Industrialization of Additive Manufacturing

Report
The industrialization of Additive Manufacturing
Olivier Jay, Head of section
Additive Manufacturing
Tel: +45 7220 1713
[email protected]
STATUS
An independent, non-profit institution
Approved as a technological service institute by the Danish
Ministry of Science, Technology and Innovation.
OBJECTIVE
The objective of the Danish Technological Institute is to
address the needs of the industrial sector and society as
a whole through the development and dissemination of
technological innovation.
KNOWLEDGE PROCESSES AT DTI
Knowledge development
Develops new knowledge through R&D activities –
national as well as international
Knowledge application
Knowledge application takes place through
general technological services, e.g.
laboratory tests, testing, calibration and
certification
Knowledge transfer
In interaction with and supplying advisory services
to private and public market players, e.g.
consultancy, education and operator tasks
THE INSTITUTE COVERS A SIGNIFICANT NUMBER OF
SMALL AND MEDIUM SIZED ENTERPRISES IN 2010
82%
Delivery of services to 14,895 companies of
which 9,449 were Danish.
Share of companies, in total 9,449
Share of revenue, in total EUR 37.4 million
43%
38%
19%
12%
6%
0-49
50-199
200+
Number of employees in companies (customers)
Additive Manufacturing AM
 RPT (Rapid Prototyping Technologies),
 ALM (Additive layer manufacturing)
 RM (Rapid manufacturing)
 AF (Additive fabrication)
 DDM (Direct digital manufacturing)
 SFF (Solid freeform fabrication)
 LM (Layered manufacturing).
 ….
AM is the application of layer manufacturing techniques for the fabrication of functional longterm models or enduse products. The physical inputs into the RP systems are the materials,
CAD model and laser. By using different RP technologies, final net shape metallic parts can
be fabricated. It is a one-step process in which tooling is eliminated thereby reducing
production time and cost.
3D Printed Violin
Additive Manufacturing – The next industrial revolution
Technologies
Stereolithography
(SLA)
Selective Laser
Sintering (SLS)
Fused Deposition
Modelling (FDM)
3D Printing
(3DP)
Metal Technologies
(SLM, DMLS)
26,4% Compound annual growth rate for 1988–2011
Electron Beam Melting (EBM®)
Principle of the SLM Process
x-y Scanner
Laser
Laser Beam
Levelling System
Inert
Gas
F-Theta Optic
Metal Powder
Part
Laser Beam
Part
Powder
Retractable Platform
Long tail
Volume
Product lifetime
Time to market
Response of the market
Personalization
Design
Price
Product Variety
EPO's European Inventor Award 2012 goes to outstanding
inventors from Germany, France, Denmark and Australia
Industry: Widex (Denmark), for their invention of a computer-aided
method to manufacture individually-fitted hearing-aid devices;
http://www.youtube.com/watch?v=Dw82KSzvkAs&feature=player_embedded
Customization Who is the developer ?
Ramp up
The beauty of Rapid Manufacturing.
”The RM technology has given us a bigger creative designing space, because we
are no longer limited by a particular geometric shape.
We do not produce tools, which means that the production process is reduced to
a few weeks where it before took between 4 to 6 months.
The time factor means that we can now try out our ideas, and it gives us
an enormous amount of freedom”
Leif Johannsen, Chief Officer of Acoustics and Technology
Qphase density for a scan velocity of 23 cm/s
100
90
Relative density (%)
80
70
21/01 test cubes
22/01 test cubes
60
50
40
0
50
100
150
Laser power (W)
200
250
Sustainable
Pumps and the world's electricity consumption



Today pumps account for no less than 10% of the world's electricity consumption.
Two third of all pumps use up to 60% too much energy [2].
If every business switched to a high efficiency pump system there could be global savings of
4% of the total electricity consumption- comparable with the residential electricity consumption
of 1 billion people
Parts with complex internal channels

Demonstrator part: crossing manifold
a manifold to let 2 hydraulic lines cross each other in limited space
230x230x54 mm
20,15 Kg
Conventional manifold design
18
dp Conventional
16
dp AM - SLM
pressure loss in/out [bar]
14
12
10
8
6
5,516
4
2
1,733
0
0,421
1,506
0,95 Kg
-2
30
50
70
90
110 130 150 170 190 210 230 250 270
flow [l/min]
80x80x50mm
Adri Overbeeke
Economy
and
Environment
Education
Design
RM
Quality
control
Production
Finish
www.rm-platform.com
Thank you for your attention
Olivier Jay
Telephone: +45 72 20 17 13
[email protected]
www.garpa.org

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