© Fraunhofer ILT
3D-Drucker/Generative Fertigung – Wie sich die Produktion verändert und die Logistik vor neue Herausforderungen stellt
Adj. Prof. (RMIT) Vis. Prof. (NUAA) Akad. Oberrat Dr.-Ing. Ingomar Kelbassa
Dr.-Ing. Andres Gasser
Dr.-Ing. Dipl.-Phys. Wilhelm Meiners
Dipl.-Phys. Christian Hinke
Dipl.-Ing. Gerhard Backes
Logistiktag 2014, Kassel, Germany, June 25, 2014
© Fraunhofer ILT
Content
Motivation
Process basics
Developments & Applications
Digital Photonic Production
© Fraunhofer ILT
Content
Motivation
Process basics
Developments & Applications
Digital Photonic Production
© Fraunhofer ILT
Value Change
„Dynaxity“
New Production
Mobility and Transport
Energy Consumption and Resources
Climate Change
„Fraunhofer Gesellschaft Z punkt.-Lebenswelten 2015 plus“, „Siemens-Horizons 2020“
Health
Globalization
Knowledge Society
Change of Work
Political Conflicts
Demographic Change
Mega Trends
© Fraunhofer ILT
Value Change
„Dynaxity“
New Production
Mobility and Transport
Energy Consumption and Resources
Climate Change
„Fraunhofer Gesellschaft Z punkt.-Lebenswelten 2015 plus“, „Siemens-Horizons 2020“
Health
Globalization
Knowledge Society
Change of Work
Political Conflicts
Demographic Change
Mega Trends
© Fraunhofer ILT
Lot size
Conventional Production
Cost
Direct Photonic Production
Digital Photonic Production
Digital Photonic Production
Increase in deposition rate = Decrease in cost! „Time is money“
© Fraunhofer ILT
Content
Motivation
Process basics
Developments & Applications
Digital Photonic Production
© Fraunhofer ILT
Laser Material Deposition LMD >> 1 step process <<
© Fraunhofer ILT
Selective Laser Melting SLM >> 2 step process <<
Metal powder Lowering of platform
Selective melting of powder layer
Deposition of powder layer
Metal part made from serial material
3D CAD model, sliced into layers
© Fraunhofer ILT
Selective Laser Melting SLM – Basic Principle
Laserstrahl
umgeschmolzene
Schicht
Schmelzbad
Bewegungsrichtung
des Laserstrahls
Pulverschicht
laser beam
scan direction
powder layer
solidified layer
melt
use of serial material
complete melting of the
powder particles
part density of 100%
preheating device
enables processing of a
wide range of materials:
- Titanium alloys
- Aluminum alloys
- Steel
- CoCr alloys
- Nickel alloys
beam diameter
layer thickness
track distance
© Fraunhofer ILT
SLM LMD characteristics
materials large materials
diversity
• limited and lower experience in comparison to LMD
limited by the handling system
limited by the process chamber
(ø : 250 mm, height : 160 mm)
part dimensions
limited nearly unlimited part complexity
0.1 mm 0.1 mm dimensional accuracy
• 3D-surface • on existing parts
• flat surface • flat preforms
build-up on
3 – 10 mm3/s 1 – 3 mm3/s deposition rate
60 – 100 µm 30 – 50 µm roughness Rz
0.03 - 1 mm 0.03 - 0.1 mm layer thickness
Selective Laser Melting (SLM)
Laser Metal Deposition (LMD)
Comparison of the characteristics SLM / LMD
© Fraunhofer ILT
Content
Motivation
Process basics
Developments & Applications
Digital Photonic Production
© Fraunhofer ILT
Fields of expertise for process development
Systems engineering Process layout Materials
Process monitoring Beam source(s) Process fundamentals
100 µm
© Fraunhofer ILT
BLISK – BLade Integrated DiSK or BLaded DISK
Source: Rolls-Royce Deutschland Ltd & Co KG Compared with conventional parts:
Pro: Lower weight (- 30 %)
Pro: Higher pressure ratio / stage
Pro: Smaller moment of inertia
Higher specific efficiency
Saving of resources
Con: High manufacture / repair costs
© Fraunhofer ILT
BLISK manufacture today and tomorrow
From material removal (Stone Age thrugh today)…
…to additive manufacture (tomorrow)
+ =
© Fraunhofer ILT
Static mechanical properties I
UTS0.2%-YS
1088
962
1100
900
1332
1155
924
594
965
575
1240
1030
1340
1100
0
200
400
600
800
1000
1200
1400 N/mm2
End user specs.
Heat treted raw material, literature
Annealed hot-rolled raw material
LMD without heat treatment
LMD with heat treatment
End user specs.
LMD with heat treatment
20 °C
650 °C
Confirmed
© Fraunhofer ILT
Static mechanical properties II
Elongation
1110
15
35
45
1210
0
5
10
15
20
25
30
35
40
45
%
End user specs.
Heat treated raw material, literature
Annealed hot-rolled raw material
LMD without heat treatment
LMD with heat treatment
End user specs.
LMD with heat treatment
20 °C
650 °C
Confirmed
© Fraunhofer ILT
Dynamic mechanical properties (HCF, 1C mode)
2,27 2,212,28
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
1,60
1,80
2,00
2,20
2,40
2,60
2,80
3,00
Failu
re lim
it [
mH
z]
LMD with heat treatment Raw material Theoretically predicted by Holographic Mode Shape Analysis
Max. movement (leading and trailing edge)Max. stress (tip middle)
Riss
20 mm
Riss
20 mm
Confirmed
Crack Crack
© Fraunhofer ILT
LMD diagram
Scanning speed La
ser
po
wer
Po
wd
er
mass
flo
w
2
[Powder efficiency, deposition rate]
[Porosity]
PL2
mP1,2
vV1,2
1
PL1
Available laser power max. (10 kW)
Ava
ilab
le s
can
nin
g s
peed
max.
Available powder mass flow max.
Depiction of appropriate process windows for a constant track width
Information regarding porosity
Information regarding powder efficiency
Track width
© Fraunhofer ILT
LMD of cuboids
η > 60 %
η > 60 % η > 70%
η > 80 %
η = powder efficiency
1
2
1
2
2
1
© Fraunhofer ILT
Collimation
Optics
Coaxial, continuous
ILT powder nozzle D40
manual
version
automatic
version
20 cm
Adjustment
motor
Zoom optics for on-line variation of laser beam diameter
© Fraunhofer ILT
HPC FRONT DRUM HCF TEST SPECIMEN
(Source: Rolls-Royce Deutschland Ltd & Co KG)
Process strategy for blade build-up
Layer n
Layer n+1
Near-net-shape build-up of BLISK blade mock-ups
Points of support Start Finish
© Fraunhofer ILT
Additive manufacture of one BLISK blade in t < 2 min. (near-net-shape)
Near-net-shape build-up of BLISK blade mock-ups
© Fraunhofer ILT
Laser Metal Deposition LMD
Process
BLISK Blade additively manufactured by LMD
© Fraunhofer ILT
Ferchau Innovation Award 2011 Additive BLISK Manufacture by Laser Material Deposition LMD
Hannover Trade Fair April 04, 2011
© Fraunhofer ILT
Innovation Challenge Award (Aviation Week) in the Category “Power and Propulsion” Additive BLISK Manufacture by Laser Material Deposition LMD
Washington, D.C. March 07, 2012
© Fraunhofer ILT
Ultra high-speed LMD
Classification of LMD processes by process velocity/ feed rate: Pulsed LMD vv = 0 mm/min
Low-speed LMD vv = > 0 – 200 mm/min
Standard LMD vv = 200 – 2,000 mm/min
High-speed LMD vv = 2,000 – 20,000 mm/min
Ultra high-speed LMD vv = 20,000 – > 100,000 mm/min
© Fraunhofer ILT
Ultra high-speed LMD
http://www.hazmat-alternatives.com/Alt_tech-Chrome.php
Replacement of Thermal spraying (APS, VPS, HVOF etc.)
Chromium plating
by LMD (thin layers between 25 and 200 µm) due to process specific advantages such as Metallurgical bond
Factor of min. 10 higher process speed
compared to conventional LMD
Smoother surface finish
http://www.advanced-coating.com/english/spraying.htm
© Fraunhofer ILT
Ultra high-speed LMD
Principle
Laser radiation
Powder gas jet
HAZ HAZ
Conventional LMD Ultra high-speed LMD
Ap = 20 – 30 % vv = 1,000 – 2,000 mm/min
Ap = 80 – 90 % vv = 100,000 – 500,000 mm/min
Tp ≈ Tm
© Fraunhofer ILT
Ultra high-speed LMD
Process velocity vv = 200,000 mm/min
© Fraunhofer ILT
100
150
200
250
300
350
400
0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45
Har
dn
ess
[HV
]
Distance [mm]
Coating HAZ Substrate
Inconel 625
Ultra high-speed LMD
© Fraunhofer ILT
LMD of a shaft used in off-shore apps. Weight of shaft: 1000 kg Process velocity vv
up to 50,000 mm/min Laser power 4000 W
Ultra high-speed LMD
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Laser Additive Manufacturing – Automotive Applications
Blankholder side panel
Pulley
Chassis component
Kinematics component
Blankholder
Blankholder
Holder gas-filled absorber
Closure clamp
Chassis component Damper intake
Luggage rack holder
Kinematics component seat adjustment
HKL hinge
Brake line holder
Hose holder
Heat protection blank steering gear
Source: N. Skrynecki, Kundenorientierte Optimierung des generativen Strahlschmelzprozesses, 2010
© Fraunhofer ILT
First SLM Hip Cup
Bone substitute implants with mesh structure made from TiAl6V4
Conventional manufacturing not possible
Improvement of bone-implant interaction
Hip cup manufactured at ILT implanted in January 2008
© Fraunhofer ILT
Actual Reseach Topics/ Precision: Dimensional Accuracy
Target: 64,00 mm Actual: 63,98 mm
Target: 64,40 mm Actual: 63,36 mm
© Fraunhofer ILT
High power SLM for Aluminum
Material: AlSi10Mg PL: 200 W Beam diameter: 200 µm Scan speed: 800 mm/s
Material: AlSi10Mg PL: 1000 W Beam diameter: 200 µm Scan speed: 2000 mm/s
© Fraunhofer ILT
skin layer (50
µm)
substrate
plate
selective melting of skin
area
selective melting of core
area Deposition of “skin layer”
(50 μm)
SLM of skin area
Re-iteration until core layer
thickness is reached (e.g. 4
times if core layer thickness
is up to 200 μm)
SLM of core area
Repetition of steps 1 - 4
Procedure
Skin-Core Strategy
© Fraunhofer ILT
Material: Stainless steel Skin PL: 350 W Beam diameter: 200 µm Layer thickness: 50 µm
Core PL: 1000 W Beam diameter: 1000 µm Layer thickness: 200 µm
Skin-Core Strategy
© Fraunhofer ILT
Additive Manufacture of skin-core demonstrator
Tool insert for injection mold
Conformal cooling channels
Layer thickness ratio of 1:4
Skin core overlap 0.75 mm
Density ~ 100%
Core dep. rate: 16.8 mm³/s
Skin dep. rate: 3 mm³/s
Average dep. rate: 10.2 mm³/s
© Fraunhofer ILT
Commercial machine with 1kW laser system
© Fraunhofer ILT
Deposition rate Since 2003 :
Industrial state-of-the-art unchanged at approx. 1.2 mm³/s
Since beginning 2007: Increase in deposition rate up
to approx. 9 mm³/s (experimental set-up)
2008:
Installation of demonstration machine
2009: Further increase of deposition rate up to min. 12 mm³/s by using higher laser power (up to 1kW)
Deposition rate [mm³/s]
time
1997 2003 2006 2009 2000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
…
2012
Actual Research Topics/ Productivity: Process speed
© Fraunhofer ILT
Selective Laser Melting SLM
SLM Machine
Process
© Fraunhofer ILT
Innovation Award of the federal state of North Rhine Westphalia 2011 Additive Manufacture by Selective Laser Melting SLM
Duesseldorf November 14, 2011
© Fraunhofer ILT
Content
Motivation
Process basics
Developments & Applications
Digital Photonic Production
© Fraunhofer ILT
Digital Photonic Production “From Bits to Photons to Atoms” Light is unique due to…
highest energy density
shortest pulses
highest speeds
massless, forceless and contactless
best controllability (CAD>Product)
© Fraunhofer ILT
Product complexity
Conventional Production
Lot size
Conventional Production
Cost Cost
Digital Photonic Production – “Production 2.0”
© Fraunhofer ILT
Product complexity
Conventional Production
Lot size
Conventional Production
Cost Cost
Digital Photonic Production – “Production 2.0”
Digital Photonic Production
Digital Photonic Production
© Fraunhofer ILT
Product complexity
Conventional Production
Lot size
Conventional Production
Cost Cost
Digital Photonic Production – “Production 2.0”
Individualisation for free Complexity for free
Digital Photonic Production
Digital Photonic Production
© Fraunhofer ILT
Product complexity
Conventional Production
Lot size
Conventional Production
Cost Cost
Digital Photonic Production – “Production 2.0”
Individualisation for free Complexity for free
Innovative products
Digital Photonic Production
Digital Photonic Production
© Fraunhofer ILT
Product complexity
Conventional Production
Lot size
Conventional Production
Individualisation for free Individualisation for free Complexity for free
Innovative products
Cost Cost
Digital Photonic Production – “Production 2.0”
Digital Photonic Production
Digital Photonic Production
© Fraunhofer ILT
Digital Photonic Production – “Production 2.0”
Product complexity
Conventional Production
Lot size
Digital Photonic Production
Conventional Production
Innovative business models
Individualisation for free Individualisation for free Complexity for free
Innovative products
Cost Cost
Producer
Product
Providing-Value Value-Co-Creation
Producer Customer
Product
Environment
Digital Photonic Production
© Fraunhofer ILT
Individualization for free – Shapeways
Source: Shapeways
© Fraunhofer ILT
Shapeways – new kind of production community
Source: Shapeways
© Fraunhofer ILT
Shapeways – huge momentum for 3D printing in 2012
1,000,000 3D printed products in 2012 over 10,000 uploads per week 8000+ Shapeways Shops shop owners earned $500,000 in 2012 230,000+ Community Members in over 130 countries
new factory opened in New York
to 3D print 3 to 5 million unique products per year
Source: Shapeways
© Fraunhofer ILT
Production Communities – i.materialise, Ponoko, Sculpteo
Source: Materialise
© Fraunhofer ILT
Tinkercad – browser based solid modeller
Source: Materialise, Tinkercad
© Fraunhofer ILT
… with direct connection to Shapeways, i.materialise, …
Source: Materialise, Tinkercad
© Fraunhofer ILT
… and a growing community for 3D design data
Source: Tinkercad
© Fraunhofer ILT
Nokia Lumia 820 3D printing community project – First major label released 3D Development Kit (3DK)
Source: Nokia
© Fraunhofer ILT
Direct Photonic Production LAM – A Paradigm Shift in Manufacture Topology optimized axle stub
with hollow structures – additively manufactured by Selective Laser Melting SLM
Engine block – additively manufactured (‚printed out‘) by Selective Laser Melting SLM
© Fraunhofer ILT
Additive Manufacturing – Process Chain
Finish Schlichten Drehen Design/
Function Additive
manufacture
Shaping
Measuring
Raw
material,
e.g. powder
Clamping CAx
Finishing Roughing Turning
Continuity/ Integration
Adaptive Automated Machining
Systems engineering Process layout Materials
Process monitoring Beam source(s) Process fundamentals
100 µm
© Fraunhofer ILT
Opportunities and challenges in part design & simulation
Material: AlSi10Mg Weight saving: ca. 30 %
Bionic design Lattice structures Topology optimization
Top: 338 elements 13 min 13 s
Center: 21,000 elements 41 min 47 s
Bottom: 2,100,000 elements ca. 48 h
© Fraunhofer ILT
Vision – Lightest material of the world
Density: 0,9 mg/cm³
99,99 % air
100 times lighter than foamed polystyrene
1000 times thinner than human hair
Source: Nature, University of California Irvine
© Fraunhofer ILT
Opportunities and challenges in part design & simulation
Source: ASME Mechanical Engineering Magazine, Netfab
Vision I: Tailored part design (designed for function, only)
Individualized parts
Design tools - patient specific - part specific
Solution-Space-Design
Real time simulation
Functional parts
Design and simulation tools for - filigree structures - multi scale structures - multi material systems
© Fraunhofer ILT
Additive Manufacturing – Process Chain
Finish Schlichten Drehen Design/
Function Additive
manufacture
Shaping
Measuring
Raw
material,
e.g. powder
Clamping CAx
Finishing Roughing Turning
Continuity/ Integration
Adaptive Automated Machining
Systems engineering Process layout Materials
Process monitoring Beam source(s) Process fundamentals
100 µm
© Fraunhofer ILT
Material development: Powder additives (Inconel 718)
TiN
inclusions
Micro
cracks
Powder O N Porosity Cracking Inclusions (TiN)
AMDRY 0.010 0.020 High Low Low
Nistelle 0.035 0.110 mid High High
TLS 0.013 0.009 Low Low Low
Now: Designed for APS, VPS, HVOF Thermal Spraying
Future: Tailored for AM
© Fraunhofer ILT
Material development: Graded & 3D multi-materials
Vision II: Tailored materials (inorganic & organic)
© Fraunhofer ILT
Additive Manufacturing – Process Chain
Finish Schlichten Drehen Design/
Function Additive
manufacture
Shaping
Measuring
Raw
material,
e.g. powder
Clamping CAx
Finishing Roughing Turning
Continuity/ Integration
Adaptive Automated Machining
Systems engineering Process layout Materials
Process monitoring Beam source(s) Process fundamentals
100 µm
© Fraunhofer ILT
Process qualification for new material(s) combinations
Vision III: Tailored processes (inorganic & organic)
• For laser and non-laser based processes such as SLM, LMD, STL, FDM, EBM (ARCAM), LIFT (organic materials) etc.
• For non powder-based processes (wire, liquids, slurry etc.)
• Below 10 µm3 resolution (voxel) with materials:
• Industrial polymers (p-T-t cycles; e.g. via pressurized process chamber)
• Hybrid materials e.g. switchable properties through switchable materials (metal-polymer, MMCs, CMCs, particle reinforced,…)
• Organic materials such as biopolymers Aim: Tissue engineering & Printable organs (approach: LIFT processes)
© Fraunhofer ILT
Additive Manufacturing – Process Chain
Finish Schlichten Drehen Design/
Function Additive
manufacture
Shaping
Measuring
Raw
material,
e.g. powder
Clamping CAx
Finishing Roughing Turning
Continuity/ Integration
Adaptive Automated Machining
Systems engineering Process layout Materials
Process monitoring Beam source(s) Process fundamentals
100 µm
Interfaces
© Fraunhofer ILT
Source: Fraunhofer IPT
Efficiency
Higher efficiency of
additive manufacturing
process
Parameters focusing on
optimum
of total process chain
Accuracy
Adaptive finishing step
provides
high part precision
Elimination of manual
rework reduces failure
sources
Design
(inner and outer)
geometry
Adaptive Finishing
Manual
rework Measuring
Correction strategy
Additive manuf. process
Holistic view on productivity and quality
Holistic view to ensure productivity and part quality
Vision IV: Tailored process and CAx
chain(s) (holistically adapted)
© Fraunhofer ILT
Internal
Perspective
External
Perspective
Pro
du
ct
Pe
rsp
ecti
ve
Pro
du
cti
on
Pe
rsp
ecti
ve
Product Program
I
Product range
Product Architecture
II
Inner structure of
the products
Production Structure
III
Resources and
processes
Supply Chain
IV
Logistic interface
to the customer
Holistic view to ensure productivity and part quality
© Fraunhofer ILT
Explainability at the
Point of Sale
Product Architecture
Flexibility
Fit o
f V
ariety
Resource Utilisation
Supply Chain Inventory Efficiency
Su
pp
ly C
hain
E
ffe
ctive
ne
ss
1
0
1
0
0
1
0
1 0 1 0
Product Program Product Architecture
Supply Chain Production Structure
II I
IV III
1
1
1 0 1 0
Pro
du
ct
Arc
hite
ctu
re
Co
mm
ona
lity
Optimization toward the
center reflects potential
for individualized
production
Pro
cess
Co
mm
ona
lity
Current operating
points of a
production system
Holistic view to ensure productivity and part quality
© Fraunhofer ILT
Explainability at the
Point of Sale
Product Architecture
Flexibility
Fit o
f V
ariety
Resource Utilization
Supply Chain Inventory Efficiency
Su
pp
ly C
hain
E
ffe
ctive
ne
ss
0
1
0
0
1
0
1 0 1 0
Product Program Product Architecture
Supply Chain Production Structure
II I
IV III
1
1
1 0 1 0
Pro
du
ct
Arc
hite
ctu
re
Co
mm
ona
lity
Pro
cess
Co
mm
ona
lity
Only the integrative
configuration within all
areas exploits the full
potential of DPP
Holistic view to ensure productivity and part quality
© Fraunhofer ILT
“Advanced Manufacturing is the use of innovative technology to improve products or processes.” (http://en.wikipedia.org/wiki/Advanced_manufacturing as of November 22, 2013)
“Advanced Manufacturing is the use of innovative technology to improve products and processes.”
“Advanced Manufacturing is manufacture for design instead of design for manufacture.”
Mission statement
© Fraunhofer ILT
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