Selective Laser Melting at its best, brought to you by.

Transcription

1 Selective Laser Melting at its best, brought to you by. Dr.ing. Voicu MAGER INCAS, mai

2 1. The company 2

3 Welcome to the North! Lübeck, Deutschland, N, O, MEZ Germany s city of science in 2012! 3

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5 5 SLM Solutions Group is already operating in key industries Selected blue chip customers Aerospace Automotive General Electric Global Research Aviation General Electric Aviation Healthcare Energy General Electric Energy Alstom Siemens BMW Airbus Innovation Works (EADS) NASA SLM Solutions Group has exposure to attractive end markets and has longstanding relationships with blue chip customers The market continues the shift from rapid prototyping to industrial applications SLM Solutions Group is well positioned to capitalise on this trend given SLM Solutions' technology and customer base BEGO More than 60 universities and research institutes Polyshape Citim Fruth 5

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7 2. The history 7

8 SLM Solutions Group and its predecessors have a history of innovation Basic Research F&S Stereolithography GmbH, Trumpf GmbH and Fraunhofer Institute for Laser Technology (ILT) Fockele & Schwarze (F&S) research leading to IP with today more than 30 own patents and applications 2002 F&S/SLM Solutions (a) partner to develop, produce and market the SLM Technology to industrial requirements 2003 Launch of first Fibre Laser technology with the MCP SLM Launch of SLM 100 as an entry model 2007 Launch of the 400 Watt technology 2009 Launch of the new SLM 250 HL World Wide cross license agreement with Trumpf, EOS and Fraunhofer ILT 2011 Launch of SLM 125 HL and SLM 280 HL with hull and core (400W & 1000W) technology and 3D laser technology 2012 Introduction of SLM 500 HL and the multi laser technology 2013 Launch of SLM 500 HL with additional automated powder handling devices 8 (a) In 2002 SLM Solutions Group was known as MCP. MCP changed its name to MTT Technologies Group in MTT Technologies GmbH was renamed into SLM Solutions GmbH in 2010

9 SLM Solutions Group a deep rooted 3D printing heritage SLM 280 HL SLM 125 HL Hull Core technology SLM 500 HL Multi laser technology & automated powder handling devices 2013 Drive industrial application of 3D metal based printing technology 2014 onwards SLM 250 HL 2011 First company to process aluminum and titanium 400 Watt technology Fibre Laser technology 2006 Development of SLM technology 2003 Rapid prototyping Since 1970 Note: History of SLM Solutions Group and its predecessors 9

10 3. The technology 10

11 Productivity of selective laser melting (SLM) Quality Build part Time Cost 11

12 Powder fed fusion: SLM process 18 12

13 Metal based 3D printing is for industrial applications direct part manufacturing Selective Laser Melting is a disruptive technology with significant potential to drive the evolution of manufacturing processes 3 13

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15 Data preparation for the SLM-machine a) Decide on orientation /.stl Dataset b) Generate support structures c) Cut the part in even slices digitally (slicing) d) Generate the Laser operation info (hatching) 15

16 Accuracy 16

17 SLM Solutions Group s technology covers the most relevant metals... Aluminium Cobalt-Chrome Inconel Titanium Tool Steel and Stainless Steel Material Properties Light weight Good alloying properties Good processability (casting and pressing etc) Good electrical conductivity High toughness High strength Good bio-compatibility Good corrosion resistance High corrosion resistance Excellent mech.strength High creep rupture strength up to 700 C Outstanding weldability High strength, low weight High corrosion resistance Good bio-compatibility Low thermal expansion Good machinability High hardness and toughness High corrosion resistance Good machinability Applications Alloys Aerospace Automotive General industrial applications AlSi12 AlSi10Mg AlSi7Mg AlSi9Cu3 AlMg4,5Mn0,4 Other Materials on request Dental Medical implants High temperature Aerospace Gas turbines Rocket motors Nuclear reactors Pumps Turbo pump seals Tooling Co212-f acc to ASTM F75 Inconel 625 Inconel 718 Inconel HX (2.4665) Bio-material for implants Aerospace F1 motor sport Maritime applications Pure titanium Ti6Al7Nb Ti6Al4V Grade X materials on request Plastic injection and pressure diecasting moulds Medical implants Cutlery and kitchenware Maritime Spindles and screws (316L) (H 13) (15-5PH) Other Materials on request Propeller for racing boats as scaled model for flow measurements Dental caps and crowns in cobalt-chrome Turbine blade of latest generation with internal conformal cooling channels to improve performance of jet engines Individual Hip Implant in Titanium made for an Australian patient Mould inserts with integrated, surface conformal cooling channels. Photo with kind permission of Gardena AG 17

18 4. The products 18

19 SLM Solutions German engineering with a global reach Key products International sales split RoW 7.7% US 16.9% Germany 32.9% SLM 125 HL SLM 280 HL International revenues: 67.1% Total 2013: 21.6m EU ex Germany 20.0% Asia/ Pacific 22.5% SLM 500 HL 7 19

20 New 400 Watt Laser! SLM 125 HL Products SLM 280 HL Up to 2x 400 Watt Lasers simultaneously! Produces highly complex metal components using fine metal powders from 3 D CAD-data files Patented bidirectional loader movement offers a safe filter system and highly efficient protective gas consumption due to internal recirculation of inert gas at laminar flow Offers software to process CAT / STL-data files as a standard feature which is also used for slicing and support generation Can process most metals. Stainless Steel, Tool Steel, Cobalt-Chromium, Inconell, Aluminum and Titanium have been processed successfully already System Parameters Build Chamber in mm (x/y/z) 125 x 125 x 125 (75) Laser Power 400 W, YLR-Faser-Laser Build Speed 15 ccm/h Pract. Layer Thickness 20 µm 75 µm Min. Scan Line / Wall Thickness µm Operational Beam Fokus variable 70 µm 120 µm Dimensions in mm (B x H x D) 1350 x 1900 (2400) x 800 Weight Circa 700 kg Provides a build chamber of 280 x 280 x 350 mm and an excellent double beam technology. This will improve not only the laser beam profile but also the quality factor of components New bidirectional loader movement, field-proven, latest software does support a production-oriented data preparation for specific applications and highly optimised building processes Covers a wide range of metals. Stainless Steel, Tool Steel, Cobalt- Chromium, Super Alloys, Aluminum and Titanium have been processed successfully already System Parameters Build Chamber in mm (x/y/z) 280 x 280 x 350 Laser Power 400 / 1000 W, YLR-Faser-Laser or dual 400 W Build Speed (a) 20 ccm/h / 35 cm/h Pract. Layer Thickness (a) 20 µm 75 µm / 150 µm Min. Wall Thickness 150 / 1000 µm Operational Beam Focus µm / 700 µm Dimensions in mm (B x H x D) 1800 x 1900 (2400) x 1000 Weight Circa 1000 kg 20 (a) Depending on material, position of the component geometry

21 Products SLM 500 HL Up to 4 x 400 Watt Lasers simultaneously! Build chamber of 500 x 280 x 325 mm and excellent double beam technology. Each of the two fibre lasers ( W) operate on the powder bed by a 3D scanning unit. Two of these units are working at the same time The transport of metal powder is done by a continuous conveying system. This automates the management of powder and eliminates the manual handling of loads with bottles and containers The system does offer a leading software in rapid prototyping. Magic AutoFab, to process CAD/STL-data files as a standard feature which is also used for slicing and support generation System Parameters Build Chamber in mm (x/y/z) 500 x 280 x 325 Laser Power 2 x 400 W, optional 2 x 1000 W YLR-Faser-Laser or 4 x 400 W Lasers Build Speed (a) 70 ccm/h Pract. Layer Thickness 20 µm 200 µm Min. Scan Line / Wall Thickness µm Operational Beam Fokus µm / 700 µm Dimensions in mm (B x H x D) 3000 x 2000 (2500) x 1100 Weight Circa 2000 kg 21

22 Double- Beam Technology 22

23 Maximum build-up speed in cm³/h 3 Illustrative build-up speed and resolution of selected powder bed fusion systems (a) High EBM Build speed advantage due to multi laser technology Functionality Speed Surface finish Accuracy Low Low Resolution (b) High Performance 23 (a) Based on 2012 Wohlers report (b) Measured by layer thickness Source: CODEX Partners, company estimates

24 SLM 500 HL with PSX500 powder handling and PRS 500 New PSX continuous powder supply unit! 24

25 5. Target aerospace 25

26 World air traffic over 24 hours!!! 26

27 Leading industrial companies see the potential of metal based 3D printing GE quotes: By 2020 GE Aviation will manufacture more than 100 additive parts for the GE9X engines. In the next 5 years we will invest more than 3.5 billion US$ in new equipment to produce advanced components. Complexity comes for free Additive manufacturing is just a great game changer! Note: Statements by General Electric,

28 How much additional costs per Kg does the industry accept for weight reduction? Aerospace projects ,- per Kg Aircraft design 1.000,- per Kg Automobile industry 100,- per Kg 28

29 Examples Hydraulic valve housing in wing Postmanufactured partmade of Titanium alloy Courtesy Uni Chemnitz, Airbus, Liebherr aerospace 29

30 Topologically optimized aero bracket Original design Height 342mm Material: Al and Ti Build time for two parts: 41:23h Re-designed aircraft bracket Courtesy of LZN-Hamburg-Germany 30

31 Industrial revolution: complexity! Weight No. of components -25% Fuel nozzles for Jet Engines 5x -95% x18 Durability Quelle: GE Aviation GE believes that ~450kg weight reduction per aircraft engine can be achieved through 3D direct manufacturing 31

32 Yes, it can be Rocket science! 32

33 6. Target medical 33

34 Building up dental bridges in high accuracy 34

35 Industrial revolution: cheaper! -70% Costs 35

36 SLM CASE STUDY MEDICAL HIP IMPLANT Acetabular cup for Hip repair Courtesy of Royal Perth Hospital 36

37 7. Target automotive 37

38 SLM CASE STUDY AUTOMOTIVE Results 3D optical measurement Automotive heat shield ALUMINIUM! As first tests with exhaust system detected the need of additional shielding Part: Automotive heat shield L: 285,17mm H: 192,78 mm B: 160,92 mm V: cm³ Complex Aluparts was just printed out in SLM -machine in complex shape 38

39 Large Structures and Designs Re-designed automotive front axle part Height 320mm Material: Al Build time: 88 h 39

40 Tire mould production with SLM Design and build mould segments easily Very thin details possible Material: Al, Steel Fast build time! 40

41 8. Target tooling 41

42 Industrial revolution: faster! Cooling channnels Cycle time - 30% 42

43 Injection mould for GARDENA garden tool Advantages SLM production of tool insert Reduction of cycle time by 35 % Ideal design of size, form and function of cooling channels Conformal cooling in tool insert Quality improvement of injection moulding Finished inserts for tool 43

44 Vă mulţumesc!