Industrialising AM - AMUG - draft 1
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Additive Manufacturing (AM) is undergoing a revolution as it moves from the model and tooling shop and onto the factory floor. A growing range of firms are deploying AM to create innovative new products that deliver increased performance in use and which could not be produced conventionally. Here we explore the drivers behind this transition and the increased demands that series production places on AM to deliver predictable, consistent parts. We look at the chains of linked processes and tools that are needed to create an integrated manufacturing process with AM at its heart, and the controls that must be employed to make AM a mainstream manufacturing process.
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Industrialising AM - AMUG - draft 1
- 1. AMUG 2016 Industrialising Additive Manufacturing Marc Saunders Director – Global Solutions Centres
- 2. • From research lab onto the factory floor • From prototypes & tooling to series production • From time compression to higher product performance • From shapes to consistent, qualified parts • From plastics to high performance alloys • From 3D printing to an integrated production process Additive manufacturing
- 3. Industrialising AM How is AM being used today? The disruptive potential of AM Integrated manufacturing process chains Productive AM processes
- 4. Low volume parts made direct from CAD Levels of AM deployment Rapid prototypes & tooling Why use AM for prototype & tooling development? • Prototypes help to de-risk system designs at low cost • No intention to use AM to make production parts • AM avoids tooling costs whilst the design is still in flux • AM enables cost-effective manufacture of complex tooling Benefit
- 5. Re-production parts, that avoid complex manufacturing Low volume parts made direct from CAD Levels of AM deployment Rapid prototypes & tooling Direct part replacement Why use AM for direct part replacement? • Gain experience with AM in low risk applications • Develop a supply chain for AM parts Benefit
- 6. Complex parts that simplify assembly & enhance reliability Re-production parts, that avoid complex manufacturing Low volume parts made direct from CAD Levels of AM deployment Rapid prototypes & tooling Direct part replacement Part consolidation Why combine parts using AM? • Simpler assembly & fewer joints / bonds Higherbenefit
- 7. New product designs that 1. Deliver lifetime benefits in use 2. Provide mass customisation Complex parts that simplify assembly & enhance reliability Re-production parts, that avoid complex manufacturing Low volume parts made direct from CAD Levels of AM deployment Rapid prototypes & tooling Direct part replacement Part consolidation DfAM optimised Highestbenefit
- 8. Industrialising AM How is AM being used today? The disruptive potential of AM Integrated manufacturing process chains Productive AM processes
- 9. Financial benefits of AM Production benefits £ Less materials £ Lower tooling costs £ Shorter process time £ Shorter lead time £ Simpler assembly £ Automation Lifetime benefits £ Less weight £ Faster product launch £ Product reliability £ Higher performance £ Better adaptation £ Product attraction £ Reduced stocking £ Higher responsiveness Financial benefit
- 10. AM impact on product design Disruptive AM capabilities Design freedom Precision & automation Complexity Thermal performance Part consolidation High performance materials New business models
- 11. Level 0 – prototypes & tooling Repeatable ‘CNC’ process Conformal cooling Production benefits £ Shorter processing £ Automation Lifetime benefits £ Product reliability £ Higher performance £ Better adaptation Production benefits £ Shorter processing Lifetime benefits £ Product reliability £ Increased performance
- 12. Level 1 – direct part replacement Near-net-shape manufacture Localised manufacturing Production benefits £ Less waste £ Lower tooling costs £ Shorter processing £ Shorter lead time Lifetime benefits £ Faster product launch Production benefits £ Shorter lead time Lifetime benefits £ Better adaptation £ Product attraction £ Reduced stocking £ Higher responsiveness Elimination of expensive tooling and simplification of production process chain makes small scale production viable
- 13. Level 2 – part consolidation Feature-rich parts Removal of joints Production benefits £ Lower tooling costs £ Shorter processing £ Shorter lead time £ Simpler assembly Production benefits £ Simpler assembly Lifetime benefits £ Less weight £ Faster launch £ Reliability £ Performance Mechanisms Production benefits £ Simpler assembly £ Automation Lifetime benefits £ Faster launch £ Attraction
- 14. Level 3 – DfAM optimised Porous parts Topological optimisation Production benefits £ Less waste £ Lower tooling costs £ Simpler assembly Lifetime benefits £ Less weight £ Faster product launch £ Better adaptation £ Increased performance Increased surface area
- 15. Level 3 – DfAM optimised Heat transfer Metal foams Production benefits £ Less waste £ Lower tooling costs £ Shorter lead time £ Simpler assembly Lifetime benefits £ Product reliability £ Better adaptation £ Increased performance £ Reduced stocking £ Product attraction £ Higher responsiveness CustomisationBuild the B.O.M.
- 16. Industrialising AM How is AM being used today? The disruptive potential of AM Integrated manufacturing process chains Productive AM processes
- 17. • To be useful every manufacturing process needs an effective tool chain Process chains – machining example 3D CAD FEA CAM MT controller CAM Inspect SPC (This only illustrates the software tool chain for CNC metal cutting)
- 18. • A tool chain can look simple until you put on information flows Process chains – machining example PLM 3D CAD FEA CAM MT controller CAM Inspect SPC (This only illustrates the software tool chain for CNC metal cutting)
- 19. • Supports multi-disciplinary teams • Encourages design around the most appropriate and controlled processes • User-friendly, connected tools • Allows information-driven decisions - use of process capability data, etc. A good process chain
- 20. Why we need chains for additive manufacturing Additive manufacturing is not an island! The advertising promise The reality
- 21. Process chains for AM • The design and manufacture tool chain 3D CAD FEA / CFD CAM AM machine CAM Inspect Verify & SPCPost- process PLM
- 22. Process chains for AM • Then there is a process chain for qualifying the machine 3D CAD FEA / flow sim CAM AM machine CAM Inspect Verify & SPCPost- process Calibrate to NMS Machine Qual
- 23. Process chains for AM • And a chain for materials 3D CAD FEA / flow sim CAM AM machine CAM Inspect Verify & SPCPost- process Metal refining Powder Prep Powder Recycle Calibrate to NMS Machine Qual
- 24. Process chains for AM – the challenges • Most current CAD packages and measurement systems are based on the capabilities of 3-axis linear devices – AM’s ability to make almost any shape challenges their relevancy • The single biggest challenge is how to validate and verify complex parts you are now able to make
- 25. Sailboat manifold – process chain CAM/ Machining In-process control Robot handling/ gauging Integrated measurement Shop floor gaugingDfAM Additive manufacture
- 26. Sailboat manifold – process chain CAM/ Machining In-process control Robot handling/ gauging Integrated measurement Shop floor gaugingDfAM Additive manufacture
- 27. Sailboat manifold – process chain Shop floor gauging CAM/ Machining In-process control Robot handling/ gauging DfAM Additive manufacture Integrated measurement
- 28. Sailboat manifold – process chain Shop floor gauging CAM/ Machining In-process control Robot handling/ gauging DfAM Additive manufacture Integrated measurement
- 29. Sailboat manifold – process chain Shop floor gauging CAM/ Machining In-process control Robot handling/ gauging DfAM Additive manufacture Integrated measurement
- 30. Sailboat manifold – process chain Shop floor gauging CAM/ Machining In-process control Robot handling/ gauging DfAM Additive manufacture Integrated measurement
- 31. Sailboat manifold – process chain Shop floor gauging CAM/ Machining In-process control Robot handling/ gauging DfAM Additive manufacture Integrated measurement
- 32. Sailboat manifold – process chain Design for AM AM build Gauging Machining Inspection ProcessesTools
- 33. Process chain for industrial AM • CAD tools optimised for AM part design • Integrated build file preparation and post- process development • Metrology as a ‘golden thread’ through the process • Process controls to minimise variation at each link in the chain
- 34. Industrialising AM How is AM being used today? The disruptive potential of AM Integrated manufacturing process chains Productive AM processes
- 35. Productive machining • 140 productive hours per week • 24 hour unattended operation • > 99.5% process yield
- 36. Process setting Predictive controls applied just before building In-process control Active controls applied during the build process Post- process monitoring Informative controls applied after building is complete Process foundation Preventative controls applied in advance Process control in manufacturing The Productive Process Pyramid™
- 37. • Laser, optics and mechanics calibration • Optical system health check • Powder sampling • Build parameter development • Test parts – density, tensile, fatigue Process controls for industrial AM
- 38. • Build file issue control • Powder level & condition checks • Filter condition • Build plate & wiper alignment • Build chamber O2 & temperature control Process controls for industrial AM
- 39. • Layer inspection • Dosing control • Weld pool monitoring & overlap • Filter condition & powder sieving • Thermal mapping • O2 concentration Process controls for industrial AM
- 40. • CMM inspection • Gauging • CT scanning • Test piece build integrity checking Process controls for industrial AM
- 41. • From research lab onto the factory floor • From prototypes & tooling to series production • From time compression to higher product performance • From shapes to consistent, qualified parts • From plastics to high performance alloys • From 3D printing to an integrated production process Additive manufacturingManufacturing
- 42. Thank you Your product design Renishaw expertise Your AM process Global support
Editor's Notes
- It is nice to think of design and manufacture as a set of steps which have to be climbed. One starts at the bottom without a design, proceeding up the steps as the design is formed, iterated through analysis, and through machining part programming, inspection part programming and then process control analysis.
- Looking at the information flows it is obviously more complex than a simple stair case. It becomes apparent where flows of information have to be compatible at a basic level, or smooth and automatic at a sophisticated level. The diagram also doesn’t include information flows from history, or in to the future – so for instance SPC data from previous similar parts may feed in to 3D CAD, and SPC from this design may feed into later designs if new information about capabilities was discovered.
- In not so many words, read the slide…
- First a very high level summary of how metal AM works.
- Just like for subtractive machining there is a tool chain for getting from design to qualified part in AM.
- There is also a tool chain which sits orthogonal to the design chain, but which intersects at the machine, in qualifying the dimensional performance of the machine and therefore the parts the machine is capable of producing.
- There is also a tool chain which sits orthogonal to the design chain, but which intersects at the machine, in qualifying the dimensional performance of the machine and therefore the parts the machine is capable of producing.
- First a very high level summary of how metal AM works.
- Summary
- Summary
- Summary
- Summary
- Summary
- Summary
- Summary
- Summary
- Summary
- First a very high level summary of how metal AM works.
- In not so many words, read the slide…
- In not so many words, read the slide…
- In not so many words, read the slide…
- In not so many words, read the slide…
- In not so many words, read the slide…
- In not so many words, read the slide…