Tips for Additive Manufacturing
in Metal
Before We Start
 This webinar will be available afterwards at
designworldonline.com & email
 Q&A at the end of the prese...
Moderator

Presenter

Leslie Langnau

Tom Pasterik

Design World

ExOne
About ExOne
•

ExOne is a leading additive manufacturing
company dedicated to the industrial manufacturing
sector.

•

ExO...
ExOne Global Facility Locations
Products Produced
ExOne Overview
Distinctive Technology Features

•

Largest build envelopes available

•

Finely detailed complex shapes

•

Print Speed

...
Direct Metal Process
-

ExOne offers digital part materialization in several metals and metal
alloys, including:

•

316 S...
In Direct Metal - Sand Process
-

ExOne offers digital part materialization in various
combinations of sand casting media ...
ExOne Systems

M-Lab

M-Flex

M-Print
S-Print

S-Max
ExOne’s Process
ExOne’s Process
ExOne’s Process
Optimizing for Manufacturing
•

With simple changes such as automated transfers and print run
layout, an additive manufact...
ExOne in a Factory Environment
Advantages of Additive Manufacturing
•

The digital process offers design freedoms not possible in
traditional molds, core...
Project Overview
•

Advance optimization of a traditionally manufactured control arm from a domestic super car by using ad...
The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part ...
The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part ...
Unlimited Variable Geometry
Finding the Best Internal Structures
Initial Reference for Cellular Structure
Base Model Control Arm
Indirect Metal Printing Process and Cast
Advanced Control Arm Is Modeled with Free Constraints
Advanced Model Passes Simulation: Export
Direct Metal Printing Process
Direct Metal Printing – Final Product
Direct Fabrication
Project Specifications
Next Steps – Advanced Designs w/ Automatic Closed Loop Simulation Feedback
Services
Questions?
Design World

Leslie Langnau
llangnau@wtwhmedia.com
Phone: 440.234.4531
Twitter: @DW_3DPrinting

ExOne

Tom Pas...
Thank You
 This webinar will be available at designworldonline.com & email
 Tweet with hashtag #DWwebinar
 Connect with...
Tips for Additive Manufacturing in Metal
Tips for Additive Manufacturing in Metal
Tips for Additive Manufacturing in Metal
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Tips for Additive Manufacturing in Metal

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With simple changes such as automated transfers and print run layout, an additive manufacturing production process can be optimized to maximize output. Hear how ExOne takes “3D printing” into the realm of manufacturing production. Tom Pasterik, Manager of Application Engineering for The ExOne Company, will discuss what it takes to shift from 3D printing/prototyping to additive manufacturing production, using an example of a traditionally manufactured control arm from a domestic super car and making it using additive manufacturing processes.
Learn how to shift from 3D printing/prototyping to additive manufacturing
Understand the pros and cons of additive manufacturing
Tips on finding the right internal structures for your designs
Learn about the various direct metal printing processes

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Tips for Additive Manufacturing in Metal

  1. 1. Tips for Additive Manufacturing in Metal
  2. 2. Before We Start  This webinar will be available afterwards at designworldonline.com & email  Q&A at the end of the presentation  Hashtag for this webinar: #DWwebinar
  3. 3. Moderator Presenter Leslie Langnau Tom Pasterik Design World ExOne
  4. 4. About ExOne • ExOne is a leading additive manufacturing company dedicated to the industrial manufacturing sector. • ExOne is a global supplier of industrial 3D printing systems and offers design and manufacturing services of 3D printed products. • ExOne Production Service Centers are located throughout the United States, Germany and Japan. • ExOne systems are able to print in a variety of industrial materials with the largest available build sizes.
  5. 5. ExOne Global Facility Locations
  6. 6. Products Produced
  7. 7. ExOne Overview
  8. 8. Distinctive Technology Features • Largest build envelopes available • Finely detailed complex shapes • Print Speed • Final Product Accuracy • Industrial Grade Materials
  9. 9. Direct Metal Process - ExOne offers digital part materialization in several metals and metal alloys, including: • 316 Stainless Steel Infiltrated with Bronze • 420 Stainless Steel Infiltrated with Bronze • Iron Infiltrated with Bronze • Bonded Tungsten - Additional material systems are currently in development, and partnership opportunities are available for specific materials. - The 3D printing process in metal includes printing, curing, depowdering, sintering, infiltrating and annealing. - Build Volume (WxDxH): 780 x 400 x 400 mm (30.7 x 15.75 x 15.75 in.) - Build Speed: 6 mm/hr (.24 in/hr)
  10. 10. In Direct Metal - Sand Process - ExOne offers digital part materialization in various combinations of sand casting media and chemical binders, depending on the desired strength and level of detail: • Silica Sand • Synthetic Sand • Other casting media - Digital production of sand molds and cores eliminates the need for hard tooling and drastically reduces lead times. - Standard foundry industry materials are used, enabling easy integration of the molds and cores into existing manufacturing and foundry procedures. - This digital process offers design freedoms not possible in molds and cores produced using the traditional pattern approach. - Build Volume (WxDxH): 1800 x 1000 x 700 mm (70 x 39 x 27 in.)
  11. 11. ExOne Systems M-Lab M-Flex M-Print S-Print S-Max
  12. 12. ExOne’s Process
  13. 13. ExOne’s Process
  14. 14. ExOne’s Process
  15. 15. Optimizing for Manufacturing • With simple changes such as automated transfers and print run layout, an additive manufacturing production process can be optimized to maximize output.
  16. 16. ExOne in a Factory Environment
  17. 17. Advantages of Additive Manufacturing • The digital process offers design freedoms not possible in traditional molds, cores and machining approaches • Endless patterns and part geometry • Functional working prototypes for real life applications • Prototyping can turn directly into low or high volume production runs • Draft angles can now be eliminated • No tool paths or tooling required • Advanced venting schemes and integrated rigging features are also possible • Different parts can be built in a single print bed • Parts can be modified on the CAD file in seconds, and reprinted without complicated tooling changes.
  18. 18. Project Overview • Advance optimization of a traditionally manufactured control arm from a domestic super car by using additive manufacturing processes. • Push the boundaries of 3D metal printing and design inside a real and applied production workflow with practical outcomes. • Examine existing and heavily optimized designs made using traditional methods and see if they can be optimized even further using new modeling approaches. • Develop new workflows and processes that can directly capitalize on the many benefits that 3DP offers. • Reduce weight while still retaining the same structural properties of the what is said to be “already optimized” traditional control arm.
  19. 19. The Idea Take existing production part and provide further optimization and modeling in pre-constrained areas of the part for three different 3DP workflows: • Printed sand mold package for traditional foundry casting • Conservative/constrained direct metal printing • Unlimited direct metal printing
  20. 20. The Idea Take existing production part and provide further optimization and modeling in pre-constrained areas of the part for three different 3DP workflows: • Printed sand mold package for traditional foundry casting • Conservative/constrained direct metal printing • Unlimited direct metal printing
  21. 21. Unlimited Variable Geometry
  22. 22. Finding the Best Internal Structures
  23. 23. Initial Reference for Cellular Structure
  24. 24. Base Model Control Arm
  25. 25. Indirect Metal Printing Process and Cast
  26. 26. Advanced Control Arm Is Modeled with Free Constraints
  27. 27. Advanced Model Passes Simulation: Export
  28. 28. Direct Metal Printing Process
  29. 29. Direct Metal Printing – Final Product
  30. 30. Direct Fabrication
  31. 31. Project Specifications
  32. 32. Next Steps – Advanced Designs w/ Automatic Closed Loop Simulation Feedback
  33. 33. Services
  34. 34. Questions? Design World Leslie Langnau llangnau@wtwhmedia.com Phone: 440.234.4531 Twitter: @DW_3DPrinting ExOne Tom Pasterik tom.pasterik@exone.com Phone: 724.765.1361 www.exone.com
  35. 35. Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #DWwebinar  Connect with  Discuss this on EngineeringExchange.com
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