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Direct Metal Printing Services

Quickparts 2015

Direct Metal Manufacturing Solutions

Technology

DMP Professional Printers

Process

DMP Application & Process Know-how

Service

DMP Contract Manufacturing

Organization 3D Systems DMP

Production Projects

DMP Contract Manufacturing & Services

Sales dept Project

Engineering FastLane

Technology Development

Production

Hardware Software Materials Process

USA - France-Belgium

3D SYSTEMS

BE–UK-USA* UK-BE-NL-DE-FR-IT-USA-BR-AU

3D Systems LayerWise, Leuven, Belgium Fully owned subsiduary

DMP Technology development center DMP Contract manufacturing reference plant

BE-USA*

DEVELOP TECHNOLOGY

DRIVEN BY FOCUSED RESEARCH

USE TECHNOLOGY

ACROSS MARKET APPLICATIONS

CLOSED-LOOP DMP EXPERTISE

DMP Evolution

2001

100% prototyping

4 materials

90 x 90 x 90 mm

First Worldwide 3D Printing of Titanium

90% Volume Manufacturing

18 materials

280 x 280 x 440 mm

Leading DMP manufacturer

technology development & production

Belgium France

ISO 9001 – ISO 13485 Quality Certified

2008 2009 2010 2011 2012 2013 2014

Research Material Parts Quality Productivity

2015

DMP Contract Manufacturing

Increase your added value through advantages of Direct Metal printing

3D Systems offers DMP technology expertise by being technology developer and production company

Market overview

Project Development

Volume Manufacturing

Customer Satisfaction

• Feasibility assessment • Quality plan (PMP) • Supply chain development • Part modeling • Process qualification • Process release

• Raw material release • Process monitoring • Full lot traceability • In-process inspections • Outgoing quality gate • Workstation management

• Customer complaint management • Return material approval process • Annual customer satisfaction survey

Machine / Material release management Supplier quality management

Failure mode & effect analysis

Control plan

Gauge R&R IQ/OQ/PQ 5S

Quality Tools Workstation management

3DS-LayerWise Quality management system

Several materials under development

3D Systems has capabilities to accommodate new materials within a typical timeframe of 3 months

Materials

Stainless steel

Tool steel

Titanium

Aluminium

Super alloy

Exotics

Aero Dental Medical Industrial

• 316L

• SS 17-4

• SS 15-5

• Maraging X3NiCoMoTi 18-9-5

• Ti commercially pure

• Ti commercially pure

• Ti6Al4V ELI

• Ti6Al4V

• Tantalum

• Tungsten

• AlSi10mg

• CoCrMo

• CoCrWMo

• Inconel 718

• Inconel 600

Key

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Volume Manufacturing Project

Technical AM Products

Fastlane 3D Print Service

3DS Fastlane or Project Teams 3DS Fastlane

Division 3DS Production Division

DM

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ervi

ces

Lead time is 6 Working days (Or shorter)

Project driven technical expertise

Supply and Quality security

Ti6Al4V Gr5 316L* Aluminum*

Ti6Al4V Grade 1,2,5, Ti6Al4V Grade Eli, 316L, 17-4, 15-5, Maraging, Inconel 718, CoCrMo, CoCrWMo,

Tungsten, Tantalum, AlSi10Mg

(x,y,z)=(250-200-180) mm (9.84-7.78-7.09 inches)

(275-275-420 mm (10.8-10.8-16.5 inches)

DMP Specification

Machine Dimensions 10.8 x 10.8 x 16.5in (275x275x420mm)

Material Density 99-100%

General Tolerances 0.5% with a minimum of +/- 0.008 (0.2mm) on downfacing surfaces

Surface Roughness Basic: Ra 150-275µin (4-7µm) Possible: Ra 0.1µm

Minimal Feature Size 0.005in (0.15mm)

Minimal Wall Thickness 0.008in – 0.01in (0.2 mm – 0.3 mm) gastight, depending on material

Text Dimensions width; height; depth = 0.02; 0.02; 0.006in (0.4 ; 0.4 ; 0.15 mm )

Manufacturing to 2D Plan Post-machining possible

Leak Tightness 10 E-9 Bar

Project approach

Project Analysis

DfX

Design for Function/Mfg

Project Delivery Validation

Management

Gas Burners

• Material Inconel 718 • Function integration • Integrated cooling channels • Improved performance and lifetime

Quartz bulb burners with

integrated cooling channels

(Courtesy of Havells Sylvania)

ESA in-space satellite engine

In-space satellite engine development

by European Space Agency (ESA) and LayerWise

Injector

Consolidated 5 parts to 1

Eliminated sealing welds

High material density

Design with optimised cooling and thermal isolation

Optimised propellant flow

Combustion chamber

Original design with strut-work ribs

Racing

• Racecar suspension • Structural part • Topology optimization • Hydraulic performance increase

Process Applications

Material 316L

Candy and icecream manufacturing

Production volume 1-1000 part/yr

Tire Technology

150 micron wall thickness

UTS,MPa Yield, MPa Elongation,%

AM* 1030±20 800±35 9.5±1.2

After HT 1330±65 1180±32 10.5±1.5

Quenching + aging 1103 1000 5

Medical Imaging

• Material : pure Tungsten • Collimation • PET & SPECT imaging

DMP Technology

Large size machines

High resolutions

Online quality control

Consistent

Printer Technology

Material Development

Software

In-house material specialists

Best material quality

Chemical stability

Productivity

Traceability

Innovation on 4 levels Materials: high-tech metals like molybdenum, tungsten, copper, …

Productivity: part printed in 2 hours instead of 20 hours

Quality: shape accuracy, finer details, thinner walls, etc.

Build size: increasing the maximum dimensions

Technology development

Direct Metal Printing =

Creating Material AND Product Simultaneously!

≠

Materials

Material development

• Controlled release of materials

• Extensive testing for initial validation and follow-up – Geometric accuracy

– Mechanical testing

– Compositional testing

• Accredited material validation – Fully equipped mechanical & metrology testing lab

– Microscopy (optical, SEM, etc.)

– X-ray (XRD, CT, micro-CT, etc.)

– Compositional analysis

100µm

Powder characterization

• Chemical composition • Particle distribution • Hall Flow

Machine / Material Parameter study

Material / Machine release level

• Prototyping • Static load bearing • Dynamic load bearing

Material Datasheet

• Layer thickness • Laserpower • Scanspeed • Dimensional

• Density

• Mechanical • Thermal

Mechanisms for Robust Quality Control & Traceability

• 1. Raw material intake control – Selection of suitable raw

material supplier – Detailed definition of powder

specification and intake control

– Clear identification numbering of raw material batches

– Dedicated storage location for different powder batches

• 2. AM part production and quality

control – Chemical composition analyses

of powder in accredited laboratories on virgin powder and when mixed

– Fixed cycle running powder sample collection for traceability

– Part production with defined parameters on qualified system for each build

– Density evaluation on each build

• 3. Continuous data collection (QMS database) – Full traceability of materials

from customer back to raw material supplier

– Documentation of all quality information for each material lot in database

• 4. Documentation

– Material lot specific material certificate containing analyses results.

– Delivered with every material delivery in printed and/or digital version

Ordering

Incoming Inspection

Use & storage

Powder Mixing

Material Analysis

Remove

Integrated solutions

Barry Assheton - Head of Sales

3D Systems Europe Ltd

Barry.assheton@3dsystems.com

Mob 07931419805

Direct Metal Printing