2012 11-15-high-value-manufacturing-sirris-gravet
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  • 1. High Value ManufacturingL’allègement par les techniques additives Une nouvelle manière de concevoir Denis Gravet Le 15-11-2012 le centre collectif de l’industrie technologique belge
  • 2. High Value Manufacturing - No chips Additive - FreeformsManufacturing - Complex shapes - Internal shapes Good opportunity - Customization to change the - Materials range World by - Graded materials - Lightweight Accelerate innovation - Internal geometries Redesign - Multi-functional New concepts - Porosities High Value Manufacturing 2 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 3. High Value ManufacturingWhy reduce weight ? - less buiding time - less waste during production (no chips) - less energy during production - less energy during transport - less energy during component using - reduce cost - Carbon footprint ? (Interreg FRED)Vanguardist sectors - Aeronautic - Spatial - Automotive -… 3 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 4. High Value ManufacturingHow reduce weight ? Functionalities Multi-functionality3D lattice structures Internal freeformsTopology optimization Porosities 4 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 5. High Value Manufacturing Pressure resistance Functionalities p using: 400b p test: 600b p rupture PM: 1.535b 5 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 6. High Value Manufacturing Mass: 1.33kg at 0.8kg)  Reduction of 38% Volume: 171 cm³ at 91 cm³  Reduction of 47% External size: similar Pressure resistance OK Cost 1 unit PM: 450€ (similar conventional) Cost 150 units PM: 43€/unit 6 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 7. High Value ManufacturingMulti-functionality  Simplification  Cooling tube removed and integrated  Support integrated  Rings and braces removed  12 components  1 part 7 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 8. High Value Manufacturing Circular profil Spherical Honeycomb Name/Description Part volume Relative Full cube 27.00 cm³ 100 % Circular profile 4.37 cm³ 16 % Spherical 2.75 cm³ 10 % Honeycomb 3.74 cm³ 14 % Double honeycomb 3.25 cm³ 12 % Reduced honeycomb 1.93 cm³ 7% 3D lattice structures ReducedDouble honeycomb honeycomb 8 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 9. High Value Manufacturing [Sirris ADD] 3D lattice structuresCourtesy of OS Orthopedic Services GmbH / inno-shape GmbH EBM - Oak Ridge National Lab 9 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 10. High Value Manufacturing Weight reduction with minimal strength reduction Biomedical implants: bone regeneration Graded structures Shock damping Vibration reduction Filtration Laser Cusing 10 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 11. High Value Manufacturing Internal freeforms Functionalities Weight Volume Pressure drops Cost Pressure resistanceManifolds 11 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 12. High Value Manufacturing Volume: 2.900 cm³ Mass: 19.2 kg External size: 210 x 210 x 70mm Volume: 244 cm³ Mass: 1.2 kg External size: 85 x 85 x 38mm 12 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 13. High Value ManufacturingPressure drops: 3,25b 13x 0,25b - Very important reduction of pressure drops and also good pressure resistance 13 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 14. High Value ManufacturingInfluence of roughness on pressure drops: 0,32b 0,25b Negligeable regarding previous result and cost of polishing. 14 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 15. High Value Manufacturing  Mass: 19.2kg at 1.2kg  Reduction of 94%  Volume: 2900 cm³ at 244 cm³  Reduction of 92%  External size: much less (210mm => 85mm)  Pressure resistance: OK  Pressure drops: 3,25 at 0,32b  Reduction of 90%  Cost 1 unit PM: 750€ at 538€  Reduction of 28%  Cost 112 units PM: 78€/unit + milling 15 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 16. High Value ManufacturingInternal freeforms Functionalities Rounded channels Changing diameters 134 drillings Same functionalities 16 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 17. High Value ManufacturingPressure drops: 1,4b 4,7x 0,3b - Very importante reducing of pressure drops 17 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 18. High Value Manufacturing Mass: 55kg at 20kg  Reduction of 63,6% Volume: 2334 cm³ External size: 265 x 200 x 165mm => 240 x 200 x 150 mm Pressure resistance: OK Pressure drops: 1,68 at 0,37b  Reduction of 78% Cost 1 unit PM: 2500€ at 3122€ + milling  increase of > 25% Cost 6 units PM: 2500€/unit at 2376€ + milling (similar) 18 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 19. High Value Manufacturing Cooling channels  Reduction of cycle time 15% up to 40% (Hipermoulding)  Reduction of the energy consumption  Improvement of the durability of moulds  Improvement of the efficiency of cooling (no warping, good filling…)  Carbon foot print 19 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 20. High Value Manufacturing Complex geometries for multi functionality 20 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 21. High Value Manufacturing Topology optimization (Topol-Samcef)• Use material only where is needed• Definition of the free space• Define maximum volume• Set of loads• Maximize stiffness 21 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 22. High Value ManufacturingFree space and set of loads FEM calcul % volume and max. stiffness Design 22 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 23. High Value ManufacturingFree space definitionEfforts repartition FEM calcul STL file Smoothing or redesign based on the STL geometry 23 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 24. High Value Manufacturing  Weight reduction: 530g  392g (-26%)  7 components  2 components  3 materials  1 material (1 technology)  Carbon foot print CFPA Al AlSi12 24 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 25. High Value Manufacturing Topology Optimisation of a Lever (Images courtesy of JCB) EADS 25 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 26. High Value Manufacturing EOS 26 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 27. High Value Manufacturing Artistic Wim Delvoye / 3DP metal SIRRIS Batsheba Grossman 27 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 28. High Value Manufacturing Jewelry 28 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 29. High Value ManufacturingFashion 29 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 30. High Value Manufacturing Technical LayerWise Steel part (Concept Laser) 30 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 31. High Value Manufacturing Medical LayerWise 31 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 32. High Value Manufacturing Added Values Global cost Customization Freedom for design Reduction of weigth Material optimization Reduction of volumes Improvement of stiffness Reduction of pressure drops Simplification (nbre of components) Reduction of assembly and millings 32 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 33. High Value ManufacturingThanks for your attention 33 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012
  • 34. High Value Manufacturing Porosities  Bruno Verlee 34 © sirris | www.sirris.be | info@sirris.be | Denis Gravet Le 15-11-2012