Additive manufacturing in Production Engineering: Chances ... 14/CIRP ICME 14_Plenary Session...
Transcript of Additive manufacturing in Production Engineering: Chances ... 14/CIRP ICME 14_Plenary Session...
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Additive manufacturing in Production Engineering: Chances and Challenges
Prof. D.Sc. M.Sc. Gideon N. Levy
Additive Manufacturing and
Electro Physical & Chemical Processes
Fraunhofer J_LEAPT Naples
9th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2014,
Capri (Naples), Italy, 23 - 25 July 2014
AM is Hot 0published 13.02.2013
“3D printing that has the potential to revolutionize the way we make almost everything“ President Obama
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World gov. funding 5`561 Mio € Mio €
Singapore 500 Mio SGD 293 Mio € 293
China 2 Billion USD 1466 Mio € 1466
UK 60 Mio GBP 74 Mio € 74
European Union (approx.) 2 Billion EUR 2000 Mio € 2000
Russia 2 Billion USD 1466 Mio € 1466
Australia AMCRC 250 Mio AUD 171 Mio € 171
Australia AM machines 17.5 Mio AUD 12 Mio € 12
US (NAMII) 30 Mio USD 22 Mio € 22
US America Makes 9 Mio USD 7 Mio € 7
New Zeland
Taiwan
South Africa
South America
Mexico
Mio € 5'561
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Additive Manufacturing government funding
WED over 45 years AM-SLS less than 25!
1969
1986
2012
1994
2004
2012
One Technology
Many applications
Many Technologies
Many applications
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems, Monitoring and Materials
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
� 4. Application Driven
� 5. Conclusion
More than 128 years ago..
This internal combustion engine was an integral aspect of the patent for the first patented automobile, made by Karl Benz on January 29, 1886
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5 Senses
Why do have AM a great potential?A
bs
tra
ct
Real
Pe
rce
pti
on Thinking
SpeakingWritingPrintingPaintingCraftingArt, Music
Virtual realitySoftware Film TVSimulation ModellingScience: Rules and equations Physics, Chemistry Mathematics
Everything we have And more0.
AM is an Enabling Multidisciplinary Technology
System / Process
Materials
Applications
Up stream/ Down stream
PolymersMetalsCeramicsCompositeBiologic
Application dedicatedAutomation
Part and powder handlingBatch to continues
00000..
Adaptive controlClosed loopProductivityRepeatability000000
Design for AM3DP design
toolPart finishing
Coating Modifications
0000
IndustryAviationAutomotiveJewelry
Medical devicesScaffolds
Organ printing00..
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Terminology - Process Categories I (2012)
1. Vat Photopolymerization Process
Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon
Liquid Photopolymers,
Ceramic or Metal filled photopolymers
2. Material Jetting Process
Multiple nozzles Single nozzles
Thermoplastics, Wax or Photopolymers, Metals,
Optical materials, Electronic materials
3. Binder Jetting process a liquid bonding agent is selectively deposited
to join powder materials.
Polymer, Metal, Ceramic powders
4. Material Extrusion Process
FDM Polymers, composite
C
C
C
T
T
CChemical
TThermal
TThermal post processing
T
Terminology - Process Categories II (2012)
5. Powder Bed Fusion Process
SLS, SLM, EBM
Polymers, metals & ceramics powder
6. Sheet Lamination Process
Bonding, hot melt, glue, US welding
Paper, Metal, Polymers
7. Directed Energy Deposition Process
focused thermal energy is used to fuse materials by melting as they are being deposited
Metal, polymers, powder, wire
T
T
T
C
CChemical
TThermal
TThermal post processing
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Process / material matrix
For most process some bio-compatibles are available.
https://www.additively.com/en/
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Gartner Hype Cycle of Emerging Technologies, Trends for 2014
The value chain in product creation
CONCEPT MODELING
RAPID PROTOTYPING
Pre-SERIE / BRIDGING
CONFORMAL COOLING / TOOLING
ADDITIVE MANUFACTURINGREVERSE ENGINEERING
The Trend
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US Patents on RP/AM in steady state trend- maturity growth?
Source: www.additive3d.com/home.htm
Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems, Monitoring and Materials
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
� 4. Application Driven
� 5. Conclusion
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AM Manufacturing and SM (subtractive manufacturing) are comparable tasks with new features
Additive manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. (ASTM standard F 2792 - 09)
Manufacturing is the use of machines, tools and labor to make things for use or sale. The term is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale.
Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".
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http://sitemaker.umich.edu/ykoren/education
Manufacturing paradigms
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AM is significant in various Manufacturing Paradigms
� Craft production
is “the application of skills and material-
based knowledge to relatively small scale
production”
� Mass Production
is “ the production of large amounts of
standardized products, including and especially
on assembly lines “
� Mass customizationwas defined by Tseng & Jiao (2001) as
“producing goods and services to meet
individual customer's needs with near mass production efficiency “
Its core is a tremendous increase in variety and customization without a corresponding increase in costs. At its limit, it is the mass production of
individually customized goods
� Mass Individualisation
“Gthat is relevant to the individual user “,
based on the user’s implicit behaviour and
preferences, and explicitly given details” – finally, the
most important part. Personalization uses both
implicit and explicit information,
AM is significant in various Manufacturing Paradigms
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� Mass customization � Mass Individualisation
AM is significant in various Manufacturing Paradigms
� Personalization (Custom-fit)
The custom-fit concept can be understood as the of offering one-of-a-kind
products that, due to their intrinsic characteristics and use, can be totally adapted to geometric
characteristics in order to meet the user requirements
AM is significant in various Manufacturing Paradigms
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Manufacturing Implemented Scientific Management (Taylorism)
� Scientific management is a theory of management that analyzes and synthesizes workflows, with the objective of improving labor productivity.
� Total Quality Management (or TQM) is a management concept coined by W. Edwards Deming. The basis of TQM is to reduce the errors produced during the manufacturing or service process, increase customer satisfaction, streamline supply chain management, aim for modernization of equipment and ensure workers have the highest level of training
� Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.
� Management philosophy derived mostly from the Toyota Production System (TPS)
Source: www.strategosinc.com/
Applic
ations
Applic
ations
Applic
ations
Applic
ations
Implement scientific manufacturing management (Tylorism)
� The first level of industrial usability was reached� Numerous applications of AM are success business
cases� Modeling, permanent continuous performance advances
are required
Process, System, Materials
Production integration
Plant integration
� Standards� TQM� Automation � Productivity
� Upstream processes� Downstream processing� business process or business
method
Applic
ations
Applic
ations
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Design Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP AM USE
The bottlenecks in AM are the challenges
Actual operator influence on results - the challenge
Partial advances:� Digitalisation� Protocoling� Laser calibration� Digital scanners� Heaters� Sensors � ---� ----
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
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SLM - Machine size categories
Small dedicated <1
Mid range 15-30
Very large > 100
China 2013 $80 million investment in AM
An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China.
Courtesy of Guancha Zhe.
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
The Additive Manufacturing TQM Model with AC
Plastics
Metals
Ceramics
Composites
Solid Liquid Gases
Powder
Foil
Wire
Material
Thermal Layering
Chemical Layering
postprocessing
traditionalprocessing
coatingfinish
Q1
Q2Q3
Q4 Q5 Q6Q3
Part
Data
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Factors influencing manufacturing process
Laser beam
Process gas
Powder
Melting process
Bechmann F., LANE conference 23th September 2010, Erlangen
Feedback control of Selective Laser Melting
P. Mercelis, J.P. Kruth, J. Van VaerenberghDepartment of Mechanical Engineering, University of Leuven, Celestijnenlaan300B, Leuven, Belgium
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
http://www.grantadesign.com/ and 3DP materials
3DP
3DP
3DP
3DP
3DP
Food
3DP
Bio-mat
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The selection of the right material is never an easy task
Material selection criteria.
The selection of the right material is never an easy task because many parameters need to be considered to obtain the best system at the lowest possible cost. The perfect material does not exists! In most of cases, you will have to compromise between different properties and clearly define the "must have" and the "nice to have" properties
AM material selection is never an easy task as well
AM additionalselectioncriteria
Process + material (one united selection)
Material properties consistent over use time
Process resolution
Part geometry process conformity
Part printing orientation
Anisotropy
Density porosity, delamination
Process provider: quality, time, cost
Post processing finish coating
Long-term duration usability
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SLA and SLA metal coated helical over time
3DP Digital Materials
100% Material A
100% Material B
75%:25%
50%:50%
25%:75%
Source: SFF 2012, Daniel Dikovsky, Ph.D.
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SLS - Thermoplastics polymers (Red= tried for SLS)
PP
Polymer material choice advances
, iRPD
; EOS
So
urc
e:
Ze
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Re
isin
SM
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ate
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Un
it,
Str
ata
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SLM - materials options
Stainless steel CL 20ES ( 1.4404 )
Hot-work steel CL 50WS ( 1.2709 )
CL 60DG ( 1.2709 )
CL 90RW (1.2083 )
Aluminum CL 30AL ( AlSi12 )
CL 31AL ( AlSi10Mg )
Titanium CL 40TI ( TiAl6V4 )
Nickel-based alloy CL 100NB ( Inconel 718 )
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
Part
Laser Beam
Powder
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
x-y Scanner Laser
Laser Beam
Levelling System
InertGas
Window
Metal Powder
Part
RetractablePlatform
Part
Laser Beam
Powder
Some trends and challenges in AM – Materials research
� Filled Materials
� Multi material
� Local alloying
� Digital Materials
� Gradual Materials
� Designed Anisotropy
� Designed local property
� Optimized metallurgical structures
� Ceramics and composite
� Medical and Biomaterials
� Nano Materials
� Micro parts
� Memory shape alloys in AM
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
Multi Physics-CAD (MP-CAD) Tools are in due
– Light weight– Ecological design– Topological optimization
– Flow – Minimal parts(Diffusor)– Static mixer– Aeronautics
– Heat transfer
– Local physical properties
– Digital materials
– Alloyed materials
– Medical
– Biological design
– Engineered surfaces
– Scaffolds
– Life Style
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Light-weight “material“ selection done by geometry
Materials designed with new additive manufacturing techniques exhibit high stiffness and low density, occupying a previously unsettled area of the Ashby material selection chart for Young’s modulus (stiffness) versus density. The octet truss structure recently fabricated by Livermore researchers is a stretch-dominated lattice.
Multi Physics-CAD (MP-CAD) Tools needed
Optimal helmet design� Aerodynamics� Air flow (noise)� Cooling� Security � Aesthetics � Personalized
MP-CAD
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AM made - (no supports) Heat exchanger
Heat exchanger 450x4050x500 mm
Topological Optimizations
Topological optimized design results are:
• Complex geometries
• Conventionally not produce able
• Have to be smoothed
• Highest geometrical freedom
• Agile manufacturing
• New design concepts
Chances for Layer Manufacturing:
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
Supply-chain optimizations potentials
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Logistics and supply chain management flexibility
Production on Demand
DirectSpare: A European Approach for Spare Parts on Demand
Birth andyouth
problems
Aging andwear
problems
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
Applications arrays divide and focus consequently on different quality issues and standards
EntertainmentMovie?
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Main Application areas of AM/ 3DP
DifficultyValue
Added Value: Translate process characterization into specific applications
� Freedom of Design
� Lightweight structures (hollow)
� No-Tool production
� Assemblies, integrated design
� Anatomical personalized
� Ergonometric design
� Customization individualization
� Conformal cooling
� Gradual materials (on the way)
� Medical scaffolds (on the way)
� Bio Materials (on the way)
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Bio inspired AM fabricated systems
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Conformal cooling systems and heat exchanger
A great chance is coming up in moulds!
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Renishaw's additive manufacturing system to boost production capabilities at Directed Manufacturing Inc
Biomedical engineering (BME) advanced complexity
Medical devices
Neural engineering
Implants
Pharmaceutical Eng.
Tissue engineering
Artificial body part
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Medical and Life Science a promising future
MCP
Dr. Anthony Atala (USA) : 3D Printing of Body Parts
Institute for Regenerative Medicine in North Carolina
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Winsun 3D printed house (China)
How a Chinese Company Built 10 Homes in 24 Hours
Winsun’s 3-D printer is 6.6 meters (22 feet) tall, 10 meters wide and 150 meters long, the firm said, and the “ink” it
uses is created from a combination of cement and glass fibers. In a nod to China’s green agenda, Winsun said in the future it plans to use scrap material left over from construction and mining sites to make its 3-D buildings
Suzhou-based construction-materials firm Winsun New Materials says it has built 10 200-square-meter homes using a gigantic 3-D printer that it spent 20 million yuan($3.2 million) and 12 years developing.
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3D Printing: now printing food too
Chocolate portraits made with a 3D scannerand 3D printer. (Photo/Agencies)
3D Printers in 30% of Households
Experts Futures Researchers
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Agenda I
� 1. Background
� 2. Scientific Manufacturing Management (Taylorism)
� 3. Systems & Challenges
– Performance (productivity, repeatability, accuracy)
– Materials (Plastics, Metals, (Ceramics, Biomaterials))
– Automation
– ..
� 4. Application Driven
� 5. Conclusion
We are on the right track
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Conclusions
� The sustainability will be a mayor issue for all of us
� The implementation of Scientific Management (Taylorism) is a must
� Hybrid systems are in due
� Productivity, Automation and quality enhancements are a permanent issue
� New application driven manufacturing tasks coupled with product innovations are just around the corner.
� Interdisciplinary and complexity are increasing
� Additive Manufacturing Processes are a great challenge and chance in manufacturing
� 5 years to go!
� The scientific AM community has to be involved
Personalized