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Tom de Bruyne - Layerwise
- 1.
Let Additive Manufacturing Inspire You
Themadag Additive Manufacturing
Mikrocentrum TNO
LayerWise 2012
1 www.layerwise.com
© LayerWise NV, all rights reserved
Click to edit Master subtitle style
6/4/2012
Who we are
“What is the manufacturing potential of
Selective Laser Melting”
Experiences at LayerWise NV
2012
2 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 2. Content
About LayerWise
Technology
Drivers for SLM manufacturing
Future outlook
3 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
About LayerWise
Increase your added value
through advantages of
Metal Additive Manufacturing
Therefore LayerWise offers its technological expertise realized by being technology
developer as well as technology user
4 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 3. About LayerWise
1989 1991 2001 2007 2008 2009 2010 2011 2012
Phd P. Full Thin Wall
Start of Start of Thin Wall Thin Wall Thin Wall Thin Wall
Mercelis Dense 0.19MM
AM METAL 0.5MM 0.3MM 0.225MM 0.18MM
Metal
Research Research Phd J. Van Samples
Vaerenbergh
RP SLM 0% 10% 50% 70% 90%
SLS Manufac Manufac Manufac Manufac Manufac
Sintering turing turing turing turing turing
5 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
About LayerWise
ISO 9001 & 13485 certified
chemical mechatronics
standard implants
dental prostheses pharma mechanization
customized implants
crowns and copings food solar-lighting
medical tools
pressure & gas electronics
medical modeling
automotive aerospace
consumer tooling
6 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 4. Technology
7 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Technology
Directly from 3D CAD
Layer-wise production
3D components by successive
connection of thin 2D layers
8 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 5. Technology
9 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Metal Additive
Manufacturing
Principle
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© LayerWise NV, all rights reserved 10
© LayerWise NV, all rights reserved 6/4/2012
- 6. Technology
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© LayerWise NV, all rights reserved 6/4/2012
Technology
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© LayerWise NV, all rights reserved 6/4/2012
- 7. Technology
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© LayerWise NV, all rights reserved 6/4/2012
Technology
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© LayerWise NV, all rights reserved 6/4/2012
- 8. Drivers for SLM manufacturing
Additive manufacturing
Same material
Same characteristics
What is the added value?
15 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
16 www.layerwise.com
© LayerWise NV, all rights reserved 16
© LayerWise NV, all rights reserved 6/4/2012
- 9. Drivers for SLM manufacturing
Manufacturing Cost Total cost of ownership - performance
Type of Driver Mostly small parts Small, medium and large parts
part
SLM feature Tool-less • Monolythic construction
manufacturing • Flow-optimized
• Miniaturisation
• Customisation
• Mass reduction
17 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
CFD analysis SLM Manufacturing
Flow type Channel shape Pressure drop Heatex
Laminar Cross section Variable sections Conformal
Turbulent 3D traject restriction Balanced
18 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 10. Drivers for SLM manufacturing
10 mm
19 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
20 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 11. Drivers for SLM manufacturing
200 mm
21 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
22 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 12. Drivers for SLM manufacturing
23 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
24 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 13. Drivers for SLM manufacturing
25 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
26 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 14. Drivers for SLM manufacturing
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© LayerWise NV, all rights reserved 6/4/2012
Drivers for SLM manufacturing
Custom made hip implants with porous structure rigidly connected to the
implant for a severe pelvic discontinuity (left) and separate parts in a multi
component revision (right). Courtesy: Mobelife NV, Leuven, Belgium
28 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 15. Future outlook
“What is the manufacturing potential of
Selective Laser Melting”
Experiences at LayerWise NV
2012
29 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Future outlook
30 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 16. Future outlook
SLM is here to stay Technology will shift
– Technology development Purpose-built AM lines
– Awareness SLM specific Automation - process control
design
Cost will decrease
Standardization is needed Build rate
– Material material
– Validation
31 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Future outlook
Materials : Stainless, super alloys, heavy metals (18+ materials)
Cost : 2008 -> 2012 - buildrate x 4
Upscaling : max dimenions x 5 to circa 500 mm
Surface control : Ra 5 -> Ra 0.9 & Ra 0.1
Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)
Pardigm shift: DfM-> design for function
32 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
- 17. Future outlook
Sustainable PRODUCTION Sustainable PRODUCTS Sustainable ECONOMICS
Material Weight Sustainability is not
(ex 1/20 BtoF) (ex 30% payl.) the incentive...
Ancilliary consumables Plant footprint
(ex tooling) (ex inj. molding)
but value creation
Re-localized production Process intensification
(ex LayerWise (ex flow reactor)
comes from
sustainable design
33 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012
Contact details
LayerWise N.V.
Kapeldreef 60
3001 Leuven
Belgium
tel: +32 16 29 84 20
fax: +32 16 29 83 19
www.layerwise.com
info@layerwise.com
34 www.layerwise.com
© LayerWise NV, all rights reserved 6/4/2012