Agenda. Introduction Drivers 10/26/16. Metal Additive Manufacturing. 25 oktober 2016, Gavere

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1 Metal Additive Manufacturing 25 oktober 2016, Gavere 1 Agenda Learn from yesterday, live for today, hope for tomorrow. The important thing is not to stop questioning. - Albert Einstein - Introduction Drivers 2 1

2 Increase the competitiveness of companies of the Agoria sectors through technological innovations Sirris 25+ years of Additive Manufacturing Team of 20 independent experts More than 10 additive technologies in house Most complete installed base in EU 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 Moving printhead Photo-polymerisation/ cooling Acrylates / epoxies / wax Material extrusion Fused deposition moddeling Material melted in a nozzle Binder jetting 3D Printing / Z-printing Binder jetted on powder bed Continious extrusion and deposition Layer of powder Drop on demand binder 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 BINDER JETTING thre3d.com Layer of powder is spread Local binder depositioning on demand Post curing & infiltration needed with metals Polymers / metals / ceramics / sand TECHNOLOGIES: COLORJET / PRO-METAL / SANDPRINTING 7 BINDER JETTING APPLICATIONS Jason Rapid Jeff Swensen for USA TODAY Uasvision i.materialise.com 3Dsystems 8 4

5 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 9 DIRECT ENERGY DEPOSITION APPLICATIONS Conocimientoslaseramplifiers industrial-lasers.com thre3d.com 10 5

6 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 / 11 POWDER BED FUSION APPLICATIONS Materialise nwrapidmfg.com Renishaw i.materialise.com 3DSystems 12 6

7 10/26/16 Agenda Introduction Drivers Learn from yesterday, live for today, hope for tomorrow. The important thing is not to stop questioning. - Albert Einstein

8 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 16 8

9 DRIVERS FOR ADDITIVE MANUFACTURING material efficiency / light weight structures What If we can use material, only there where needed 17 Helicopter frame Original (7) parts 530g 7 parts 3 materials Design volume Optimised structure 392g 2 parts 1 material 18 9

10 DRIVERS FOR ADDITIVE MANUFACTURING Flow optimization What If we can create complex channels inside our products 19 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 20 10

11 DRIVERS FOR ADDITIVE MANUFACTURING Integration of functions What If we can add multiple functionalities in one part 21 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 22 11

12 summer 2015 edition sirris /06/ DRIVERS FOR ADDITIVE MANUFACTURING mass customization What If we can start a serieproduction where each part is slightly different 24 12

13 Hearing aids phonak Invisible 100% custom made / perfect fitt / more comfotable > stuks 25 NOW it s YOUr turn material efficiency - light weight structures flow optimalization integration of functions mass customization 26 13

14 NEED HELP? WANT TO GET STARTED? GET IN TOUCH! STIJN LAMBRECHTS #sirris 14