Industrial Additive Manufacturing
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- Norma Golden
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1 Industrial Additive Manufacturing Importance of Standardization Unrestricted GPDIS_2017.ppt 1
2 Oh how far we have come GPDIS_2017.ppt 2
3 Design for Additive Manufacturing Traditional and new design workflows supported From Traditional Prototyping Design Prepare Make TO Scan to print Scan Simulate Modify Make Optimize to print Design Optimize Validate Make GPDIS_2017.ppt 3
4 Opportunities abound Individualization Product Optimization Manufacturing Efficiency Business Models Courtesy of Materialise LIMITLESS FREEDOM: Individual part design one-offs Personalized products implants, shoes, car parts Scan - repair repair of non digital parts LIMITLESS CONTROL: Weight reduction light-weight structures topology optimized geometries Functional optimization complexity for free Systems instead parts Reduce number of parts LIMITLESS AGILITY: Part reduction product simplification Low series lot size 1 Finished products printed as assembled LIMITLESS OPPORTUNITY: Inventory reduction zero inventory On-demand product availability Supply chain optimization GPDIS_2017.ppt 4
5 Shift from conventional design to enterprise DFAM Product transformation Optimizing Paths for AM Scan modify print Lightweighting Assembly simplification Functional performance optimization Multi-material parts Digital materials Advancing Products Impacting Business Individualization Replacement parts / digital inventory Accelerate innovation cycles Design anywhere. Print anywhere. Repair parts Supply chain restructuring / shrinkage Status quo Advancing Manufacturing Manufacturing transformation Eliminate castings Eliminate injection molding Rapid manufacturing aids Checking / tool fixtures Composite part printing Low volume (lot size of one) Multi-material parts Shift from prototyping / experimentation to mainstream industrial production GPDIS_2017.ppt 5
6 How do you achieve Industrialization? Smart model-driven process Design Simulate 3D Print Data Management and Shop Floor Connectivity Siemens Production Software and MES Systems Partnerships GPDIS_2017.ppt 6
7 Design for AM Advancing Products Generative design using topology optimization Design with Convergent Modeling TM Lattice structures Design rules for manufacturability GPDIS_2017.ppt 7
8 Design Evaluation Product performance simulation Validate optimized designs Generate simulation models to validate convergent body Access all validation and editing tools in one environment GPDIS_2017.ppt 8
9 Changing the face of Manufacturing Advancing Manufacturing Powder bed fusion Multi jet fusion Drive additive manufacturing technologies for real production Integrated post-printing machining and inspection programming Hybrid additive Multi-axis FDM GPDIS_2017.ppt 9
10 General Climate for AM Today Customer Requirements CAD CAE CAM AM Machine Post Process Finishing Quality Assurance Product Print Process Q Material Conventional thinking Multiple data conversions Uncontrolled workflow Disconnected software Certification GPDIS_2017.ppt 10
11 Moving from Prototype to Production DESIGN AND ANALYZE PLAN AND MANUFACTURE PART REQUIREMENTS MANUFACTURING REQUIREMENTS INTEGRATED PRODUCT DEVELOPMENT DOCUMENTATION DESIGN DECOMPOSITION PART FILE PREPARATION FEATURES & SETUP DEFINITION DEPOSITION STRATEGY SECONDARY OPERATIONS ADDITIVE PLANNING TOOLPATH GENERATION ADDITIVE OPERATIONS MULTI-AXIS SLICING DIRECTLY ON MODEL SEQUENCING MACHINE ENVIRONMENT COLLISION, REACHABILITY & SINGULARITY DETECTION MACHINE SIMULATION POST CAM TO CONTROLLER ROBOT TO TABLE SYNCHRONIZATION TOOLPATH TO ROBOT PATH CREATION PLANNING AND SCHEDULING PRODUCTION EXECUTION PRINT PART VALIDATE PART SCADA MANUFACTURE CAD/CAE/CAM MACHINE CONTROL and MONITOR DATA, PROCESS AND MANUFACTURING OPERATIONS MANAGEMENT GPDIS_2017.ppt 11
12 What can happen without comprehensive control? GPDIS_2017.ppt 12
13 Holistic Approach Product Manufacturers Design Engineering / Optimization Cloud-based, open IoT operating system Print Preparation Finishing & Quality System Engineering Process Sim & VC Throughput Optimization Security & Quality Machine Control Data Analytics Operation / Execution (MOM/MES) Co-innovation ecosystem Collaboration platform Security & Quality Machine design & simulation Virt. commissioning Machine Control Data Analytics Machine Builders Simulation Machine commiss. Automation engineering GPDIS_2017.ppt 13
14 Digital Enterprise GPDIS_2017.ppt 14
15 AM Eco-system A global, digital collaboration platform for distributed, industrial additive manufacturing (AM) and co-innovation solutions Our digital platform links together an ecosystem of product developers, experts, manufacturers, 3D printing machine OEMs, AM material vendors and software providers Micro-factories and job shops Machines co-innovating Engineering community Software providers Expert service s Our digital platform provides a secure, transparent and automated process from idea to finished-part delivery Equipment vendors Part buyers Materials GPDIS_2017.ppt 15
16 The Digital Twin Cloud-based, open IoT operating system feed back insights to continuously optimize product and production Digital Twin of the product the product Digital Twin of Digital Twin of the production the production Digital Twin of the the performance GPDIS_2017.ppt 16
17 Predicting Build Issues Courtesy of Sciaky Distortions Defects Build failure Local over-heating GPDIS_2017.ppt 17
18 Predictive DfAM SAMCEF Multiphysics Macro-scale Residual Stresses Distortions Meso-scale Over-heating Meltpool morphology Porosities Powder distribution Micro-Scale GPDIS_2017.ppt 18
19 Case Study on Inconel 718, SLM process Distortion calculation has been performed, based on effective values of multilayer shrinkage Diameter from CAD : 133mm Measured Distortion : 0.4mm Simulated distortion : 2*0.19=0.38mm GPDIS_2017.ppt 19
20 The journey to Industrialized AM Customer Requirements CAD CAE CAM AM Machine Post Process Finishing Quality Assurance Product Print Process Q Material Conventional thinking Multiple data conversions Uncontrolled workflow Disconnected software Certification GPDIS_2017.ppt 20
21 Begins with collaborative development Customer Requirements CAD/CAE/CAM PLM Data Management Manufacturing Operations Management ERP Order Parts Part and Process G1 X1.1 Y4.2 G1 X2.5 Y GPDIS_2017.ppt 21
22 Extends into Machine Integration Customer Requirements CAD/CAE/CAM PLM Data Management Manufacturing Operations Management ERP Order Parts Part and Process G1 X1.1 Y4.2 G1 X2.5 Y AM Machine Print Process 2 Material Handling 1 GPDIS_2017.ppt 22
23 Followed by Post Operations Customer Requirements CAD/CAE/CAM PLM Data Management Manufacturing Operations Management ERP Order Parts Part and Process G1 X1.1 Y4.2 G1 X2.5 Y AM Machine Post Process Finishing Print Process 2 3 Material Handling 1 GPDIS_2017.ppt 23
24 Lastly the certification process Customer Requirements CAD/CAE/CAM PLM Data Management Manufacturing Operations Management ERP Order Parts Part and Process G1 X1.1 Y4.2 G1 X2.5 Y AM Machine Post Process Finishing Quality Assurance Print Process 2 3 Q1 Q2 Q3 Q Products Material Handling 1 GPDIS_2017.ppt 24
25 All together comprises an Industrialized Approach Customer Requirements CAD/CAE/CAM PLM Data Management Manufacturing Operations Management ERP Order Parts Part and Process G1 X1.1 Y4.2 G1 X2.5 Y AM Machine Post Process Finishing Quality Assurance Print Process 2 3 Q1 Q2 Q3 Q Products Material Handling 1 GPDIS_2017.ppt 25
26 What can help us get there? A focus on standards Nadcap - provides independent certification of manufacturing processes for the industry ASTM - Subcommittee F42.05 on Materials and Processes 3MF Data Analytics for Mfg ISA-95 for AM GPDIS_2017.ppt 26
27 Standards Drive Design and Manufacture ASTM - Subcommittee F42.05 on Materials and Processes 3MF Data Analytics for Manufacturing ISA-95 for AM Topology Optimization Simulation Generative Design Mixer GPDIS_2017.ppt 27
28 Design for Additive Manufacturing Traditional and new design workflows supported From Traditional Prototyping Design Prepare Make TO Scan to print Scan Simulate Modify Make Optimize to print Design Optimize Validate Make Generative Design System Generated Design Validated Make GPDIS_2017.ppt 28
29 Let s not be this guy GPDIS_2017.ppt 29
30 Thomas Hoffman Sr. Enterprise Engineer R&D Siemens PLM Software Thank You! GPDIS_2017.ppt 30
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