Metallien lasersintrauksen haasteita

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Metallien lasersintrauksenhaasteitaFirpan pikavalmistusseminaari

Aalto-yliopisto, Dipoli, Espoo22.5.2013Olli NyrhiläEOS Finland

EOS PowerPoint Template 2012.potx | EOS | 2

EOS: Technology and Market Leader for Design-Driven, Integrated e-Manufacturing Solutions

EOS Headquarter in Krailling

EOS ManagementEOS GmbH Electro Optical Systems: family-owned, founded in 1989Hidden champion headquartered in Krailling near Munich, GermanyEOS is an integrated solution provider for additive manufacturing Solution portfolio: Additive Manufacturing (AM) systems, materials – both plastics and metals, software and services Complete end-to-end solutions: from part design, data generation to part building and post-processingEOS enables competitive advantages for a variety of industries, such as medical, aerospace, tooling, industry, lifestyle products and automotiveEOS is committed to Innovation – Quality – Sustainability

Dr. Hans J. Langer Dr. Adrian Keppler Christian Kirner Peter Klink


NorthAmerica

~ 13%

Europe and Rest of World~ 70%

Asia~ 17%

EOS: Global Presence

EOS worldwide installed base* EOS global footprint

~ 1.100 systems• 1/3 Metal systems• 2/3 Plastic systems

• 210 customers with > 1 system

Customers in more than 30 countriesEOS sales/application/service offices in 11 countries, distribution partners in 22 countriesWorldwide staff of ~440 (~ 340 in Germany)Strong patent portfolio: More than 700 active patents in nearly 100 patent familiesR&D Spendings of ~15% of Sales

Source: EOS, *approx., number as per July 2012. Staff figures as per 30 Sep 2012.


EOS: A Continuous Success Story

Source: EOS; Numbers for fiscal years as per end of fiscal year 2011/2012.

162 177 208 232 252 284 328 332 390 440

Turnover (in m €)

Number of Employees


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Additive Manufacturing: “The Manufacturing Technology that will Change the World”

Source: The Economist 12/02/2011; EOS

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EOS Finland

EOS Finland was founded October 2000

• Origin• Development and metal powder sourcing group of Electrolux Rapid

Development• Development partner of EOS from 1994 on, the beginning of commercial

DMLS (Direct Metal Laser Sintering)• Joint development of materials and processes for EOS metal platforms

• As result of outsourcing activities of Electrolux the development and sourcing group was acquired by EOS

• Foundation of EOS Finland• Fully owned by EOS


EOS Finland in EOS Group

EOS Finland has several functions in EOS

• Global sourcing of metal powders• Metal powder manufacturing• Development of EOS metal powder products

• Commercialization through EOS GmbH• Development of EOS metal process products for EOS metal systems

• Commercialization through EOS GmbH• Competence center of medical applications

• Complete Solutions for medical industries• Hardware, software, material, process, instructions for use• CE certified SP2 powder and manufacturing process for dental copings and

bridges• ISO 13485 certified


EOS Finland

Organization

• 20 people• Management 1• Quality 2• R&D

• Metal materials & process development 3• Medical applications development 4

• Service 1• Supply chain 2• Laboratory 2• Operations 2• Admin 3


Additive Manufacturing (AM) Offers Various Advantages

AM technology key differentiators compared to conventional manufacturing processes

Freedom of design Cost advantages CustomizationOrganization

Time to market

LightweightStatic: weight of partsDynamic: moving, accelerated parts

Complex componentsE.g. alternative structures of heat exchangers (see below)

Integrated functionalityEmbedded functionality without assembly

Individualized partsCustomer specific adaptationsCost efficient small series up to"lot size one"

Rapid prototyping and serial applications

Fast feasibility feedback of virtual modelsHaptic feedback

Image sources: WITHIN Labs, EOS, Hettich

Laser adjustment unit Finger implantsHeat exchanger Washing rotor


Additive Manufacturing (AM) Opens Two Roads to Success

Enabling a completely new design approach

AM can enable design that in conventional manufacturing environments has not been possible beforeLeading to completely new solutions, e.g

Move from metal to plasticMaking a part lightweight, yet functional

AM can resolve constraints of the conventional design of an existing solution by e.g.

Reducing part complexityReducing costs normally caused by e.g. tooling needed after manufacturing

Resolving the constraints of conventional manufacturing

1 2

Example: Washing rotor (Hettich)

From 32 components to 2 laser-sintered parts + 1 steel ring

No tooling necessary

Functional integration, product customization, production on demand

Example: Load-bearing engine block (WITHIN Labs)

New design not possible with conventional methods

Integrated conformal cooling channels, lightweight design

Reduced cycle times, increased part quality, weight reduction


Automotive

EOS Offers Solutions for Many Industries

Tooling

Industry

Sources (top, left to right): Morris Technologies; M. Kandler, Frauenhofer IPA; Festo; (bottom l. to r.): WITHIN Labs/EOS; EOS; BKL

Medical

Aerospace

Lifestyle


EOS Additive Manufacturing (AM) Aerospace Application Examples

Sources Images (left to right): Morris Technologies, EOS, University of Southampton

Jet Engines UAVInteriors

Challenge: For University of Southampton, to design an aircraft to demonstrate the use of leading-edge manufacturing technology in UAVsSolution: Manufacturing of a flight-capable prototype within one week, using EOSINT P 730

Optimised: functional integration simplifies assembly and excludes the need for fastenersFreedom of design: production of complex structures to achieve the best-possible flight characteristicsSpeedy: from sketch to maiden flight in less than one month

Challenge: Build highly complex design (fuel injection swirler) as ‘one piece’Solution: Manufacturing with DMLS using EOS technology and EOS CobaltChrome MP1

Optimised: Improved design, no brazed joins, increased robustnessSpeedy: Reduction in time to create – 2 weeks (vs. 6 weeks)Economic: Significant cost reduction – at least 50% less cost

Challenge: Build air duct for mixing and distribution of cabin ventilationSolution: Manufacturing with EOS plastic laser-sintering technology

Optimised: Meets performance requirements – flame retardancy, low toxicity of smoke, light weightWide range of use: Already used in several aircraftsEconomic: Significant cost and fuel reduction through light weight

Morris Technologies Swirler Airduct SULSA aircraft made of PA 2200


EOS Additive Manufacturing (AM) Automotive Application Examples

Individualised partsLightweight, complex components Integrated functionality

Sources Images (left to right): University of Warwick; Fraunhofer IPA; Rennteam Uni Stuttgart

Challenge: Build a reliable, lightweight axle pivot with high rigidity in short timeSolution: Production of topology-optimised steering stub axle using EOS technology

Optimised: Perfect form and contouring – weight reduced by 35%, rigidity increased by 20%Speedy: Significantly shorter development and production time Safe: Reliable on the track

Challenge: Build lightweight drive shaft for Formula Student racing carSolution: Carbon-titanium drive shaft with laser-sintered double-walled ends

Flexible: Part design without design restraintsEconomic: Weighs only 350 g (length 50 cm). 70% weight reduction (vs metal version), supports trend towards reducing CO emissions

Challenge: Create light-weight car seat with innovative ergonomic designSolution: Functional integration via laser-sintered plastic elements

Comfortable: Thanks to anatomical seat adjustmentEconomic: Significant weight reductionFunctional integration: Reduces installation costs – pneumatic actuators replace servomotors; integrated heating and ventilation

University of Warwick drive shaftRennteam Uni

Stuttgart axle pivotConceptual

car seat


EOS Additive Manufacturing (AM) Industry Application Examples

Heat exchanger: complex and scalable components

Gripper: Lightweight and complex components

Special purpose machinery: Integrated functionality

Sources Images (left to right): Festo; kuhn-stoff; EOS; components built into EOS systems; 3T RPD/WITHIN Labs

EOS FORMIGA Laser adjustment unit

Challenge: Production of a bionic gripper that can reliably pick up and safely put down objects gently and flexiblySolution: Small batch production using EOS FORMIGA P 100

Optimised: Function integration reduces number of single parts and assembly expenditureEconomic: Light-weight and long-lasting through innovative manufacturing method Efficient: Tool-less production saves time and money.

Festo gripper Bionic Assistance System

3T RPD/WITHIN LabsHeat exchanger

Challenge: Create heat exchanger that can efficiently increase or dissipate heat; geometry to be adapted to part that needs coolingSolution: Production on EOSINT M 270 with EOS Aluminium AlSi10Mg

Optimised: Self-supporting, integrated cooling fins on outside surfaces. Tear drop tubes, fully self supportingEconomic: Turbulators inside cooling tubes disrupt flow of cooled fluid to maximise heat transferSpeedy: Build time ca. 85 hours

Challenge: For EOS FORMIGA, produce device to adjust laser mirror in Y and Z directionSolution: Production with EOS plastic laser-sintering technology using EOS material PA2200

Optimised: Functional integration:Integrated cam levers to fix regulating screwsIntegrated control angle markings (no stickers required)

Economic: Manufacturing on Demand possible, enabling adjustments and offering spare parts


EOS Additive Manufacturing (AM) Lifestyle Products Application Examples

Footwear & Sports Fashion/Accessories Architectural Models Interior Design Jewelry

Ross Barber shoesContinuum Fashion/

Shapeways bikini Foster+Partner: British Museum Digital Forming Lamp

Sources Images (left to right): Ross Barber, Continuum Fashion/Shapeways, Foster + Partner, Digital Forming, Cookson

Cookson gold jewelry

Challenge: DMLS suitable for goldSolution: New technology capable of series production offering design flexibility

ResultSpecially built laser optics and raw mat.Less raw material requiredCompletely new possibilities for designers

Challenge: Provide customer with option to online-customise complex design of a lampSolution: EOS plastic laser-sintering technology

ResultCustomer is free to change the basic design within defined parametersMass customisationpossible: combines personalization and mass production

Challenge: Produce high-fashion men footwear with a complex designSolution: EOS plastic laser-sintering of sole and cushioning structure

Result8 unique designs with organic structureDesign could only be manufactured with EOS technology

Challenge: Produce model of complex architectural designsSolution: Laser-sintering of dedicated plastic material

ResultShort production timeExact replication of CAD-created designHigh-profile architects use the technology: Foster + Partner, Zaha Hadid

Challenge: Wearable and printable fabric to produce customised bikinisSolution: Manufacturing on FORMIGA P 100 using EOS PA 2200

ResultMaterial enables thread-like connectionsComplex, yet customised designInnovative and affordable fashion


EOS Additive Manufacturing (AM) Medical Application Examples

Dental ApplicationsOrthopedic Devices, and Implants Surgical Instruments Medical Devices

Sources Images (left to right): EOS; WITHIN Labs/3T;L FHC Inc.; Hettich

STarFixMicroTargeting™ platform Hettich wash rotor RotolavitIndividualised finger implants

Challenge: Simplify production of washing rotor ROTOLAVITSolution: Laser sintering on EOSINT P 380 with PA 2200as series material

ResultHigh functional integration3 parts (laser-sintered parts plus 1 steel ring) instead of 32 partsFinish and assembly effort reduced

Challenge: Manufacturing of patient-matched frameless stereotactic fixturesSolution: Small-batch production of precision surgical components using EOS FORMIGA P 100

ResultCustumised design shortens OR timeParts consolidation resulting in in simpler designs with more featuresUses less material, faster manufacturing turnaround

Challenge: Economic production of patient-specific restorations made of high-performance alloySolution: Manufacturing fully dense restorations w/o porosity using EOSINTM270

ResultFast and cost-efficient manufacturingProvided accuracy of units is +/- 20 micronsRestorations are durable, capable and have a consistently high quality

Challenge: Production of individualised implants, e.g., hip, skull and spinal disc implantsSolution: DMLS using EOS technology and EOS metal materials

ResultLighter, more strain-resistant design (shape, structure)Improved functionality: Grid structure enables optimised coalescencesCost reduction


EOS Additive Manufacturing (AM) Tooling Application Examples

Sources images (left to right): Innomia, Ecoparts, LBC, PEP

Smarter design of conformal cooling channels: cost savings, cycle time reduction, increased performance, scrap rate reduction

Injection Molding Repairing Die Casting Rapid Tooling

Innomia mug holder tool LBC tool insert for die castingPEP (Pôle Europeen de Plasturgie)

Tool insertEcoparts Tool insert

Challenge: Building a tool insert for a mug holderSolution: Using EOS Direct Metal Laser Sintering

Result2 cooling towers (instead of 8)Cooling time 16 s (28.5 s)Cycle time 26,5 s (38.9)Tool building time 13 days (23 days)

Challenge: Repair a partially damaged tool insert Solution: Generation of a new reference surface; Positioning of part in EOS machine; On-top construc-tion of missing parts

ResultSave costs of a complete new insert constructionReduction of lead time: partial construction instead of complete construction

Challenge: Injection moulding tooling for 50,000 electrical component partsSolution: Redesign of inserts with conformal cooling channels; inserts built in EOS MaragingSteel MS1

ResultLead time and cost reductionHigher mould productivity Better thermal management

Challenge: Build an insert for a die casting applicationSolution: Cooling system optimisation; insert built via DMLS on EOSINT M 270 in EOS MaragingSteel MS1

Result20% cycle time reduction180,000 parts manufactured in serial production


EOS Plastic Laser-Sintering Systems

Source: CDR

FORMIGA P 110 EOSINT P 395 EOSINT P 760 EOSINT P 800

Build size Width 200 mmDepth 250 mmHeight 330 mm

Laser CO2 laserNominal power 30 WWave length 10.6 µmLaser spot size ~0,4 mm

Layer thickness0.12 mm 0.10 mm0.06 mm


Laser CO2-LaserNominal power 50 WWave length 10.6 µmDigital scanner

Layer thickness PA 2200: 0.06 mm; 0.10 mm; 0.12 mm; 0.15 mm; 0.18 mm All other materials: 0.15 mm


Laser 2 CO2 laserNominal power 50 W eachWave length 10.6 µm

Layer thickness PA 2200: 0.06 mm; 0.10 mm; 0.12 mm; 0.15 mm; 0.18 mm All other materials: 0.12 mm


Laser 2 CO2 laserNominal power50 W eachWave length 10.6 µm

Layer thickness Standard: 0.12 mm


EOS Metal Laser-Sintering Systems

Data Preparation

SoftwareMaterialise MagicsEOS EOSTYLE Support GenerationEOS RP ToolsEOS PSW

Quality Assurance

Recording & ReportingEOSTATE BaseEOSTATE QAEOSTATE ControllingEOSTATE MPM

Part Production – Material and Processes

EOS MaterialsMaraging Steel Stainless SteelNickelAlloyCobalt Chrome Titanium Aluminum

EOS Parameter SetsSurfacePerformanceSpeed

EOSINT M280 200 WEOSINT M 280 400W

IPCM Material & Platform Handling Modules


EOS Plastic MaterialsComposition Trade name Colour of laser-

sintered partsMain feature Typical applications

Polyamide 12 PA 2200 white • Multipurpose material• Balanced property profile• Variety of certificates available (Biocompatibility, Food

contact, ecological)

• Functional parts

PrimePart PLUS (PA 2221)

natural • Economic multipurpose material• Balanced property profile

• Functional parts

PA 2202 black anthracite black • Balanced property profile• Anthracite black colour

• Functional parts in anthracite black colour

Polyamide 12,glass bead filled

PA 3200 GF whitish • High stiffness• Wear resistance• Improved temperature performance

• Stiff housings• Parts with requirements on wear and abrasion• Parts used under elevated thermal conditions

Polyamide 12,aluminium filled

Alumide® metallic grey • Easy post-processing, good machinability• High temperature performance• Thermal conductivity (limited)• High stiffness

• Applications with metal-like look• Parts which need machining• Parts with thermal loads

Polyamide 12,carbon fibre reinforced

CarbonMide® anthracite black • Extreme strength and stiffness• Thermal and electrical conductivity (limited)• Best strength/weight-ratio

• Light and stiff functional parts• Metal replacement

Polyamide 11 PA 1101 Natural • Very high ductility / elongation at break• 100% from renewable sources (castor/ricinus oil)• Acceptable tensile strength

• Functional parts which need impact resistance• Parts with functional elements (film hinges)

For special applicationsPolyamide 12 PA 2201 natural • Multipurpose material

• Material certificates available (Food contact)• Medical, food

PA 2105 Gum colour • High surface quality and detail resolution • DentalPolyamide 12,flame retardant

PA 2210 FR white • Economic flame-retardant material• Halogen-free

• Aerospace• Electric & Electronic

Polyamide 12,flame retardant

PrimePart FR (PA 2241 FR)

white • Economic flame-retardant material • Aerospace• Electric & Electronic

Polystyrene PrimeCast® 101 grey • High dimensional accuracy• Low residual ash-content

• Patterns for investment casting• Master patterns for vacuum casting

Polyaryletherketone EOS PEEK HP3 beige-brown • High performance material• Excellent temperature performance, strength, stiffness

and chemical resistance• Excellent wear resistance• Inherently flame retardant• Biocompatibility and sterilizability

• Metal replacement• Aerospace• Automotive and motorsports• Electric & Electronic• Medical• Industrial


EOS Metal Materials

Material Group Trade name Material type Typical applications

Maraging Steel EOS MaragingSteel MS1 18 Mar 300 / 1.2709 Injection moulding series tooling; engineering parts

Stainless SteelEOS StainlessSteel GP1 Stainless steel

17-4 / 1.4542Functional prototypes and series parts; engineering and medical

EOS StainlessSteel PH1 Hardenable stainless15-5 / 1.4540

Functional prototypes and series parts; engineering and medical

Nickel AlloyEOS NickelAlloy IN718 Inconel™ 718, UNS N07718, AMS

5662, W.Nr 2.4668 etc.Functional prototypes and series parts; high temperature turbine parts etc.

EOS NickelAlloy IN625 Inconel™ 625, UNS N06625, AMS 5666F, W.Nr 2.4856 etc.

Functional prototypes and series parts; high temperature turbine parts etc.

Cobalt ChromeEOS CobaltChrome MP1 CoCrMo superalloy,

UNS R31538, ASTM F75 etc. Functional prototypes and series parts; engineering, medical, dental

EOS CobaltChrome SP2 CoCrMo superalloy Dental restorations (series production)

Titanium EOS Titanium Ti64 Ti6Al4V light alloy Functional prototypes and series parts; aerospace, motor sport etc.

Aluminum EOS Aluminium AlSi10Mg AlSi10Mg light alloy Functional prototypes and series parts; engineering, automotive etc.


System Set-up & Production

Removal &Cleaning

ProductionMonitoring

EOS EOSTATE

EOSHardware

SYSTEMSEOS FORMIGA P110EOS EOSINT P395EOS EOSINT P760EOS EOSINT P800

PERIPHERYEOS IPCM / IPCM+EOS Unpacking /Sieving station P1/P3/P7EOS Cooldown Station P7

EOSMaterials

EOS PA 2200EOS PA 2221EOS PA 2202 black

EOS PA 3200 GFEOS Alumide®EOS CarbonMide®

EOS PA 2201EOS PA 2105EOS PA 2210 FR

EOSSoftware

EOS EOSTATE

EOS SINTAFLEX 201EOS PrimeCast® 101EOS PEEK HP3

EOS Process PortfolioProduction Plastic

EOS Blasting CabinetNormfinish

Partner Solutions

Miniature Basting System Type Micro Tip 1


LS-SYSTEMSEOS EOSINT M280 200W/400WEOS EOSINT M270 Dental

PERIPHERYEOS IPCM MEOS Comfort Powder Module

EOS MaragingSteel MS1EOS StainlessSteel GP1EOS StainlessSteel PH1

EOS NickelAlloy IN718EOS NickelAlloy IN625EOS CobaltChrome MP1

EOS CobaltChrome SP2EOS Titanium Ti64EOS Aluminium AlSi10Mg

EOS EOSTATE

EOS Process PortfolioProduction Metal

EOS QA for Laser Power

EROWA Alignment System

EOSHardware

EOSMaterials

EOSSoftware

Partner Solutions

System Set-up & Production

Removal &Cleaning

ProductionMonitoring


Technical Services

System installationMaintenanceRepair Spare parts logisticsSystem upgradesSoftware updatesRemote support

Training Services

Trainings for operation of EOS systems

at EOS training centerat customer location

Application Services

BenchmarkingFeasibility studiesDesign consultingCustomer material qualificationApplication consultingCustomer-specific development

Quality Management Services

Factory Qualification Installation QualificationOperation QualificationPerformance Qualification

EOS: Consistent Service Offer

EOS supports customers

throughout the relationship


EOS: Global Service Organisation

Regional Service Hub

Local Service Site

EOS HeadquarterKrailling (Germany)30 Field Technicians

9 2nd Level Support Technicians4 Hotline Employees

EOS North AmericaNovi (USA)

14 Field Technicians

EOS Asia-PacificSingapore

13 Field Technicians

EOS has Regional Service Hubs on three continents

Service resources are managed from regional hubs, but located in national markets

Local Service Sites with own depots ensures customer vicinity in key markets


A Peek into the Lab: EOS Intends to Extend the Platform-based DMLS Strategy

1) Requires dedicated business case * In development, subject to technical changes

Larg

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Prod

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R&D

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Pr

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Plat

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Appl

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spec

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1)

Manufacture application in production environment

Develop & qualify applicationsFreeze system settings for productionProduce small scale volumes

Derive application-specific system, e.g. PRECIOUS M 080

Focus on productionSemi-automated processesModular conceptSingle field with 1kW laserMulti-field with 200/400W lasersXL build chamber (400x400x400mm)

Focus on flexibilityDesigned for flexible material exchanges200 / 400 W laserBuild chamber (250x250x325mm)

Focus on applicationAdapted system to match requirements of specific applications 1)

Dedicated materials and parameters (e.g. gold)

Scale up for production

Adapt to application


A Peek into the Lab: Depending on Application, EOS will offer a Single or Multi-Field Solution

1) Laser power can be adapted for similarity purposes (e.g. 200 W) * In development, subject to technical changes

Single field*Multi-field

with overlap*Multi-field

without overlap*

1 x

1,00

0 W

4 x

400

W 1)

4 x

400

W1)

Focus on speed

Big & bulky partsSurface roughness allowedFunctional surfaces typically finished

Focus on accuracy

Rather small partsHigh resolution requiredDirect similarity to M 280

Application-specific approach


A Peek into the Lab: Micro Laser-Sintering (MLS)

No investment for product variantsCost benefits for small seriesReduced time-to-market

Complexity for free

Small feature size

Micro gears designed by Morris Technologies, Inc.

Complex designs without extra costOptimised functionalityAdditive manufacturing on a micro scaleSmallest feature size around 50 µm, depending on geometry

Customization, functional integration, miniaturization

Freedom of design Freedom of design

Tool-less manufacturing

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Metallien lasersintrauksen haasteita

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