Agenda. Introduction Drivers AM in mould technology 10/23/17. Additive Manufacturing voor matrijzenbouw. 23 oktober 2017, Sint-Niklaas

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1 Additive Manufacturing voor matrijzenbouw 23 oktober 2017, Sint-Niklaas 1 Agenda Learn from yesterday, live for today, hope for tomorrow. The important thing is not to stop questioning. - Albert Einstein - Introduction Drivers AM in mould technology 2 1

2 Increase the competitiveness of companies of the Agoria sectors through technological innovations Sirris AM-team Since experts 10+ technologies in house Metals, polymers, ceramics 2

3 DEFINITION ADDITIVE MANUFACTURING Layer by layer Functional end products with excellent mechanical properties Starting from a 3D CAD model Metals Polymers Ceramic Freeform complexity for free Few design restrictions No moulds, no tooling Down to series of 1 Near net shape Sustainable Materialise Rapid Prototyping Rapid Manufacturing Direct Digital Manufacturing 3D Printing Additive Manufacturing AM 5 CONDITION ASTM classification PROCES LAY-OUT LAYER FORMING PHASE CHANGE MATERIALS LIQUID Vat photopolymerisation Material jetting Stereolithography Digital light processing Polyjet Liquid resin in a vat, irradiated by UV light through a laser Liquid resin in a vat, irradiated by UV light through a projector Droplets of photopolymer, irradiated by uv light or cooling Liquid layer deposition Photo-polymerisation Acrylates / epoxies / filled resins Liquid layer deposition Photo-polymerisation Acrylates / epoxies / filled resins Photo-polymerisation/ Moving printhead Acrylates / epoxies / wax cooling Continious extrusion and Material extrusion Fused deposition moddeling Material melted in a nozzle deposition Layer of powder Drop on demand binder Binder jetting 3D Printing / Z-printing Binder jetted on powder bed deposition Directed energy deposition Lasercladding Powder injection through nozzle in laser spot Continious powder injection Solidification by cooling No phase change of powder, solidification by binder Powder melting by laser Solidify by cooling (Filled) Polymers / wax Ceramics / metals / polymers / sand Metals / composites Direct metal laser sintering Powderbed in chamber of inert gas, sintered through laser Layer of powder Powder sintering and re-solidification by cooling Metals (limited) POWDER Selective laser melting Powderbed melted through laser Layer of powder Powder melting solidify by cooling Metals (limited) Powder bed fusion Electron beam melting Powderbed in chamber of inert gas, melted through electron beam Layer of powder Powder melting by electron beam solidify by cooling Non-ferro metals Selective laser sintering Powderbed sintered through laser Layer of powder Powder melting by laser solidify by cooling Polymers Selective heat sintering Powderbed sintered by thermal printhead (IR) Layer of powder Powder melting by heat solidify by cooling Polymers VAST Sheet lamination Laminated object manufacturing Feeding, cutting and binding of sheets Deposition of sheet material Binding by phase change of solder, glue or others Paper, polymer, metals, composites, ceramics 6 3

4 LIQUIDS MATERIAL JETTING Chemical thre3d.com Droplets of build and support material out of inktjet printhead Photopolymer= expoxy or acrylate Immediatly cured by UV light Supports = other material Plastics / electronics TECHNOLOGIES: OBJET / AEROSOL JET 7 LIQUIDS MATERIAL JETTING APPLICATIONS Objet i.materialise.com i.materialise.com 8 4

5 LIQUIDS MATERIAL EXTRUSION Thermal thre3d.com Thermoplastic polymer wire Melted and extruded through a heated nozzle (sausages) Deposited on previous layer or preheated build platform Polymers / composites TECHNOLOGIES: FUSED DEPOSITION MODDELING / 3D PLOTTER / HOME PRINTERS 9 LIQUIDS MATERIAL EXTRUSION APPLICATIONS Stratasys Makezine RapidPSI i.materialise.com i.materialise.com 10 5

6 DIRECT ENERGY DEPOSITION thre3d.com Powder injected in a heat source (EB, laser, ) Powder melting by laser, solidify by cooling Metals / composites TECHNOLOGIES: ELECTRON BEAM DIRECT MANUFACTURING / ION FUSION FORMAT LASER POWDER FORMING 11 DIRECT ENERGY DEPOSITION APPLICATIONS Conocimientoslaseramplifiers industrial-lasers.com thre3d.com 12 6

7 POWDER BED FUSION thre3d.com Layer of powder is spread Powder is locally melted by laser or IR source Solidified by cooling Polymers / composites TECHNOLOGIES: SELECTIVE LASER SINTERING / SELECTIVE HEAT SINTERING / SELECTIVE LASER MELTING / LASER BEAM MELTING / ELECTRON BEAM MELTING / 13 POWDER BED FUSION APPLICATIONS Materialise nwrapidmfg.com Renishaw i.materialise.com 3DSystems 14 7

8 Agenda Learn from yesterday, live for today, hope for tomorrow. The important thing is not to stop questioning. - Albert Einstein - Introduction Drivers AM in mould technology

9 Drivers Flow improvements Integration of functions Shorter time to market Mass customization Miniaturization Internal channels Freeform complexity for free Few design restrictions No moulds, no tooling Down to series of 1 Near net shape Sustainable Unique parts Prototyping Weight reductions Create metamaterials Less waste Shorter R&D cycles sirris info@sirris.be Product DRIVERS material efficiency - light weight structures flow optimalization integration of functions mass customization 18 9

10 DRIVERS FOR ADDITIVE MANUFACTURING material efficiency / light weight structures What If we can use material, only there where needed 19 Helicopter frame Original (7) parts 530g 7 parts 3 materials Design volume Optimised structure 392g 2 parts 1 material 20 10

11 DRIVERS FOR ADDITIVE MANUFACTURING Flow optimization What If we can create complex channels inside our products 21 Heat exchanger cm³ vs 244 cm³ 19.2 kg vs 1,2 kg 210 mm vs 85 mm 750 vs (112 parts) Pressure drops 90% reduced 22 11

12 DRIVERS FOR ADDITIVE MANUFACTURING Integration of functions What If we can add multiple functionalities in one part 23 Jet engine nozzle Source: GE 25% lighter - results in significantly less fuel consumption! From 18 parts to 1 5 times more durable; no brazes and welds, less maintenance = more flying 24 12

13 summer 2015 edition sirris /06/ DRIVERS FOR ADDITIVE MANUFACTURING mass customization What If we can start a serieproduction where each part is slightly different 26 13

14 Hearing aids phonak Invisible 100% custom made / perfect fitt / more comfotable > stuks 27 Agenda Learn from yesterday, live for today, hope for tomorrow. The important thing is not to stop questioning. - Albert Einstein - Introduction Drivers AM in mould technology 28 14

15 DeSter Flat mould + 2-sided tape Moulds as printed + center pins sirris info@sirris.be Mould inserts 15

16 Mould inserts Cycle time: 43 % Conformal cooling Famous companies applying conformal cooling: ØTupperware ØRowenta ØLego Ø ETMM, May 2014 sirris info@sirris.be 23 October

17 Key Take Aways SUCCESS is in the design AM will not replace all traditional manufacturing technologies but AM can disrupt your business model Lessons learned 1 RESPONSIBLE for AM Task = find out what AM can bring to company. Involves colleagues where needed and gets official support. DO IT Make a (re)design of a component, together with an experienced party Low hanging fruit can be found in your production facility Result Get familiar with the technology Get confidence in the technology Get your colleagues involved 17

18 NEED HELP? WANT TO GET STARTED? GET IN TOUCH! STIJN LAMBRECHTS #sirris 18