Additive manufacturing metal

© 2011 Infotech Enterprises. All Rights Reserved
We deliver Global Engineering Solutions. Efficiently.December 31, 2012
Additive Manufacturing

© 2011 Infotech Enterprises
 Definition and Various Techniques
 Areas/Industries of application and adoption
 Features/Benefits
 Limitations
 Example of company that manufacture equipment for additive manufacturing
 Cost Illustrations
 Examples of adoption
Index
2

 Additive manufacturing (AM) is a process of making
three dimensional solid objects from a digital model.
 Where an object is created by laying down successive
layers of material.
 Traditional machining techniques (subtractive
processes) which mostly rely on the removal
 AM process takes virtual designs from computer aided
design (CAD) or animation modelling software,
transforms them into thin, virtual, horizontal cross-
sections and then creates successive layers until the
model is complete.
 Though many techniques are available, Direct Metal
Laser Sintering (DMLS), Selective Laser Sintering
(SLS), Fused Deposition Modelling (FDM) and
Stereolithography (SLA) are popular. Of these, DMLS
and SLS have been widely adopted.
Additive Manufacturing
3

Various Techniques
4
Additive technologies Base materials
Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders
Direct Metal laser sintering (DMLS) Almost any metal alloy
Fused deposition Modelling (FDM) Thermoplastics, eutectic metals
Stereolithography (SLA) Photopolymer
Digital Light Processing (DLP) Liquid resin
Fused Filament Fabrication (FFF) PLA, ABS
Melted and Extrusion Modelling (MEM) Metal wire, plastic filament
Laminated object manufacturing (LOM) Paper, metal foil, plastic film
Electron beam melting (EBM) Titanium alloys
Selective heat sintering (SHS) Thermoplastic powder
Powder bed and inkjet head 3D printing, Plaster-based 3D
printing (PP)
Plaster
Source: AIM practice, Infotech, Secondary research incl. Wikipedia

Areas of Adoption
5
Adoption of Rapid Prototyping in respective industries
Additive Manufacturing (AM) Industry projected to be a $5.2 billion industry
by 2020 – Wohlers Associates
Industries such as auto and consumer have maximum
adoption rates of additive manufacturing – prime reasons
being additive manufacturing aids in reduction of their
‘prototyping to manufacturing’ life span thus reducing
time to market
Aerospace and military agencies
have a lower adoption rates due to
regulatory complexities and size
complexities
Source: AIM practice, Infotech, Secondary research incl. Wikipedia

Benefits/Features
6
 Helps reduce the need for tooling (moulds/jigs)
 Simplifies the supply chain & reduces capital investment - helps variablizing costs of jigs and fixtures
 Enables complex geometries
 Part consolidation, Optimized geometries, Personalized & customized products
 Enables weight reduction and optimization
 For e.g. Virgin Atlantic’s first class monitor arm weighs 0.8 kg if machined while 0.37 kg if done through
additive mfg.
 EADS quotes that about 150 kg can be reduced from aircraft if 1000 parts are manufactured through AM
techniques i.e. $13.5 M in fuel savings alone per aircraft over 30 years life span
 Enables carbon foot print reduction by 50% on a typical long-haul application
 Enables faster design to build cycles by cutting down the lead time required for prototyping and mfg. phases
 Enables new business and supply chain models
 Distributed manufacture with less transportation - production closer to the consumer
Source: AIM practice, Infotech, Secondary research, Econolyst report

Limitations
7
• Large volumes production may not be feasible.
• Process Certification for each Part production.
• Limitation on machine table size.
• Huge size parts cannot fit the table size.
• Initial machine investment & maintenance are very high
Benefits
Challenges
Source: AIM practice, Infotech, Econolyst

© 2011 Infotech Enterprises 8
Laser Sintering Process Technique …..
Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3)
• Laser-sintering is an additive layer manufacturing technology and the key technology for e-Manufacturing.
• It enables the fast, flexible and cost-effective production of products, patterns or tools directly from 3D
models
• Production of tooling inserts, prototype parts and end products using Direct Metal Laser Sintering
Process Description
• Building part layer-by-layer
• Starting with thin powder layer on platform
• Fusing powder in shape of 2D cross-section
• Lowering platform about next layer thickness
• Filling lowered volume with powder and fusing again
Beam Source
Powder Laser Beam
Source: AIM practice, Infotech, primary research with supplier, secondary research

Laser Sintering Process Technique …..
Direct Metal Laser Sintering (DMLS)
• Process used for Aero engine parts Manufacture and
Repair or Tooling development
• The technology fuses metal powder into a solid part by
melting process through focussed Laser beam.
• Additive manufacturing process layer by layer
• Parts produced with high Accuracy, Surface quality and
excellent Mechanical properties
• Material ranging from Steel to Super- Alloys and
Composite metals can be processed
• Cost effective mfg. of raw parts substitution of castings.
• Mfg. of tooling, rig and development of hardware.
• Mfg. of functional structures to reduce weight and cost.
• Compressor vane segments with integrated
honeycombs (IN718).
A DMLS Machine
Raw material manufacture
Compressor Vane segments with
honeycombs
Hydraulic manifold -
Structures development
Source: AIM practice, Infotech, primary research with supplier, secondary research

A DMLS Machine Cost - EOS
Machine Cost :
Euros 600,000
Machine cost Includes:
• Machine Installation
• Customization settings
• Training
• Warranty period
DMLS Machine
Machine Cost
• The machine cost : Euros 600,000* (Installation +Training+ Warranty Period).
• The Time required to market the Parts produced would take minimum 1 year –
after machine installation.
* Import duty charges not considered in the cost
 Determine material property database
 Define process and quality specifications
 Improve productivity
 Establish a robust manufacturing process
 Generate experience as supplier
Conditions - Time to Market
Source: AIM practice, Infotech, primary research with supplier

Comparison - NRE vs. Variable Cost
NRE’s
• Facility – Machine and Manpower.
• 3D Model - CAD Software.
• Technical training
Variable Cost
• Materials used for production process
• E.g. DMLS for Aero requires IN718 or TI64 types of metal powders which
cost approx. EUR 150 - 500 per kg depending upon the grain size. Typical
wastage is around 3-5%. So a kg of part will require about the same
quantity of metal powder
• Maintenance expenses (10-20% of the fixed cost)
• Plus other operational expenses such as power, fuel etc.
Powder / Consumables Cost of Powder Euros/ Kg
EOS Maraging Steel MS1 235.00
EOS Stainless Steel GP1 80.00
EOS Stainless Steel PH1 90.00
EOS CobaltChrome MP1 280.00
EOS Titanium Ti64 (dangerous good - special packaging required) 485.00
EOS Nickel Alloy IN718 155.00
EOS Nickel Alloy IN625 155.00

Profile of EOS – Supplier of Equipment …
DMLS Machine (EOSINT M280)
EOS supplies to MTU
• Partially MTU (USA) is using this process for manufacturing of Aero engine parts and development of Rigs /
tools.
• MTU have 6 EOSINT Machines – 4 Production machines & 2 Technology machines.

Applications
13

Metal Applications
14

Aerospace Applications
15

Potential Aero Engine parts
16
• Nose cone
• Swriler
• Vanes
• Blades
• Variable Geometry
parts
• Honeycombs
• Panels
• Fairings
• Bearing Cases
• Discs
• Rings
• Blisk
• Cases
Parts Category

Outlook for Additive Manufacturing (AM)
Source: Boeing Research
• New materials are becoming available for AM processing
• Benefits of AM will be extended beyond current applications with new
materials
• Patent system and excessive litigation, have slowed development in AM
• These technologies are viable in high labour cost nations, even in the face
of competition
• AM equipment needs to become more robust, look to CNC and injection
moulding history
• Analysis methods need to grow with new geometric capabilities

Few benefits/features of DMLS in aerospace sector
Benefits
• No tooling
• Long product lifetime
• Storage of tools and fixtures
• Modifications and upgrades
• Spare parts on demand
• Design for function not for production
• Weight reduction
• Integrated subsystems
• New functionality
• Highest flexibility
• Investing in parts not in tools
• Just in Time Investment

DMLS Specifications and Logistics
EOSINT M280 – Technical Data
Machine Cost :
Euros 600,000
Machine cost Includes:
• Machine Installation
• Customization settings
• Training
• Warranty period
DMLS Machine

3D Printer – Working Principle
3D Printer - SST1200es
21

Laser Sintering Process
EOS materials
• EOS Systems can process a variety plastic and metal powder materials.
Laser Sintering Technology
• Laser-sintering is an additive layer manufacturing technology and the key technology for e-Manufacturing.
• It enables the fast, flexible and cost-effective production of products, patterns or tools directly
from 3D models
• Production of tooling inserts, prototype parts and end products using Direct Metal Laser-Sintering
(DMLS).
Process Video

Additive manufacturing metal

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