2012 11-15-high-value-manufacturing-sirris-gravet

High Value Manufacturing

L’allègement par les techniques additives
Une nouvelle manière de concevoir

Denis Gravet Le 15-11-2012

le centre collectif de l’industrie technologique belge

- No chips
Additive - Freeforms
Manufacturing - 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


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© sirris | www.sirris.be | info@sirris.be |

Why 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
-…

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How reduce weight ?

Functionalities

Multi-functionality

3D lattice structures

Internal freeforms

Topology optimization

Porosities

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Pressure resistance Functionalities
 p using: 400b
 p test: 600b
 p rupture PM:
1.535b

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 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

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Multi-functionality

 Simplification
 Cooling tube removed and integrated
 Support integrated
 Rings and braces removed
 12 components  1 part

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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 Reduced
Double honeycomb
honeycomb

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[Sirris ADD]

3D lattice structures

Courtesy of OS Orthopedic Services
GmbH / inno-shape GmbH

EBM - Oak Ridge National Lab

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 Weight reduction with minimal strength reduction
 Biomedical implants: bone regeneration
 Graded structures
 Shock damping
 Vibration reduction
 Filtration

Laser Cusing

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Internal freeforms

Functionalities

 Weight
 Volume
 Pressure drops
 Cost
 Pressure resistance

Manifolds

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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

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Pressure drops:

3,25b

13x

0,25b

- Very important reduction of pressure drops and
also good pressure resistance

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Influence of roughness on pressure drops:

0,32b

0,25b

Negligeable regarding previous result and cost of polishing.

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 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

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Internal freeforms

Functionalities

Rounded channels
Changing diameters
134 drillings
Same functionalities

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Pressure drops:

1,4b

4,7x

0,3b

- Very importante reducing of pressure drops

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 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)

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 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

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Complex geometries for multi functionality

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Topology optimization (Topol-Samcef)

• Use material only where is needed
• Definition of the free space
• Define maximum volume
• Set of loads
• Maximize stiffness

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Free space and set of loads

FEM calcul

% volume and max. stiffness Design

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Free space definition

Efforts repartition

FEM calcul
STL file Smoothing or redesign
based on the STL geometry

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 Weight reduction: 530g  392g (-26%)
 7 components  2 components
 3 materials  1 material (1 technology)
 Carbon foot print

CF
PA

Al AlSi12

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Topology Optimisation of a Lever
(Images courtesy of JCB)

EADS

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EOS

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Artistic Wim Delvoye / 3DP metal SIRRIS

Batsheba Grossman

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Jewelry

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Fashion

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Technical

LayerWise

Steel part (Concept Laser)

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Medical

LayerWise

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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

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Thanks for your attention

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Porosities  Bruno Verlee

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2012 11-15-high-value-manufacturing-sirris-gravet

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