ProMetal Rapid Manufacturing

Transcription

1 ProMetal Rapid Manufacturing Rapid Metal Casting for Defense Applications CTMA 2005 Jeffrey McDaniel

2 ProMetal Rapid Casting Technology Introduction Technology Applications

3 In the News: ProMetal A Division of ExOne Corporation March Larry Rhoades announces formation of Ex One Corporation Divested Extrude Hone finishing business (Abrasive Flow Machining) to Kennametal Ex One retains emerging manufacturing process technologies Ex One strengthens position as manufacturing technology integrator: ProMetal Direct Metal ProMetal RCT SoneX ultrasonic machining MetreX metrology products ECX electrochemical machining and micro-machining Impact Innovative Products for advanced body protection ExOne R&D

4 ProMetal Triad Equipment Materials Rapid Manufacturing Contract Production

5 ProMetal Technology Based on Three Dimensional Printing Developed at MIT ProMetal holds exclusive and non-exclusive rights to metal and ceramic 3D Printing patents Enables rapid manufacture of metal parts and casting molds directly from CAD data Achieve very complex parts and molds Internal geometries Molds with integral cores

6 ProMetal Processes Option 1 Direct Metal Printing 1. Convert 3D CAD data to 2D slices 2. 3D print metal powder into porous metal preform 3. Thermally process metal powder 4. Finish machine Option 2 Rapid Casting Technology 1. Convert 3D CAD data to 2D slices 2. 3D print foundry binder into permeable casting media 3. Remove unprinted media from mold/core 4. Cast

7 ProMetal Printing Process 1. Spread layer of metal or pre-mixed quartz sand 2. Selectively dispense binder using inkjet printing technology 3. Cure & spread next layer Repeat steps 1-3 Extract and prep part Sinter or Cast...

8 Rapid Manufacturing Equipment S x750x700 mm

9 ProMetal RCT

10 ProMetal RCT Casting Materials Aluminum (Automotive, Prototyping) A356 Copper Alloys (Marine, Bearings, Fittings) Brass Bronze Aluminum bronze Monel Ferrous Alloys (Automotive, General purpose) Grey Iron Ductile Iron Steel

11 ProMetal RCT: Casting Innovation Conventional Production Workflow idea drawing pattern mold 1 = mold 2 = mold 3 = mold n cast part 1 = cast part 2 = cast part 3 = cast part n

12 ProMetal RCT: Casting Innovation Digital Production Workflow No pattern required and multiple, unique molds can be produced at the same time

13 ProMetal RCT Defense Applications Legacy Systems Sand casting molds and castings Functional prototype parts Series production

14 ProMetal RCT Defense Applications Future Systems Functional prototypes Low volume production Series production Research Development

15 ProMetal RCT: Casting Innovation CAD drawing Potential Time Savings CAD mold design production pre-processing pattern-production Pre-processing Tool Mfg mold Cast part cast preparation Cast part 5 days 17 days Time (labor days)

16 ProMetal RCT S15: Specifications Binder content: < 2% by weight Max. dimensions: 1500x750x700 mm (59 x 29 x 27 in) Layer thickness: Part strength: Build speed: mm > 300 N/cm² 1 layer / minute = mm / h

17 AMCast Manufacturing Supports DoD Casting Requirements NUWC Keyport (Keyport IDIQ N ) Engineering services Part design CAD modeling ExOne-ProMetal casting services Re-engineering: 27 Piece assembly reduced to one

18 Application: Automotive Intake Manifold Data Preparation and Part Layout = 1 hour Build Time for two Intake Manifold Core Packages = 14 hours Part Cleanup and Extraction =1 hour

19 Application: Automotive Intake Manifold

20 Application: 4-Cylinder Engine Molds/Casting Data Preparation and Part Layout = 1 hour Build Time Single Block Core Package = 33 hours Part Cleanup and Extraction = 1 hour

21 Application: Single-Cylinder Head Prototype

22 Application: Pump Housing Conventional manufacture would require at least 14 cores plus and associated tooling

23 Application: Turbo Charger Mold and Core design Print Time (4 mold sets) Core and Mold clean/prep Foundry pour (A356) 2.0 days 14.0 hours 1 hour 1 day

24 Application: Automotive Intake Restrictor Mold and Core design Print Time (4 mold sets) Core and Mold clean/prep Foundry pour (A356) 1.5 days 5.5 hours 1 hour 1 day wall thickness

25 Application: Air Pressure Device Fabrication time: 6 hours

26 Application: Static Turbine Blade 500 mm Four Castings in 48 hours

27 Illustration: Short run production Faucet Core 204 mm Up to 435 cores in S15 build volume 204 mm

28 Illustration: Simultaneous production

29 Illustration: Pump Impeller

30 Illustration: Customization Serial Numbers

31 Illustration: Large Molds

32 Summary ProMetal offers: Manufacturing Equipment Service Materials ProMetal technologies: Reduce lead time Increase productivity Enable impossible geometries AMCast AMCast POC: Kyle Morris

33 Future Possible project topics : Titanium Magnesium Shell castings Complex mold design Permeable casting media development Binder system development

34 Thank You Knotted Gear - Oskar van Deventer jeffrey.mcdaniel@ex-1.com