Advantages of Additive Manufacturing for the production of technical parts
Dr. Benjamin VAYRE EBM and R&D
Our technology : Powder Bed Additive Manufacturing (Laser or Electron Beam melting) Direct Laser Forming Applying new powder layer
Melting by Laser/EB
3D-CAD Model in layers
New geometries out of serial metallic materials
Standard Metal Powder
Lowering of Build Platform
Académie des technologies – Paris, 08/04/2015
Our technology : Additive Manufacturing (Selective laser and Electron Beam melting) • Use of standards materials
• Layer-by-layer manufacturing
Tool Steel Stainless Steel Titanium alloy Aluminum alloy Nickel Based alloys …
Actually 18 different materials
Académie des technologies – Paris, 08/04/2015
Our Metal division :
Trumpf DLF250
EOS M270 (4 machines)
EOS M280 (2 machines)
ARCAM Q20
Concept Laser Xline
04/2011
04/2008
03/2014
03/2013
07/2010
07/2012
Concept Laser M2
Concept Laser M1
12/2013
07/2014 06/2014
SLM Sol. 280HL
SLM Sol. 500 Académie des technologies – Paris, 08/04/2015
EBM equipment : the new Q20 from ARCAM Largest in the market, higher productivity, better surface quality
Hot process Ti6Al4V Diam 370 mm, 380 mm high New PRS LayerQam (in situ monitoring)
Académie des technologies – Paris, 08/04/2015
Our Polymer division : FDM process
SLS Polymer systems
Académie des technologies – Paris, 08/04/2015
Our post manufacturing equipments :
•
several HT ovens
• 5 axis CNC
• Chemical etching ….
Académie des technologies – Paris, 08/04/2015
Our Quality department Internal Control laboratory
Académie des technologies – Paris, 08/04/2015
Part 2 : What is our understanding of additive manufacturing?
Simultaneous creation of a near net shape component, material microstructure and properties through layered addition of material
Académie des technologies – Paris, 08/04/2015
Part 2 : What is our understanding of additive manufacturing? To qualify this process we need : -Understanding in the material science -Understanding in the process -Understanding in the design rules
Académie des technologies – Paris, 08/04/2015
Industrial cases Motor sport
• Small series production
Aerospace Aerospace
• Manufacturing of complex geometries
• Very complexe geometry • Ligth weigth parts, integration of functions,… • Short delivery time
Medical
• Manufacturing of individual implants directly from CAD-data
• Manufacturing costs independent • Reduction of manufrom shape complexity facturing times and improvement of medical • Ligth weigth parts, integration of characteristics functions,…
Académie des technologies – Paris, 08/04/2015
Using special CAD software based on FEA and free form additive manufacturing technologies offers new opportunities for new performances
Académie des technologies – Paris, 08/04/2015
Poly-Shape in the aerospace and aeronautical Aerospace
53 flying metal parts in the nEUROn since December 2012 Académie des technologies – Paris, 08/04/2015
Aerospace
Weigth reduction in an Helicopter application Case study : Aluminum part Application : Bracket Curent manufacturing solution : milling Volume of the milled part : 476 gr Initial part
Académie des technologies – Paris, 08/04/2015
Weigth reduction in an Helicopter application
Different designs for different loading cases Académie des technologies – Paris, 08/04/2015
Pivot link for solar panels Weigth reduction in a Satellite
Presented by TAS at CNES exhbition 2013 Académie des technologies – Paris, 08/04/2015
Conclusion • Additive manufacturing process gives new opportunities in the aerospace market. Added value can be in a better buy to fly ratio, new performances, higher flexibility of the supply chain or reduction of NRC for example. • Some parts produced by ALM are already flying. • To use this new manufacturing process a deep and total understanding is needed (Design, Material and process) • One risk is to believe that this is just a « push buton » 3D printing process
Académie des technologies – Paris, 08/04/2015
Thank you for your attention !
AddiCtive Manufacturing ®! www.poly-shape.com
[email protected]
Académie des technologies – Paris, 08/04/2015
