Industrialization of Additive Manufacturing Phil Hatherley, General Manager, Materials Solutions A Siemens Business
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1 Industrialization of Additive Manufacturing Phil Hatherley, General Manager, Materials Solutions A Siemens Business Siemens AG 2018 All rights reserved. Materialssolutions.co.uk
2 Additively manufactured and tested gas turbine blade in Alloy 247 major breakthrough
3 3D printing Additive Manufacturing.. Different solutions for different challenges Hybrid additive Directed energy deposition Multi-axis Fused deposition modeling Powder bed fusion Laser material fusion Multi jet fusion Agent jetting/ inkjet technology
4 Additive Manufacturing game changer for manufacturing industry across all sectors Industrial Metal 3D printing is becoming a reality Combination of end to end digital & physical thread offers key differentiator Industrialization happening from hobby to real industry
5 Trend 1: Metal 3D printing is becoming a reality Impacting the Product Lifecycle Rapid prototype for actual application LRIP ready Innovation, cost out, customisation Reduce Extend Secure
6 Trend 1: Metal 3D printing is becoming a reality Design for AM Burners H² capability Emissions Spare parts on demand 6 months leadtime reduction SGT 9000HL - ACE combustion system Improved lifetime 12 1 parts hrs repaired parts 2016 Commercial OPs Nox reduction Massive ramp-up in Siemens AM Business Development of new Business Models Enabled by AM serial parts
7 Trend 2: End to end digital & physical thread turning into key differentiator PLM Software Automation Engineering & Manufacturing NX PBF Module with integrated topology optimization and lattice structure generation New generation AM machines being equipped with automation systems from Siemens SGT-400 turbine blade designed for AM, printed and successfully tested Additive Manufacturing Network: Let us connect the eco-system AM Consulting: Let us accelerate your industrialization
8 NX One integrated Additive Manufacturing Solution From requirement driven Generative Design to 3D Printing 1 - Product design 2 - Production planning Requirements Generative Design Adaption Performance Validation Manufacturing Validation Pre-Processing & 3D Printing Part Finishing & Quality Data and Process Management
9 Trend 3: Industrialization happening from hobby to real industry SIEMENS Power & Gas as leading user of AM 40+ printers EXPERIENCE in high-temp metals Alloy 247 Wide-range of Ni / Ti / Maraging Steels Large MATERIALS DATABASE 100,000 hrs ENGINE experience on Siemens GTs 100+ engineers Focused on DESIGN, R&D and MFG + = Materials Solutions leading AM service provider Siemens 9000HL parts A world first! SGT 400 B1 >1500 rig/test parts Adv. combustion designs Ni based parts Ti-light weight structurals Other industry applications / Tooling SIEMENS enables Industrialization 1. Broad Range of qualified Materials and Processes 2. 2 Applied Design for AM knowhow 3. 3 Proven end to end process and quality control 4. 4 Right first time via digital twin, powered by Siemens NX 5. 5 Proven AM Serial Components 6. 6 Effective global service centre footprint Imagine how the industrialization of AM can unlock business potential in your company 1
10 The Materials Solutions story
11 The Materials Solutions Journey 2006: Materials Solutions Founded by Carl Brancher Nov 2008: First customer approval Rolls Royce Jan 2008: ISO 9001 certified May 2010 AS9100 Customer/ quality approvals continue Jan st M400 installed outside EOS 2016 SGT1000 Burner insert first fully qualified AM component in customer engine xx First EOS 2 nd M270 installed M installed 3 rd EOS M270 installed Move to GWBP Worcester 3 machines 7 Employees M270 fleet up to 6 machines 2017 SGT LC blade 1 WvS award Aug 2016 Siemens completes acquisition 2015 Conversion to Ltd company & Siemens shareholding Old faithful
12 Current production and materials processing capabilities M4XX machines 2 EOS M400 1 EOS M400/4 M2XX machines 7 EOS-M270 1 EOS-M280 6 EOS-M290 Difficult to weld Nickel Superalloys CM247LC In738LC C1023 MAR M002 Ferrous alloys SS 17-4 SS 15-5 SS 304 SS 316L Duplex 2205 Maraging Steel M300 Readily weldable Nickel Superalloys Hastelloy X C263 In625 In718 In718+ Haynes 230 Cobalt alloys CoCrMo Titanium alloys Ti 6/4 Aluminum alloys (under development) One of the largest Commercially available Metal AM Printer fleets in the world
13 Proven track record in PowerGen, Aerospace & Automotive makes us a trusted technology & supply chain partner Siemens Power Generation Burner Repair & Components SGT700/ part 30,000hrs engine hours each Aerospace Automotive Spare Parts on Demand SGT1000F Burner Head 6 months lead time reduction hrs engine hours SGT400 Blade 1 1,250 Gas, 1,000 mph 11 tons pull 18 3 months technology validation Hours Engine Experience Aero Applications Ni-High Temp, > 1,500 rig parts Light weight structural parts Advanced combustion designs Hydraulic manifold for front landing gear depployment Tooling for engine block manufacturing Material: M300 (Steel) Structural Parts Titanium: light weight structural parts High strength stainless steels Other Tooling, Motorsports Differentiation through materials and customer references
14 No matter where you are on your AM journey Siemens can provide value adding services Part identification Materials & Processes Design & Engineering Manufacturing & Factory Production and Post-Processing AM Parts feasibility Material design and print process Development services Licensing Design for AM Reverse Engineering Functional Engineering 1) Production requirements Material handling and EHS Certification support AM production consulting Manufacturing Services First off development parts Rig/tests parts in low volume Spare parts on demand Low rate initial production Serial production Key success factors Applied design for additive manufacturing Material and process expertise Material assurance and process certification Connected digital and physical thread end2end with Siemens PLM applications 1) Future offer
15 Showcasing the Siemens AM End2End Factory of the Future Flexible AM cell approach (M290/ M400 cells) Printing and post processing all under one roof Gravity fed powder solution Future proof flexible approach (room for automatic inventory movement/ robotics) Capacity to maintain production and R&D Siemens NX for AM and other software applications
16 To industrialize the processes must be in Control In order to industrialize AM, increase productivity and reduce cost the journey needs to continue in control Continued understanding of the manufacturing process Continued understanding of the material properties AM is currently at the top of the opportunities pyramid. Quality controlled systems Increase focus on production for AM machines Standardisation Opportunities Continued education (DFAM)
17 To understand, apply and industrialize AM you need understanding, application and control challenging Yes, but with fantastic opportunities!
18 Siemens is a world leader in applied Additive Manufacturing Materials Solutions A Siemens Business is open for business opportunities in aerospace, automotive, motorsports, tooling industry and other applications within O&G manufactures prototypes and small series offers also high quantity serial productions of metal AM components plans to expand its global footprint to become an active player in North America Siemens invests 27 Mill in a new state-of-the-art production facility in Worcester (UK) to support the industrialization of AM gets ready for true serial production provides an end-to-end portfolio fully powered by Siemens Digital Enterprise pioneers the industrialization of AM and demonstrates its leading position realizing the fourth industrial revolution
19 Contact Us Phil Hatherley General Manager, Materials Solutions Limited Kendra Rauschenberger Business Development, Materials Solutions Limited Materials Solutions Limited Unit 8, Great Western Business Park. McKenzie Way, Worcester, WR4 9GN, UK
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