Factory of the Future; Additive Manufacturing Jon Porter Business Development AMSC
About Renishaw World leading metrology & engineering company A FTSE 250 company with headquarters in United Kingdom Advancing operational performance Transforming manufacturing efficiencies and raising product quality Maximising research capabilities Improving medical procedures and patient outcomes
Renishaw worldwide Turnover 436.6M 16% re-invested in R&D 35 Countries 4,286 employees
Inspection & process control solutions Gauging Process control CMM inspection
Motion control and calibration solutions Machine calibration and performance monitoring Position encoders
Healthcare solutions Robotic neurosurgical systems
3D printed medical implants Dental restorations Neuro drug delivery system Maxillofacial implants
Industrial additive manufacturing solutions Concept to realisation Design for AM Process validation Process capability
Value creation Commitment knowledge Levels of Additive Manufacturing deployment New product designs that 1. Deliver lifetime benefits in use 2. Provide mass customisation DfAM optimised Complex parts that simplify assembly & enhance reliability Part consolidation Re-production parts, that avoid complex manufacturing Direct part replacement Low volume parts made direct from CAD Rapid prototypes & tooling
Unique AM capabilities Repeatable CNC process Conformal cooling Rapid prototypes & tooling
Unique AM capabilities Near-net-shape manufacture Localised manufacturing Direct part replacement Rapid prototypes & tooling
Unique AM capabilities Feature-rich parts Removal of joints Mechanisms Part consolidation Direct part replacement Rapid prototypes & tooling
Unique AM capabilities Light-weight structures Topological optimisation Increased surface area DfAM optimised Part consolidation Direct part replacement Rapid prototypes & tooling
Unique AM capabilities Heat transfer Metal foams Build the B.O.M. Customisation DfAM optimised Part consolidation Direct part replacement Rapid prototypes & tooling
Summary Direct part replacement Adapt for AM Design for AM 12/14/2016 Slide 16 Version Mass (kg) Saving Direct part replacement 4.6 - Adapt for AM 1.0 78% Design for AM 0.4 91%
Industrial AM essential requirements High part performance Automated manufacturing Consistent part quality Safe & sustainable Strong process economics Future-proof technology
New RenAM 500M Designed for series production Advanced laser processing Stable processing environment Automation and ergonomics Powerful process development & reporting tools Integrated process solutions
Optical system Optical system with 500 W laser Fully Renishaw designed and engineered 500 W ytterbium fibre OEM laser Dynamic focusing Prepared to adopt both on- and off-axis sensing technologies
Dual SafeChange filtration system Dual high capacity SafeChange filter system The intelligent control system actively senses the condition of the filter and automatically redirects the gas circuit to the clean filter before the process conditions deteriorate The user is then alerted to change the filter cartridge following the correct safety procedures of wetting the filter to render the process emissions inert Enables builds to be run for long periods Stable and controlled atmosphere
Powder re-circulation cycle 1. Powder is loaded into the hopper at waist height 3 2. All powder from the hopper is sieved ultrasonically 3. Sieved powder is transferred pneumatically to the dosing silo 4. Powder is dosed and spread across the build plate to create the subsequent build layers 1 5 4 5. All un-melted powder is transferred back into the load hopper to continue the cycle 2
Ultrasonic sieve Ultrasonic sieve All powder from the load hopper is sieved ultrasonically before transfer to the dosing silo Ultrasonic vibrations prevent the sieve from blinding Any oversized powder will be removed from the bulk and pneumatically transferred to a separate vessel within the RenAM 500M system
19 inch touchscreen user interface 19 inch user interface Capacitive touchscreen Based on a Windows operating system with a dedicated user interface Large icons show the build set-up workflow for ease of navigation through the various process steps
Z-axis Z-axis Incorporating a high accuracy Renishaw RESOLUTE linear encoder for a precision build
QuantAM build preparation software Designed for Renishaw AM platforms.stl geometry import Part orientation & support structures Material development module Duplicate, orientate & position multiple parts Rapidly geometry and laser tool path review Review discrete laser exposures within each slice
AM Solutions Centres Try before you buy: develop your product and process, acquire knowledge, build your business case Global network of centres providing facilities, machines, post-processing and engineering support
Renishaw Solutions Centre for Additive Manufacturing
Solutions Centre services Concept embodies AM benefits Benchmark part: benefits tangible Optimise process & verify part Demonstrate process stability AM & finishing processes to make saleable product
Integrated manufacturing capabilities Support removal Heat treatment Machining CMM inspection Build plate removal Surface treatment Polishing Gauging
AOB Multi-laser Enlarged build area Lightweight materials Aluminium v titanium
Thank you