LEICHTBAU. Additive. Manufacturing

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1 LEICHTBAU Additive Manufacturing AM

2 The process ELiSE AM: of dimensioning additive manufacturing components We present you the potential of ELiSE AM by using the example of the innovative folding cycle Bionic Bike. 2

3 ELiSE AM for your product ELiSE Leichtbau is a unique bionic product development process for superior lightweight design solutions. In our projects, we enable weight reductions of more than 50 % as well as cost-effective material substitutions, great performance increase and we develop improved products by functional integration. ELiSE Leichtbau is not sector dependent and also independent of the material and manufacturing processes to be used. Deploy ELiSE AM to successfully develop your product in additive manufacturing. With ELiSE AM, you exploit the full potential of additive manufacturing and of the bionic structural optimization of ELiSE Leichtbau in equal measure. By this means, we achieve the freedom to realise products that could not be put into practice so far.. Is AM of interest for me? If one or more of the following items is true for your product, a closer lk at the possibilities of additive manufacturing is worthwhile: Weight reduction and lightweight design are important factors for my product My product consists of many single parts. I can exploit cost advantage by functional integration into one component. Without restrictions in the production process, my product would lk different. Many tls are necessary because of the great individualisation of my product A lot of time passes before a new construction is manufactured I produce in small quantities or my product has very small geometric measurements. 3

4 Additive manufacturing Status Quo Support structures Component Definition the terms additive manufacturing, 3D printing or generative manufacturing processes are terms of wide comprehension for the layered manufacturing of components. Construction platform Manufacturing in selective laser melting (SLM) by citim GmbH Urheber citim GmbH 4

5 Additive manufacturing develops into a new core technology that complements existing processes. Due to continuously sinking costs, the market share of additively manufactured products steadily increases. The possibility to additively manufacture components enhances the functionality and the performance of technical solutions. With the costs still being higher for now in comparison with conventionally manufactured products, it is essential to consider the conditions of additive manufacturing already when beginning to develop the product. To use the benefits of additive manufacturing, such as the considerably greater freedom of shaping, in an economically efficient way, a product development is required that takes into consideration the capabilities of the process to be used. The production process The 3-dimensional part is formed by additive joining of material layers. Varied processes for materials like plastics, resins, ceramics and metals are now available. For example, selective laser melting (SLM) proceeds as follows: 1. Product design as 3D data which is appropriate for manufacturing process and material 2. Fractionation of the 3D data set into fine layers 3. Layer-by-layer construction of the final product from the powder bed 4. Heat treatment to improve the material properties (optional) 5. Mechanical postprocessing to remove support structures Distributer Mirror Component Laser Support structures Powder Store chamber Pressure chamber Construction platform 5

6 ELiSE AM develops cost efficient hi-tech components for additive manufacturing. Development with ELiSE AM Functional integration LED-lighting We are convinced that better products are developed by means of a close intertwining of design and simulation. The Bionic Bike shows the result of the ELiSE product development process, where classic engineering methods are combined with bionic developing tls: Topology optimization to determine optimal load paths Parametric optimization on the basis of evolutionary algorithms to design the ideal frame geometry with adaptable shapes of cross sections and wall thickness CAO to reduce notch stresses Structural stiffening by use of adaptive beam structures in highly loaded sections inside the structure Integration of bionic principles, modelled on the lightweight design of diatom shells Functional integration Cable duct Connecting joint based on the model of diatoms 60% weight reduction 6

7 Bionic Bike was developed using the patented ELiSE product development process. L E I C H T B A U Complex bionic edge stiffening concepts based on the model of radiolaria Manufactured using selective laser melting (SLM) by citim GmbH Load specific cross sections and wall thickness. Asymmetry for homogenic load distribution Complex bionic connection concepts based on the model of diatoms Stiffening lattice structues at highly loaded spots 7

8 Adaptive lattice structures for load-specific stiffening Additive manufacturing provides hitherto unparalleled freedom in shaping. At the same time, it offers the possibility to selectively adapt hollow structures to local loads. These sections can be stiffened with loadspecifically designed lattice structures. Algorithms specifically developed for this purpose are available in ELiSE AM. For instance, the Bionic Bike benefits from this stiffening method by the use of adaptive lattice structures in the sector of the highly loaded bottom bracket. Free combination of inner stiffening structures and outer boundary surfaces Alignment of struts into one principle direction for the anisotropic stiffening of main load paths 8

9 Your benefits A closer examination of additive manufacturing shows many advantages that your products may benefit from: Usage of adaptive lattice structures for load-specific stiffening Exploitation of the whole potential of bionic structural dimensioning with ELiSE Leichtbau Patented product development process for best optimization results Freedom in the design of highly optimized structures Lightweight design in a new dimension No tl cost Cost reduction through functional integration and reduction of the number of single parts Flexible Just-in-time Fertigung Quickly ready for the market Individualised products and variants Adaptive fineness of lattice structure to flexibly design the grade of stiffening 9

10 Our Service: Innovative product development ELiSE AM for your product development Eventually, there is a limit to the optimization potential of continuously improved components. With ELiSE Leichtbau, we take up at exactly this point. ELiSE Leichtbau consists of ELiSE Concept and ELiSE Engineering. With ELiSE Concept, we generate radically new concepts along the lines of nature, setting new standards for your product, realising completely new ideas, and exploring unconventional solution processes. With ELiSE Engineering, we offer you a wide range of engineering services. A strong coupling of design, simulation and optimization is an excellent basis for being able to develop efficient and customized lightweight design solutions. In cperation with you, we refine your existing products or use the radically new concepts of ELiSE Concept as a starting point for the product development. With ELiSE AM, we finally ensure that the boundary conditions and possibilities of additive manufacturing are taken into consideration in the bionic product development process ELiSE Leichtbau. The modular structure of ELiSE Leichtbau enables us to perfectly customise any project to your individual needs. 10

11 Concept Engineering Manufacturing Additive Manufacturing Parametric Optimization Parametric Optimization FE-Analysis Optimization Level Recommendation FE-Analysis FE-Analysis CAD Topology- Optimization CAD ELiSE Screening Topology- Optimization Contact us for a noncommittal project offer Technical specification Technical specification Technical specification Technical specification S M L Your project 11

12 Bionic Bike. Developed with ELiSE AM. Dr. Christian Hamm Alfred - Wegener - Institut (AWI) Bussestraße 27, Bremerhaven Mail: christian.hamm@awi.de Fon: Web: