Fabrication additive par procédé de fusion laser sur lit de poudre :vers la production de série. Confidentiel

Transcription

1 Fabrication additive par procédé de fusion laser sur lit de poudre :vers la production de série Dr. Stéphane Abed CEO

2 Part 1 : Our company Part 2 : What is our understanding of Additive manufacturing? Part 3 :Evolutions of the process (Larger, Better, Faster) Part 4 :New design for new performances

3 Part 1 : Our company 24 employees dedicated to direct manufacturing since 2007 (30 at the end of 2014) Located around Paris (500 m2) and Salon de Provence (1500 m2) Turn-over 2013 : 65 % exportation Poly-Shape SAS Aerospace and Engine parts production ISO 9001:2008 and EN 9100:2010 Poly-Shape SAS Medical, Aerospace and Engine parts production ISO 9001:2008, EN 9100:2010 EN :2003

4 Our organisation

5 Our technology : Powder Bed Additive Manufacturing (Laser or Electron Beam melting) Direct Laser Forming Applying new powder layer Melting by Laser 3D-CAD Model in layers New geometries out of serial metallic materials Standard Metal Powder Lowering of Build Platform

6 Our technology : Additive Manufacturing (Selective laser and Electron Beam melting) Use of standards materials Layer-by-layer manufacturing Tool Steel Stainless Steel Titanium alloy Aluminum alloy Nickel Based alloys Actually 18 different materials

7 Our Metal division : Concept Laser Xline ARCAM Q20 EOS M280 Trumpf DLF250 EOS M270 04/ / / / / / / / /2014 Concept Laser M2 Concept Laser M1 SLM Sol. 280HL SLM Sol. 500

8 Our EBM equipment : the new Q20 from ARCAM The largest in the market, higher productivity, better surface quality TA6V Diam 350 mm and 380 mm high New PRS

9 Our Polymer division : 9 machines for plastic parts SLA SLS for production SLS for development SLA for production

10 Our Quality department Internal Control laboratory

11 Our post manufacturing equipments : several TTH ovens 5 axes CNC..

12 Our Quality department Certifications : EN ISO 9001 : 2008 EN ISO : 2004 EN ISO 9100 (March 2014) And Several Customer Qualifications (Aerospace, Medical, motorsport, )

13 Part 2 : What is our understanding of additive manufacturing? Our definition : Simultaneous creation of a near net shape component, material microstructure and properties through layered addition of material

14 What is our understanding of additive manufacturing? To qualify you need : -Understanding in the material science -Understanding in the process -Understanding in the design rules

15 Part 3 : Evolutions in the process

16 Twin laser system Higher productivity : reduce the cost and faster delivery

17 Higher productivity for serial production needs machines with 2 lasers simultaneously : Higher productivity : reduce the cost and faster delivery

18 Quad laser system Higher productivity : reduce the cost and faster delivery

19 Higher productivity for serial production needs machines with 4 lasers simultaneously : Higher productivity : reduce the cost and faster delivery

20 Durée de production : 48h

21 Quality control on each layers : Picture of the powder bed On and off line control

22 Part 2 : Large parts and high productivity Our Xline 1000 R machine : Only 5 in the world (one at Daimler and one at SNECMA for exemple)

23 Our Xline 1000 R machine :

24 Our Xline 1000 R machine :

25 Our Xline 1000 R machine :

26 Our Xline 1000 R machine : 5 Large Aluminium Parts for Aerospace application Total Melted volume : cm3 Production time : 108 h

27 Part 4 : New design for new performance Using special CAD software based on FEA and free form additive manufacturing technologies offers new opportunities for new performances

28 Industrial cases Motor sport Aerospace Medical Small series production Very complexe geometry Ligth weigth parts, integration of functions, Short delivery time Manufacturing of complex geometries Manufacturing costs independent from shape complexity Ligth weigth parts, integration of functions, Manufacturing of individual implants directly from CAD-data Reduction of manufacturing times and improvement of medical characteristics

29 Motor sport Optimisation of the steering wheel attachment using topological optimisation - material: aluminium - Integrated nut lock and steering angle sensor attachment - Mass reduction = 56 % (128g)

30 Motor sport Optimisation of the suspension Rocker (TA6V) using topological optimisation The part is in the ENIM Formula Student car since this year

31 Poly-Shape in the aerospace and aeronautical Aerospace 53 flying metal parts in the neuron since December 2012

32 Aerospace Weigth reduction in an Helicopter part Different designs for different loading cases

33 Medical Poly-Shape in the medical Manufacturing of bone-like structures with SLM for implantology Ligthweight customised implant Material : TA6V

34 Conclusion Additive manufacturing process gives new opportunities Added value can be in a better buy to fly ratio, new performances, higher flexibility of the supply chain or reduction of NRC for example. To use efficiently this new manufacturing process a deep and total understanding is needed (Design, Material and process) One Risk is to believe that this is just a «push buton» 3D printing process Those process can be qualify for critical parts applications

35 Thank you for your attention! AddiCtive Manufacturing!