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Gregor van Baars - TNO

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  • 1. Mikrocentrum AM themadag: Additive Manufacturing opening a revolutionary future for High Tech equipment Gregor van Baars, TNO Technical Science, (gregor.vanbaars@tno.nl) june 7th, 2012AbstractAdditive Manufacturing is a rapidly developing field that opensrevolutionary opportunities for many applications and industrial sectors.This presentation focuses on high tech equipment development andprecision mechatronic systems. Starting from the future challenges asrepresented by high tech equipment roadmaps, a vision will bepresented on how AM may enable new and revolutionary solutions inthe development of precision mechatronic systems. Illustrativeexamples will be presented to illustrate the potential of innovativecombination of new manufacturing technologies and mechatronicdesign.
  • 2. Additive Manufacturing claimed tolaunch the 3rd industrial revolution)Introduction Adaptive Manufacturing is developing fast AM processes and technologies, materials, process control and AM product quality, design tools/input Will have impact on many industrial sectors Creativity / art / @ home Health / medical / implants / Food Industrial manufacturing High tech equipment ??? My focus = High tech systems Views on Mechatronics & Manufacturing innovation
  • 3. High Tech System trends High Tech Systems (examples)Semiconductor Solar cell Printed electronics OLED lighting Flat panel display Wide format printing Aerospace ... AND OTHERS ... High Tech Processes High Tech System Equipment - Lithography - Better accuracyApplication - Printing Generic - Higher productivityspecific - Thin film requirements - Bigger substrates - Layer deposition - Lower costSpecific - Imaging Shared - Faster time to marketinnovation - … innovation - Less failure / maintenance - More autonomy, intelligence - Less calibration, self learning - … High Tech Systems: future challenges Primary roadmap challenges: Mechatronic bottlenecks: Better accuracy Internal deformation Higher productivity Mass avalanche Bigger substrates Thermal behaviour Overall complexity Now is the time to develop new solutions:  System architectures  Mechatronics technologies  Optimized design  Manufacturing technologies
  • 4. Combined mechatronics and manufacturing innovation New system architectures Next generation HPS architectures Optimal design tools Enabling multiple High tech New design analysis tools applications Healthy eco-system academia Mechatronics R&D centers Manufacturing innovation innovation Supply chain OEM More design freedom New materials Lower NRE cost New production technologies High speed production New production equipment Complexity at no extra cost Small series at no extra cost Vision on High Tech Systems innovationOptimizing complex, multi-criteria, Need for breakthroughmulti-disciplinary designs requires equipment architecturesdesign support High Precision Systems and technologies Mechatronics Provides ultimate design Architecture freedom + integrationMulti-physics modelsMulti-scale models If you can design it, youEfficient optimization can make it at low NREalgorithms Optimization AdditiveHandle design constraints based design manufacturing Need to understand and control the AM process + material properties Expand range of high tech materials Equipment for High Tech Additive ManufacturingIndustrial size of productsHigh resolutionMulti-materialFeasible production speedScale up from lab toequipment performance
  • 5. Additive Manufacturing Lots of AM technologies, expertise Already applied in aircraft, automotive industry Rapid developments towards High Tech: AM processes High Tech materials : metals, ceramics, .. AM equipment Real parts and products “Manufacturing for design” instead of “Design for Manufacturing” AM impacts whole innovation chainTraditional innovation chainAM enabled innovation chain 4. Additive manufactured components AM as an integral step in the innovation chain will have impact on every other step ..and will enable a revolutionary breakthrough for the whole chain
  • 6. AM enables new High Tech Systems solutions High Precision Systems Mechatronics Architecture Optimization Additive based design manufacturing LIGHTWEIGHT INTEGRATED FREEFORM AM propositions to High TechLIGHTWEIGHT Lightweight Mass reduction is desired for many reasons Design optimization results can be manufactured almost directly Typically factor of two mass reduction, or even more Freeform Design for optimal function and performance, instead of design for manufacturing Especially interesting for flow and thermal design (channel diameter, bends, pressure loss)INTEGRATED Reliability through high integration level Fewer BOM parts, less assembly Fewer connections e.g. in cooling channels, small assemblies Avoiding difficult manual integration Material properties by design Spatial distribution of stiffness, damping, density etc. Isotropy is a choice, anisotropy is a design freedom FREEFORM Multi-material combinations during manufacturing; grading of properties Fast design iterations because of low NRE cost Can have first product fast, concept/design confirmation Complexity at no additional cost Small series at no additional cost Lean logisitics: fewer parts, less spare parts stock, life cycle management
  • 7. How to make this High Tech revolution happen? Have the skill to design, analyse, and manufacture high tech system parts that fully exploit the new design freedom as provided by AM for the next generation high tech equipment This will hinge on: Designing with AM posibilities in mind instead of conventional design for manufacturing and assembly constraints Mastering optimization based design tools Material knowledge and AM process control to get the desired quality and repeatability Embedding AM in the high tech supply chain Development of adequate high tech AM equipment and materials Working together : across technologies and across the eco-system End of presentation

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