Marco Domingos Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation 39

40 Feedback control of Selective Laser Melting P. Mercelis, J.P. Kruth, J. Van Vaerenbergh Department of Mechanical Engineering, University of Leuven, Celestijnenlaan 300B, Leuven, Belgium Agenda I 1. Background 2. Scientific Manufacturing Management 3. Analysis and Synthesis for AM Economics The workflow bottle necks TQM Total Quality Management TPM Total Productive Maintenance 4. Application Driven 5. Systems, Monitoring and Materials Performance (productivity, repeatability, accuracy) Materials (Plastics, Metals, (Ceramics, Biomaterials)) Automation 40

41 Layer Manufacturing RP - Prototyping - Concept modelers Patterns RM - Manufacturing components RT - Tooling inserts Direct Indirect Plastics Metal Ceramics Composite Design Models Parts Parts Parts Parts Functional Models Long-term use Long-term use Long-term use Long-term use Tooling Long-term use Tooling Long-term use Electrical - Aviation - Medical - Thermoforming Injection molding - - Fiber Molding Die casting - - MIM, CIM The structures of biomaterials for AM Source :irpd 41

42 Interaction manufacturing process material Performance Cast Traditional processing Non Traditional processing Additive processing Thermal chemical micro AM (e.g.bea (e.g. AM AM Forming Cutting cutting Electrical Biologic m Phtopoly Chemical Thermal Forming al Energy) mer) Properties Bulk (wire, powder liquid) Preform Structure Atom Molecule Electron Elementary particle SLS - Thermoplastics polymers (Red= tried for SLS) Polymer material choice advances ; EOS PP, irpd 42

43 SLM - materials options Stainless steel CL 20ES ( ) Hot-work steel CL 50WS ( ) CL 60DG ( ) CL 90RW ( ) Aluminum CL 30AL ( AlSi12 ) CL 31AL ( AlSi10Mg ) Titanium CL 40TI ( TiAl6V4 ) Nickel-based alloy CL 100NB ( Inconel 718 ) x-y Scanner Laser Laser Beam Levelling System Window Inert Gas Metal Powder Part Laser Beam Part Powder Retractable Platform Some trends and challenges in AM Materials research Filled Materials Multi material Local alloying Digital Materials Gradual Materials Designed Anisotropy Designed local property Optimized metallurgical structures Ceramics and composite Medical and Biomaterials Nano Materials Micro parts Memory shape alloys in AM 43

44 9. Gradable materials (on the way) CF process allows to customise the tibial component of a total knee implant, that fits the individual anatomy of the patient improving stability of the artificial knee joint 100% Ti 100% CoCr Automated designed tibial baseplate Graded CoCr Ti materials Take CT scan of tibia bone Customise material grading to fit individual patient physiology 3DP Digital Materials 100% Material A 75%:25 % 50%:50 % 25%:75 % 100% Material B Source: SFF 2012, Daniel Dikovsky, Ph.D. 44

45 Agenda II 6. Pre- /Post Processing Upstream Processes Downstream Processes 7. Business Model Key users: Experimental validation and certification Mainstream users: Service Bureaus Modern users: E- Shopping (online / on site) 8. Conclusions Design for AM e.g. Potential in der Aero industries 45

46 SLS Material selection data base I Young Modulus v/s Elongation SLS Material selection data base IV Tensile Strength v/s Density 46

47 Design considerations on Laser Cusing and for the EBM process Design considerations on Laser Cusing and for the EBM process 47

48 Topological Optimizations Topological optimized design results are: Complex geometries Conventionally not produce able Have to be smoothed Chances for Layer Manufacturing: Highest geometrical freedom Agile manufacturing New design concepts ATKINS Project: a low-carbon footprint manufacturing solution The 2.7 Million ATKINS Project 48

49 Post processing options for functional and visual parts enhancements Enhancement by finishing A. Surface roughness B. Aesthetic C. Functional functional no surface treatment SLS parts coating how to do it? surface refining man made machine made visual/aesthetic water-tight -repellent chemical resistance laquere finish film finish flock finish pressure/ vac. tight wear resistance how to do/proof it? UV-/ light protection powder coating vapor C/PVD Best in Class - SLM parts Polishing 49

50 Engineered surfaces - Engineered Trabecular Structures The material can incorporate integrated Trabecular Structures and Engineered Surface Porosity (ESP). This enables design for osseointegration and reduces the number of process steps in manufacturing. Pictures of bone growing into titanium implants with Engineered Surface Porosity, manufactured in the EBM process. Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg, and ARCAM SLM HIP Hot Isostatic Pressing 50

51 SLM post heat treatments Agenda II 6. Pre- /Post Processing Upstream Processes Downstream Processes 7. Business Model Key users: Experimental validation and certification Mainstream users: Service Bureaus Modern users: E- Shopping (online / on site) Others? 8. Conclusions 51

52 Around 30 AM Systems SLA SLS Harvest Technologies, which was started by David K. Leigh and his father David E. Leigh out of their barn, celebrated the opening of its 40,000 square foot facility 17 M270 und 1 M280 SLM Anlagen The company that was created, Rapid Quality Manufacturing (RQM), has as its entire focus and business model the creation of highervolume production parts using DMLS and other additive fabrication technologies. Greg Morris, CEO, Morris Technologies, Inc. Headquarters: Cincinnati Ohio, United States Revenue: $3 Million Employees: 75 52

53 Shapeways is a spin out of the lifestyle incubator of Royal Philips Electronics Agenda II 6. Pre- /Post Processing Upstream Processes Downstream Processes 7. Business Model Key users: Experimental validation and certification Mainstream users: Service Bureaus Modern users: E- Shopping (online / on site) 8. Conclusions 53

54 We are on the right track Conclusions The sustainability will be a mayor issue for all of us The implementation of Scientific Management (Taylorism) is a must Hybrid systems are in due Productivity, Automation and quality enhancements are a permanent issue New application driven manufacturing tasks coupled with product innovations are just around the corner. Interdisciplinary and complexity are increasing Additive Manufacturing Processes are a great challenge and chance in manufacturing 5 years to go! The scientific AM community has to be involved 54

55 Personalized Construction of a CUBESAT using AdditiveManufacturing Additive manufacturing The sky is the limit! 55

56 Conclusions by Albert Einstein The formulation of a problem is often more essential than its solution, which may be merely a matter of mathematical or experimental skill. The process of scientific discovery is, in effect, a continual flight from wonder. All meaningful and lasting change starts first in your imagination and then works its way out. Imagination is more important than knowledge. Albert Einstein 56