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Erin Komi

AM Specialist, AMO Team

+358 40 650 7716

erin.komi@etteplan.com

Design for Additive Manufacturing

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EtteplanA growth company

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Rapidly growing and

developing engineering

services company

Our customers are global

machine and equipment

manufacturers

We stand out by the

high-level competence

and service attitude

Founded 1983 | Nasdaq Helsinki Ltd

263,3REVENUE, EUR MILLION 2019

~ 3,500NUMBER OF PERSONNEL

Engineering Solutions

56% (56%)

Software and Embedded

Solutions 25% (25%)

Technical

Documentation Solutions

19% (19%)

* Etteplan renewed its organization as of January , 2019.

Before that the service areas were called Engineering

services, Embedded systems and IoT and Technical

documentation

*

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CORE FACTS

HOW WE WORKSTRENGTHS

20+AM DESIGNERS

100+YEARS OF

EXPERIENCE

50+DESIGN PROJECTS

Strong partner network

AM business case creation

Simulation driven design for AM

Heavy industry expertise

We believe in making ideas concrete very early, delivering cost estimations to support decision making and working closely with our customers to ensure AM feasibility.

And many more…

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Pushing forward

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Levels of AM QualityAMOTool HX-project

www.amotools.com/

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ADDED

VALUE

COMES FROM

DESIGN!

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Delivery to manufacturer

Design validation

Final concept & detailed

design

Ideation & concept creation

Starting data review with customer

Business case creation

AM design workflow

Cost and ROI estimation

before design work starts

Material and manufacturing method chosen early;

freeze the process to guarantee quality

Driven by simulation &

experience

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Key roles

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AM Method

Product

Expert

AM DesignCFD/FEM

Simulation

AM

MaterialsAM Process

Simulation

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Simulation & design tools for AM

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Advanced 3D

Modelling

Computational Fluid

Dynamics (CFD)

Finite Element

Analysis (FEA)

Topology

Optimization

Print Process

Simulation

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Software tools for AM design … & more every day

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Source:

AMFG – AM Landscape

Infographic 2019, 2020

Design & CAD Software

Simulation Software

Added to list in 2020

Case: hydraulic block for John Deere

Forestry Oy

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Background

• Redesign hydraulic block on

tree harvester boom to take

advantage of AM

• Goals:

- Decrease pressure drop

- Reduce weight

- Minimize manufacturing costs

- Easier assembly

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Team of experts:

• Product owner (customer)

• AM method & materials

• AM design

• Fluid dynamics

• Structural analysis

• Print process

Tools:

• CFD

• FEM

• Advanced 3D modelling

• Print process simulation

Design approach

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Initial design

evaluation

Concept creation,

CFD analysis & comparison Fine-tuning chosen

concept (flow)

Component design FEM validation &

fine-tuning (strength)

Print process

simulation

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Benefits

• Pressure drop reduced by 40%

• Mass reduced by 60%

• Works well with high velocity

flow & in both flow directions

• Size reduction improved ease

of assembly for surrounding

components

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Case: pressing tool for Wärtsilä

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Background

• Description: part of pressing tool assembly

for cylinder head valves

- 2 exhaust valves & 2 inlet valves

- Double springs on inlet valves

• Initial design deemed unsafe after FEM

calculations

• Material options: 316L, Ti6Al4V, MS1

• Size: ~200 x 195 x40 mm

• Objectives:

- Need one part, and fast!

- Price < 1000 € to print and post-process

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Team of experts:

• Product owner (customer)

• AM method & materials

• AM design

• Structural optimization

• Print process

Tools:

• Topology optimization

• FEM

• Advanced 3D modelling

• Print process simulation

Design approach

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Load case & design

space definition

Topology

optimization

Preliminary FEM

analysis

Design concept

generation

Finalizing design FEM validation AM process

simulation

Optimized design

geometry

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Benefits

• Time from when

starting data was

set to final design

sent to be printed

< 1 week!

• Manufacturing

costs below budget

• Safer design

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Case: component cooling for

Rosendahl-Nextrom

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Background

• Main assembly located in a hostile

environment – temperatures over

1000°C

• Aluminum components kept under

melting point by circulation of cooling

water

• Existing design could not be successfully

manufactured

• Goal: utilize AM where needed to

improve manufacturability, while

reducing welds and number of

components

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Original cooling channels

8 manufactured components

11 welds

Machining after each welding

Note. Details of the design have been modified and/or hidden

to protect the Intellectual Property of Rosendahl Nextrom

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Team of experts:

• Product owner

(customer)

• Design for

manufacturing &

assembly

• AM method & materials

• AM design

• Print process

Tools:

• Advanced 3D modelling

• Print process simulation

Approach: hybrid manufacturing

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LPBF

LPBF x 2

Lathe x 2

Lathe

/ wire cut

Welding Lathe

Final assembly

Summary:

- 5 manufactured components

- 2 welds

Orange color

represents machined

surfaces

Note. Details of the design have been modified and/or hidden

to protect the Intellectual Property of Rosendahl Nextrom

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Benefits

• Significant reduction in:

- Manufactured parts (8 → 5)

- Welds (11 → 2)

- Number of machining cycles

- Mass (5.8 → 4.3 kg)

• This component with integrated

cooling can now be successfully

manufactured

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