Strategic Research Agenda (SRA): The Route to Mass Exploitation of AM Dr Rob Scudamore Technology Group Manager Electron Beam, Friction and Laser Processes For RM/AM Platform 29 June 2010
Aim of the SRA To promote the benefits of AM and identify the challenges to mass exploitation Executive Summary Style Document
Contents 1. Additive Manufacturing Overview A. Techniques B. Benefits/Commercial 2. Applications and Development Areas 3. Strategic Research Agenda A. Overview and Vision B. Objectives C. Challenges D. The Future 4. Summary
Additive Manufacturing The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing technologies ASTM Standard
1. Additive Manufacturing: CAD to Part CAD, CAM and processing CNC entry and processing
1A. The Approaches Powder bed based Net Shape, capable of producing finished product Feed techniques Near Net Shape, usually need small amount of machining Hybrid Addition of features to Near Shapes, e.g. tube or plate Solid State - Need for larger amount of machining, Near Shape Other We must be inclusive
1A. AM Techniques Laser Both metallic and polymeric e.g. Selective Laser Melting (SLM), Laser Metal Deposition (LMD) Electron Beam Metallic i.e. Electron Beam Melting (EBM), Electron Beam Freeform Fabrication (EBF 3 ) Other heat sources Polymeric and metallic, UV/IR lamps GMA, TIG, PTA, Thermal Spraying (HVOF and Cold Spray), etc. Solid state AM Other We must be inclusive
1B. AM Main Benefits Design freedom Complex structures to provide light-weighting or performance benefits High level of agility with no tooling, reduction of lead times Commercial and Environmental Material utilisation Light-weighting Reduction of part miles Clean manufacturing process Supply chain benefits e.g. supply chain compression and flexible supply
1B. Myth Busting There is not unlimited design freedom BUT there is great design freedom It is not rapid BUT it is very agile AM does not yet have 100% material usage BUT we are getting close AM will not be suitable for all applications BUT it could is currently especially good for small batches of complex and/or personalised parts
1B.The Market Opportunity 1400 1200 1000 $M 800 600 400 200 0 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
1B. Potential Markets Example Metallics Casting and forging markets are >$100Bn per annum Aerospace 24,300 new aircraft in the next 20 years worth $2.8 Trillion 20 Million tonnes of billet 2 Million tonnes used $10,000 per tonne? Medical Automotive Others there have to be others! Environmental 1 tonne of Titanium = 32 tonnes of CO 2 Social
2. Multi-Phase Functional Materials Polymers Ceramics Metallics Other?
2. Scale Up e.g. Solid State AM Recent Ti-6Al-4V Demonstration Part: Part Specification LFW Preform (part machined) Demonstration work carried out in conjunction with Thompson Friction Welding, LFW machine suppliers: (www.linearfrictionwelding.com)
2. Functionally Graded Materials Material graded from Ti-64 to Ti-6242 Increasing Ti-6242
3B. Objectives 1. To exploit AM for commercial gain 2. To address the Grand Challenges EU Economy Environment Social aspects, e.g. the ageing population 3. For AM to become a realistic option for manufacturing
3B. Alignment Factories of the Future PPP Strategic Multi-Annual Roadmap Sustainable manufacturing ICT-enabled intelligent manufacturing High performance manufacturing* Exploiting new materials through manufacturing Addressing the challenges to adoption for AM will enable the community to address all of the above
3A. SRA Overview and Vision Additive Manufacturing The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing technologies Strategic Research Agenda Addressing the challenges The installation of AM as a viable alternative manufacturing route and become recognised as conventional processing Three workshops held to provide the starting point that has been circulated - inclusive
3B. TRL + Manufacturing Readiness Level
3C. Challenges to Mass Exploitation Four Main Areas A. Cost B. Material and Process Performance C. Design and Implementation D. Understanding Environmental benefits There are other related and non related issues!
3C. Typical AM Cost Analysis Process Material Other
3C. Cost Reduction Processing speed/productivity Quicker layers Faster turnaround Reduction in equipment cost Reduction in material cost and improvement in material utilisation Reduction in post-processing processing Improve stability and reduce scrap
3C. Material and Process Performance Material quality and performance Larger parts Improve surface finish Geometrical stability Smaller features Hybrid processing Assemblies
3C. Material and Process Performance Stability Build to build Batch to batch System to system Platform to platform, e.g. EOS to MTT Right first time processing Capability to insert CAD file and process Will require data and guidelines package from empirical sources and modelling
3C. Design and Implementation Design Implementation and Education Designers need knowledge and software tools Next generation Disseminate the successes Standards Supply chain Reduced lead times Design flexibility Personalised product Reduce part miles Reduction of recurring costs tooling
3C. Environmental Benefits Understand and measure benefits Material utilisation/recycling validation Development of light-weighting for transport applications Development of light-weighting for reduction in transport footprint Processing improvements More efficient heat source Reduce in-process losses Clean and Sustainable processing development Reduction of waste
3D. The Future Fundamental - Replacement of the conventional approach Unique - The creation of new and unique opportunities Need to innovate to keep ahead of the competition
3D. Printing Human Organs
3D. Functioning Metallic Systems
3D. Impacts of AM use Address the Grand Challenges EU Economy Environment Social aspects, e.g. the ageing population STEEP Social Technological Environmental Economical and Political. e.g. globalisation, climate change, raw materials, employment, ageing population, public health, poverty, increasing waste, Money, Jobs, Environment Quantify the benefits
4. Summary Many different Additive Manufacturing approaches Market opportunity Challenges A. Cost B. Material and Process Performance C. Design and Implementation D. Understanding Environmental benefits The future is conventional and unique We have to innovate to maintain a competitive advantage We have to deliver the identified impacts regarding the Grand Challenges and STEEP
Next Steps - SRA Input from the community during the meeting Input after the event This will be used to produce a further draft for circulation This will then have final amendments and be ratified by the RM/AM Platform as the recognised SRA Thank you for your help!
Robert Scudamore robert.scudamore@twi.co.uk +44 114 269 9046 Acknowledgments: EADS Fraunhofer ILT/LLT LPW Technology Ltd. Morris Technologies Optomec Corporation Swinburne Univ. Arcam Materialise Huffman Corporation Material Solutions MTT Ltd. Rolls-Royce Royce Plc Trumpf GmbH Wohlers Report EC and TSB