Das Programm im Überblick – Düsseldorf 2017
Inside 3D Printing Conference & Expo - Düsseldorf - Tag 1 - Donnerstag, 2. Februar 2017
Thermal management has become more important in recent years due to its potential to save energy. A way of achieving is to improve cooler efficiency.
Mahle Industrial Thermal Systems Gmbh as manufacturer of heat exchangers for non-automotive vehicles uses the benefits of Selective Laser Melting (SLM) in order to produce sophisticated heat exchangers.
SLM as additive manufacturing technique gives rise to implementing it for heat exchanger design due its degrees of freedom in design and high dimensional accuracy.
Moreover, the benefits of SLM can be applied for turbulator development as it is independent of conventional tooling. Experimental thermal hydraulic tests can be conducted much faster as a result of the rapid prototyping approach.
- Concept Car EDAG Light Cocoon as visionary approach to a compact dynamic electric sports car with a bionically optimised, additive manufactured vehicle structure combined with a weatherproof textile outer skin.
- NextGen Spaceframe demonstrates a flexible BIW concept by additive manufacturing in combination with 3D-bending and laser joining
- On-board charger with a hybrid power electronics housing and cooling structure
- Functional model of the personalized and functional integrated GenLight headlamp
3D metal printing is becoming established as a production technology in more and more industries. Entire manufacturing centers with multiple machines and numerous machine operators are being created. Safety is a key aspect, no matter whether you are operating a single machine or multiple machines, but this is a crucial criterion for large companies in particular.
Additive manufacturing technology demands different safety measures in some cases to the known, established subtractive processes. This is firstly due to the new type of manufacturing and secondly to the materials which are to be processed, for example reactive powder materials. It is therefore all the more important to familiarize yourself with the safety aspects of this manufacturing process, especially as guidelines for users also exist in addition to regulations for manufacturers.
- What particular aspects need to be considered with powder-bed-based 3D metal printing?
- Which sources of danger exist with this manufacturing process?
- What protective equipment is the correct equipment?
- What needs to be observed during powder handling?
- Which equipment should be used?
You will get answers to these and other questions relating to safety in additive manufacturing in this talk.
Over the last years, the use of Selective Laser Melting (SLM) as a technology for manufacturing highly complex metal parts additively has been growing rapidly. Among others, these parts are used in jet engines, gas turbines and medical implants.
Several direct and indirect advantages compared to traditional manufacturing methods such as casting and subtractive methods make metal additive manufacturing increasingly economical for an ever wider range of applications.
SLM is a relatively new technology and is becoming increasingly viable for the production of end-use parts. However, there are several hurdles currently limiting a faster adoption of SLM as a technology for end-use part production. Overcoming these hurdles not only requires further improving the stability of the highly complex SLM manufacturing process but also the successful integration into existing production and quality management environments.
Close collaboration among machine suppliers, their customers and other partners is a crucial success factor for quickly tapping the vast market potential.
The market of Additive Manufacturing is growing fast. Experts forecast growing rates of > 30% per year. Companies like GE, Airbus, Boeing or Google focus “3D-Printing” and see a viable alternative to conventional manufacturing. 3D-printed products are hyped as something special and valuable. What is the right AM business model? What are the benefits and the disadvantages of AM? What are the challenges?
A continuous process chain, an optimized product design, and innovative materials are the requirements for reasonable Direct Manufacturing. In this presentation the PROTIQ GmbH offers an insight in its daily work. As a case study the design of an injection mold is described. The combination of topology optimisation, conformal cooling and Additive Manufacturing leads to faster mold production, lower production costs and shorter cycle time in the process of injection molding.
This technology not only offers design freedom with optimized structures and surfaces; it has also tremendous savings potential for small and medium-sized production runs. Each printed part can be unique with low cost differences, offering customized products and limited series, accelerating product development and increasing production Efficiency.
An industrial standard is not achieved until reproducibility and quality are in balance through the material’s dimensional stability, homogeneity, density and strength. However, this requires an absolute command of the process. With respect to surface quality: As a rule, 3D blanks require reworking or finishing before product quality is high enough to be considered marketable. Coloring plastic laser sintered parts is a key factor for production in these cases. The color must be lightfast as well as water, UV and abrasion resistant. It should also stand up to sweat, which is very important for eyeglasses and jewelry. In recent years the eyewear industry in particular has increased its use of laser sintered eyeglass frames, as this makes it possible to quickly modify model designs and adapt colors to the latest trends. The short production time of approx. 9–11 workdays makes this an extremely interesting method of production.
The presentation is aimed at developers, designers, department managers and executives in all branches of small-series manufacturing along with artists who wish to leverage the advantages of the generative process in their own production.
Aerospace is the industry that other industries look to for a glimpse at what’s on the horizon. Aerospace has a long history of being an early adopter, innovator and investigator. What this industry was doing decades ago has now become commonplace, almost pedestrian. For example, the aerospace industry was the earliest adopter of carbon fiber, and it was the first to integrate CAD/CAM into its design process. There are many other examples that show that trends in aerospace are predictors of future trends in manufacturing across all industries.
3D printing has a growing influence over the way Airbus Group designs, builds and maintains its products. Ideal for small volumes and customized production, 3D printing makes lighter-weight, fully assembled components at a fraction of the cost and time compared to just a few years ago.
Parts can now be created with complex geometries and shapes that in many cases are impossible to create without 3D printing.
In Aerospace the main focus is today on printing metals. The focus here is on Titanium alloys, whereas Aluminium- and other metallic materials are under investigation, as well.
AM is already used in manufacturing of Aerospace parts. Airbus and Premium Aerotec for example got their first AM manufactured part out of Titanium being certified by the EASA for the use in the A400M. Even if this part is not critical to fatigue, it is a first step towards industrialisation of metallic printing. For sure more applications will follow, soon.
The process chain for AM has lots of single steps and several of these are influenced by Quality Assurance (QA) Testing and Non-Destructive Testing (NDT).The following topics are discussed with this presentation:
- Simulation of NDT capabilities during design
- Database for material properties
- Powder quality determination
- New Testing needs (e.g. Pressure Tests, etc.)
- Online-Monitoring and Big-Data approach
- NDT technologies (Optical Methods, Penetrant Testing, X-Ray inspection, Computed Technology, etc.)
- Submicron X-Ray
The Smart Factory concept integrates all technologies to produce several new business models for manufacturing industries. Amongst other things, it will enable highly customised products to be produced at acceptable unit costs and with much lower levels of emissions and environmental impact.
The landscape of the Smart Factory concept will feature complex and extensive networks linking suppliers, manufacturers and customers.
Within the Smart Factory either completely bespoke or most flexible processes will be most successful. H&H is developing a Smart Factory concept which will be fully digitalized, scalable and learning.
Inside 3D Printing Conference & Expo - Düsseldorf - Tag 2 - Freitag, 3. Februar 2017
Additive Manufacturing (AM) is a promising technology and has advanced over the last years in terms of cost- and product optimization potential. The advantages of AM have been identified already in early stages from the aerospace and space industry. Here a strong interest in lightweight design is explained by financial revenues resulting from low buy-to-fly ratios and decreased part weight. Hence, these branches may allocate large budgets for technology development.
Based on this motivation, fundamental work on the design of very complex lightweight load and stress optimized structural elements e.g. for satellites have been performed. The result is a methodology for an easy to use and cost efficient topology optimization-process, which will be presented in the speech.
Based on this methodology not only aero-/space parts are discussed, but also industrial applications (e.g. from machine tools). The speech will show the transfer from results in the aerospace sector into everyday industrial applications. With regards to the cost development, AM will soon be seen not only in space but in earthbound machines at the shop floor.
Additive layer manufacturing is one of the technologies that is significantly influencing the way of how products will be designed and how products will be delivered to the point of need. This covers processes that deal with civilian, as well as military, applications.
Based on the requirements of military applications, an autonomous mobile 3D printing solution for metal parts is drafted that allows the supply of spare parts and special parts close to the point of need. The approach is going to render an end-2-end solution suited to comprise a mobile shelter, pre- and post-processing steps and a laser-printing system completed by a set of supporting services.
Beneath the current status of the project, the currently limitating factors will be highlighted. A prospect of applicable solutions and next steps will be shown.
Additive layer manufacturing of plastics is experiencing a paradigm shift. Following its initial development in rapid visual prototyping, the industry is now looking into the technology as a full production technique to achieve tailored design but also new lightweighting solutions which are not viable with other manufacturing methods.
To support this transition, the engineering workflow which is daily applied for traditional manufacturing processes needs to be replicated and adapted to additive manufacturing. Printer manufacturers, material suppliers and end-users need predictive simulation tools to bring the additive manufacturing efficiency and performance to the next level required by the industry. This paper presents a holistic simulation approach for additive manufacturing of plastics and composites, covering material engineering, process simulation and structural engineering of both SLS and FDM type of processes.
Additive manufacturing modeling is a true multi-scale challenge. Insights on how the simulation of the 3D-printing process can be solved via multiscale thermo-mechanical models are presented. The numerical simulation follows the real printing workflow, takes into account all process parameters and allows to predict the deformed shape of the part, residual stresses and the process microstructure, such as porosities distribution and printing direction. Some optimization techniques are further considered to minimize part warpage.
Multiscale material modeling techniques applied to additive manufacturing of polymers (unfilled and reinforced) will be detailed. Applications include the computation of the effective mechanical response of lattices, the homogenization of the material behavior of reinforced polymers and the build-up of nonlinear material models as a function of the printer toolpath by reverse-engineering experimental tensile datasets.
Finally, to bridge the gap between process and as-printed part performance, a strongly coupled process-structure methodology will be shown, as key enabler for predictive simulation of new lightweight high performance designs. This approach links the material anisotropy, the process-induced microstructure and the part performance. The part strength sensitivity to the printing direction is demonstrated and validation against experimental tests is achieved.