SIRRIS – ADDDesign for Additive ManufacturingThierry Dormal
Agenda ESMA - November 8Design for additive manufacturing   – 25 min – Thierry DormalAM Technologies for polymer parts   –...
Sirris ADD capacities & competenciesADD (1990 – 2012)   • 15 engineers and technicians   • Two locations: Liège (10 p.) an...
Raw materials for AM   Liquid                      Powder                   Plate or sheet                  PasteStereolit...
Rapid Prototyping  Additive manufacturing•   Cost reduction and short leadtime•   High geometrical complexity and freefor...
Additive Manufacturing•   Three different ways of using AM technologies•    Prototyping for visual models or functional p...
Additive Manufacturing % conventional techniques•   With the conventional technologies (milling,    moulding), the design ...
Additive Manufacturing Limitations    •    Geometrical limitations:          • Wall thickness: 0.3 mm – 1.5 mm          • ...
Geometrical Complexity (Polymers)•   No tool required for series production:•    No draft angle required for demouldabili...
Geometrical Complexity (metal)•   No tool required for series production:•    No draft angle required for demouldability•...
Less components - Assembly reduction•   Redesign of a laser collimator for space app.:•   13 components  2 components•   ...
Integration of functions•     Integration of snap fits, hinges,...                                      EOS    EBM - Oak R...
Integration of functions•   The design of a complex part with    several local functions (spring effect,    damping effect...
Lightweight parts – Lattices structures•   Weight reduction using lattices structures        with minimal strength reducti...
Lightweight parts - Topology optimization•   Automated design based on the applied constraints (Topol)•   Same mechanical ...
Stress verification   Lightweight parts - Topology optimization Free space definition                          Flying Cam ...
Customization – unique parts & short series•   Unique parts for art, aerospace,    biomedical (hearing aids)•   Mass custo...
Customization – unique parts & short series• Olaf Diegel(Massey University)                                       Design: ...
Customization – unique parts & short series  Aline Salmon                          Sac féminin haut de gamme  3DP métal (S...
3D surface texturing•   Library of texturing types available for the designer•   Stone, wood, marble, leather, …•   Visual...
3D surface texturing                       ©Materialise Software                                               21
Conformal cooling channels - Hipermoulding project4 injection moulds produced with & without conformal cooling channels   ...
Catamaran (Hydrauvision) – Compolight projectHydraulic units with complex internal channelsReduction of the weight and siz...
Functionaly Graded Materials Example with Ti alloys (source OPTOMEC):     3 different Ti alloys with 3    specific functi...
Porosity control (3DP Prometal ex-One) • The porosity isInvestigation ways to manage the porosity:(not a macro porosity wi...
Drilling machine for aerospace•Technical reasonsMechanical characteristics of TitaniumDesigned for weight optimizationInte...
FLYING-CAM             UNMANNED AERIAL SYSTEMSMost of the components produced by AM44 parts in PA + C31 parts in PA (white...
Summary•   AM : huge design freedom•   Some limitations / guidelines need to be known•   AM should be considered from the ...
Additive Manufacturing – E-learning & Handbook•   KTRM Leonardo project•   Partners: ASCAMM, SIRRIS, ASERM, iSmithers, Mat...
Additive Manufacturing                   ThanksContact: Thierry Dormal   thierry.dormal@sirris.be                         ...
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2012 11-08-3 d-printing-event-design

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2012 11-08-3 d-printing-event-design

  1. 1. SIRRIS – ADDDesign for Additive ManufacturingThierry Dormal
  2. 2. Agenda ESMA - November 8Design for additive manufacturing – 25 min – Thierry DormalAM Technologies for polymer parts – 25 min – Laurent VoetsAM technologies for metal parts – 30 min – Julien MagnienAM technologies for ceramic parts – 20 min – Tommaso SforzaBiomedical applications – 20 min – Carsten EngelLunch: 13h – 13h30Lab tour : 45 min – 3 groups (+/- 12 persons)15 minutes for each lab:AM metalAM polymer & ceramicAJP 2
  3. 3. Sirris ADD capacities & competenciesADD (1990 – 2012) • 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)In-house additive technologies • Stereolithography (normal & hi-res) • Paste polymerisation for ceramics and metals (2 Optoform) • 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal) • Laser sintering of polymeric powder (PA,…): P360 – P390 • Objet Connex 500: bi-material • Laser Melting (MTT) SLM 250 HL for metal parts and inserts • EBM Arcam A2 (Titanium & CoCr) • Laser Cladding (Irepa Laser EasyCLAD) • 3D Printing of wax (Thermojet) • Makerbot Replicator & Fab@home • 3D scanning & metrology (GOM, Metris, Wenzel) 3
  4. 4. Raw materials for AM Liquid Powder Plate or sheet PasteStereolithography Laser Sintering (LS) Stratoconception® Optoform Envisiontec Laser Melting (SLM) LOM, MCor 3D Printing … … + others : spool, cartridges Objet FDM, Makerbot, … 4
  5. 5. Rapid Prototyping  Additive manufacturing• Cost reduction and short leadtime• High geometrical complexity and freeform design• Extended customization• Short series production without any tool• Compliance with sustainable economical growth 5
  6. 6. Additive Manufacturing• Three different ways of using AM technologies•  Prototyping for visual models or functional parts•  Direct production of parts (light redesign, only validation)•  Direct production of parts redesigned for AM (no way back to conventional production) 6
  7. 7. Additive Manufacturing % conventional techniques• With the conventional technologies (milling, moulding), the design of a new part is usually limited by the production process•  Technical and economical constraints•  Limitations in the freedom of creation• With AM:•  Almost no geometrical limitations•  Optimization and customization•  Geometrical complexity is not more expensive than a simple part Continuum Fashion : shoes, clothes,… 7
  8. 8. Additive Manufacturing Limitations • Geometrical limitations: • Wall thickness: 0.3 mm – 1.5 mm • Length of internal channels (powder removal) • Max. size: 100 mm  2000 mm. • Anisotropy (axe Z) for the mechanical properties • Surface quality (layer thickness, orientation) • Support structures for 3D building with some AM techniques. (generation, building, removal)• Some understanding of the AM processes are required for • The designer (dimensioning) • The manufacturer (part orientation, support generation, shrinkage factor, warping) 8
  9. 9. Geometrical Complexity (Polymers)• No tool required for series production:•  No draft angle required for demouldability•  No mould filling problems Hettich: Rotolavit Blood centrifuge (< 1.000 units / year) Freedom of Creation 30 % less expensive than with injection moulding 32 components  3 components (2 with LS, 1 with IM) Manufacturing on demand (customization) 9
  10. 10. Geometrical Complexity (metal)• No tool required for series production:•  No draft angle required for demouldability•  Internal walls and details Steel part (Concept Laser) Wim Delvoye / 3DP metal SIRRIS 10
  11. 11. Less components - Assembly reduction• Redesign of a laser collimator for space app.:• 13 components  2 components• Cooling system and geometry optimization 11
  12. 12. Integration of functions• Integration of snap fits, hinges,... EOS EBM - Oak Ridge National Lab Materialise MGX 12
  13. 13. Integration of functions• The design of a complex part with several local functions (spring effect, damping effect) usually requires the assembly of components in different materials.• With AM, this is possible in one step with bi-material process like the Connex machine (Objet) Zcorp Color Connex (Objet) 13
  14. 14. Lightweight parts – Lattices structures• Weight reduction using lattices structures with minimal strength reduction• Local variation of lattice types  graded porosity• Shock damping, vibration reduction• Biomedical implants: bone regeneration 14 [Sirris ADD]
  15. 15. Lightweight parts - Topology optimization• Automated design based on the applied constraints (Topol)• Same mechanical properties SIRRIS redesign (Compolight) 15
  16. 16. Stress verification Lightweight parts - Topology optimization Free space definition Flying Cam example (Compolight project)Efforts repartition Smoothing or redesign based on the STL geometry STL file
  17. 17. Customization – unique parts & short series• Unique parts for art, aerospace, biomedical (hearing aids)• Mass customization: variants for each country 17
  18. 18. Customization – unique parts & short series• Olaf Diegel(Massey University) Design: presets or user defined 18
  19. 19. Customization – unique parts & short series Aline Salmon Sac féminin haut de gamme 3DP métal (Sirris) YAMM (200 pièces) 15 avril Anne Valérie Bribosia 3DP métal (Sirris) 19
  20. 20. 3D surface texturing• Library of texturing types available for the designer• Stone, wood, marble, leather, …• Visual effect as well as adherence & special grip 20
  21. 21. 3D surface texturing ©Materialise Software 21
  22. 22. Conformal cooling channels - Hipermoulding project4 injection moulds produced with & without conformal cooling channels 4 mm Drastic reduction of the cycle time (up to 35%) Enhancement of part quality Enhancement of tool lifetime Profitability up to 200.000 euros/year (prod. 6 Mparts) 22
  23. 23. Catamaran (Hydrauvision) – Compolight projectHydraulic units with complex internal channelsReduction of the weight and size of the original part3DP Prometal (Sirris) 23
  24. 24. Functionaly Graded Materials Example with Ti alloys (source OPTOMEC):  3 different Ti alloys with 3 specific functions: impact resistance, fatigue and creep 24
  25. 25. Porosity control (3DP Prometal ex-One) • The porosity isInvestigation ways to manage the porosity:(not a macro porosity with lattice structures) • Sintering parameters • Composition of the powder mixture • Addition of organic particules Applications: fluid control, filtering, … 25
  26. 26. Drilling machine for aerospace•Technical reasonsMechanical characteristics of TitaniumDesigned for weight optimizationIntegration of functionsVibration reduction• Marketing reasonsHigh technology productSpecific design for customers• Economical reasonsCheaper solution than conventionalmachining or casting. 26
  27. 27. FLYING-CAM UNMANNED AERIAL SYSTEMSMost of the components produced by AM44 parts in PA + C31 parts in PA (white, black, painted or not,…)1 part in Connex500
  28. 28. Summary• AM : huge design freedom• Some limitations / guidelines need to be known• AM should be considered from the product conception phase
  29. 29. Additive Manufacturing – E-learning & Handbook• KTRM Leonardo project• Partners: ASCAMM, SIRRIS, ASERM, iSmithers, Materialise, ULPGC, ITIA• Handbook (220 pages) and e-learning courses (17 modules)• Introduction• 13 AM Technologies• Design and Analysis• AM Materials• Business models for AM• Conclusions Contact: Thierry Dormal thierry.dormal@sirris.be 29
  30. 30. Additive Manufacturing ThanksContact: Thierry Dormal thierry.dormal@sirris.be 30
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