Chancen und Grenzen von 3D-Druckern in der industriellen Produktion

26 th of November 2013 Chancen und Grenzen von 3D-Druckern in der industriellen Produktion Prof. Dr. Reinhart Poprawe, M.A. Lehrstuhl für Lasertechnik RWTH Aachen University Fraunhofer Institut für Lasertechnik, Aachen

Facts and Figures of Fraunhofer ILT and RWTH Aachen University LLT, TOS, NLD About 30 Mio. operating budget (without investments) About 5 Mio. investments per year More than 300 current projects for industrial partners per year About 400 employees ILT, 150 RWTH-Chairs DQS certified according to DIN EN ISO 9001 2 branches abroad: - Center for Laser Technology CLT - Coopération Laser Franco-Allemande CLFA One patent application per month on average Approx. 1 spin off per year, 30 in last 25 years

Digital Photonic Production Eine Industrielle Revolution? Kosten Kosten konventionelle Produktion konventionelle Produktion Losgröße Produktkomplexität

Digital Photonic Production Eine Industrielle Revolution? Individualisation for free Individualisation for free Kosten Kosten laserbasierte Fertigung laserbasierte Fertigung konventionelle Produktion Digital Photonic Production Losgröße Digital Photonic Production konventionelle Produktion Produktkomplexität Laserstrahl Bewegungsrichtung des Laserstrahls umgeschmolzene Schicht Schmelzbad Pulverschicht SLM 1-3 cm 3 / min LMD 10-30 cm 3 / min Ablation 0,2-0,5 cm 3 / min

Digital Photonic Production Eine Industrielle Revolution? Individualisation for free Individualisation for free Kosten Kosten Digital Photonic Production Digital Photonic Production konventionelle Produktion konventionelle Produktion Losgröße Produktkomplexität

Digital Photonic Production Eine Industrielle Revolution? Individualisation for free Individualisation Complexity for for free free Kosten Kosten Digital Photonic Production Digital Photonic Production konventionelle Produktion konventionelle Produktion Losgröße Produktkomplexität Innovative Geschäftsmodelle

Digital Photonic Production Lightweight Construction Kosten Individualisation Less Complexity weight less for for free cost free Digital Photonic Production Conventional Production Weight reduction Coherent objectives

Digital Photonic Production Bits to Photons to Atoms Using light as a tool means highest power density highest speed shortest interaction (precision) mass-less, force-less, no tools best controllability (CAD to product)

Digital Photonic Production Example Selective Laser Melting

Selective Laser Melting Basic principle Deposition of a powder layer Melting of the powder by a laser beam 3D-CAD model in slices Novel geometries of serial-materials Powder Lowering

Third Industrial Revolution Production 2.0 The Economist, Februar 2011 The Economist, April 2012

Worldwide first ILT Industrial Application: SLM Dental Restaurations Application reconstruction of single teeth Process steps: preparation model digitalization design (CAD) manufacturing (DLF) control of model ceramic cover Production start: Nov. 2002 In cooperation with BEGOmedical AG

First SLM Hip Cup bone substitude implants with mesh structure out of TiAl6V4 Conventional manufacturing not possible Improvement of bone-implant interaction Hip cup manufactured at ILT implanted in January 2008

Current Research Topics Various Materials: SLM of ceramics Ceramic materials Zirconium-based ceramics Density approx. 100% First demonstration parts manufactured Current R&D-focus: Avoidance of micro-cracks

Current Research Topics Various Materials: Bio Resorbable Bone implants Composite material Stent Bio resorbable stent from PDLLA Medtronic

Current Research Topics Construction Design Optimizing Weight and Functionality Airbus A320 Nacelle Hinge Bracket Weight reduction by 64% 918 g 326 g Source: Altair, EADS Innovation Works

Current Research Topics Productivity: Process Speed Deposition rate Since 2003 : Industrial state-of-the-art unchanged at approx. 1.2 mm³/s 15 14 13 12 Deposition rate [mm³/s] Since beginning 2007: Increase in deposition rate up to approx. 9 mm³/s (experimental set-up) 11 10 9 8 7 2008: Installation of demonstration machine 6 5 4 2009: Further increase of deposition rate up to min. 12 mm³/s by using higher laser power (up to 1 kw) 3 2 1 1997 2000 2003 2006 2009 2012 time

Laser Additive Manufacturing Automotive Examples Hose holder Kinematics component Blankholder Chassis component Pulley Blankholder Holder gas-filled absorber Blankholder side panel Closure clamp Brake line holder Heat protection blank steering gear Kinematics component seat adjustment HKL hinge Luggage rack holder Damper intake Source: N. Skrynecki, Kundenorientierte Optimierung des generativen Strahlschmelzprozesses, 2010 Chassis component

Vision SLM 2030

Thank you very Questions? much for your Attention

Current Applications (3) Tooling industry tool inserts for injection moulding and die casting materials: 1.2709, (1.2343) conformal cooling shorter cycle times Source: ILT, EADS

Applications in Realization: Virtual Storage Qualification of Aluminium-alloys Festo. High Volume- Pneumatic-Valve (Die-casting of GD-AlSi10Mg) Production time: 11.5 hours for 2 parts

High Power Selective Laser Melting Demonstrator (Inconel 718) Nozzle guide vane 50 mm Source: Turbomeca Theoretical build up rate: conv. SLM (200 W) Skin: Core: Total: 3,8 mm³/s High Power SLM (1kW) 8 mm³/s 14,4 mm³ 8,4 mm³/s

Laser Additive Manufacturing Automotive Examples Motor Block Mock up 1/3 original size Material: AlSi12 400W Laser, 54 days 19h Cast: app 3 months

Increasing productivity of SLM Results aluminium State-of-the-art SLM process P L = 200 W High Power SLM P L = 1000 W

Current Research Topics Multi-Materials Material combination SLM manufacturing of the shell of a part Filling the hollow core of the part by casting (same material or different material) First demonstrational parts realized Topic of research: Application for tooling

Skin-Core Strategy Procedure Deposition of skin layer (50 μm) SLM of skin area Re-iteration until core layer thickness is reached (e.g. 4 times if core layer thickness is up to 200 μm) SLM of core area Repetition of steps 1-4 substrate plate selective melting of skin area selective melting of core area skin layer (50 µm)

Skin-Core Strategy Material: Stainless steel Skin P L : 350 W Beam diameter: 200 µm Layer thickness: 50 µm Core P L : 1000 W Beam diameter: 1000 µm Layer thickness: 200 µm