Hybrid Machining: The Intersection of Metal Removal and Additive Technologies

Transcription

1 Hybrid Machining: The Intersection of Metal Removal and Additive Technologies

2 PRESENTERS Mike O Donnell Senior Engineer The Robert E. Morris Company Jeff Holtzapple Business Development Manager - Additive Manufacturing Morris Group, Inc. Wade Anderson Product Specialists Sales Manager & Tech Center Manager Okuma America

3 THE ROBERT E. MORRIS COMPANY Founding division of Morris Group, Inc. Headquarters: Windsor, Connecticut Services Provided: Applications Engineering, Machine Tool Service and Maintenance, and Financing States with Distribution Rights: Connecticut, Massachusetts, Maine, New Jersey, New Hampshire, New York, Rhode Island, Vermont

4 OKUMA AMERICA Product Configurations: Vertical and Horizontal Machining Centers, 5-Axis Machines, Multi-Function CNC Lathes, Double-Column Machining Centers, CNC Grinders, Flexible Manufacturing Systems, and CNC Controls Super Multitasking Machines Laser Metal Deposition Laser Hardening Wade Anderson Product Specialists Sales Manager Tech Centers Manager Okuma America Corporation Westhall Drive Charlotte, NC 28278

5 New Technologies Creating a new Standard for Manufacturing in a Rapidly Changing World

6 120 Years of Metal Cutting Excellence 1898 Noodle-Making Machine 1914 First Patent for: Automatic Gear Cutting Lathe 1918 Started Producing Metal Working Machine Tools

7 Changes happen at amazing rates

8 Changes happen at amazing rates 1985 F150 4,400 LBS 2 People (3 maybe) 2018 F150 5,400 LBS 5 People 150 HP V8 14 MPG Avg 282 HP V6 22 MPG Avg

9 Changes happen at amazing rates

10 Changes happen at amazing rates OKUMA Laser EX Series

11 Extreme Multi-Tasking

12 Changes happen at amazing rates Laser Metal Deposition Part modification Part reinforcement Cladding functional surfaces Corrosion protection Wear resistance Part repair Structure generation

13 Changes happen at amazing rates LASER HARDENING Bearing diameters Splines Wear edges

14 LASER HARDENING Where will technology take you?

15 DESKTOP METAL Founded: 2015 Products and Materials: Studio System 3D Metal Printer, Production System, MIM (Metal Injection Molding) Start-to-end 3D Metal printing Mass producing 3D Metal printing Jeff Holtzapple Morris Group, Inc. Business Development Manager Additive Manufacturing Desktop Metal 63 Third Avenue Burlington, MA 01803

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17 Desktop Metal was founded in 2015 by leaders in advanced manufacturing, metallurgy, and robotics to make metal 3D printing accessible for engineering and manufacturing.

18 $1 trillion Metal parts produced by top ten manufacturing countries Metal 3D Printing $1B

19 Metal printing 3D has barely scratched surface. for prototyping. the It s too industrial and expensive It s not fast enough or lowcost enough for mass production.

20 Two metal 3D printing systems covering the full product life cycle from prototyping to mass production.

21 3D Printing Applications Rapid prototyping Part consolidation Complex geometries Customization On-demand manufacturing Supply chain re-engineering Rethinking product lines and designs Small, nimble manufacturers can now compete High-Volume Production

22 Leveraging Proven Technology Metal Injection Molding (MIM) $3B Market 30+ years of industrial applications 200+ alloys characterized Adapted FDM (Fused Deposition Modeling) to make metal 3D printing accessible for engineering & manufacturing

23 MIM Mix metal powder + binder into feedstock The Process Affordable Mold (requires tooling) Debind Sinter Studio System DM Studio System Feedstock Print (no tooling) Debind Sinter Powder Bed Fusion $- $200,000 $400,000 $600,000 $800,000 $1,000,000 $1,200,000 Printer Support equipment Facility, Operators, Installation, training, etc.

24 Overview Two systems to cover the full product lifecycle Primary Use Print Technology Environment Prototyping + Lowvolume production Bound Metal Deposition (BMD) Offic e Media MIM Bound Metal Rods Mass productio n Single Pass Jetting (SPJ) Industri al MIM Powder

25 Desktop Metal Studio 10x cheap er

26 Competitive costper-part

27 SUMMARY Key differences between LMD and FDM/BMD LMD used to add metal to an existing part FDM/BMD is used to make a part from scratch Applications best suited for each LMD- part repair, cladding, surface hardening and part modification FDM/BMD- rapid prototyping, non-machinable geometry New developments to look forward to LMD- Ultra High Speed for coating and corrosion protection 3D Printing- Single Pass Jetting (SPJ)

28 LEARN MORE AT BOOTH #351 Thank You! See a prototype created on the Studio System and then finished on the GENOS M460V-5AX See other live cutting demos on Okuma and Tsugami machine tools integrated with advanced Tooling, Accessories, Software, Automation and more. Network with your peers and some industry experts to learn about the latest technology