The collective centre of the Belgian technology industry
Driving industry by technology•   Mission?    To help companies implement   technological    innovations•   Why?    Streng...
The collective centreFederation                           Collective centrefor the technology industry          of the tec...
of the technology industry      Aerospace Automotive Construction products  Contracting & Maintenance Electrical engineeri...
Sirris members                             2450 companies125 large companies   (>250 employees)         2325 SME’s        ...
Mission statement in practiceMaking the right technological choicesfor sustainable economical growthTranslating new techno...
What does Sirris mean to you?   From individual services                                           to common research prog...
Domains of competence•Materials Engineering   •Additive Manufacturing•Production Technology   •Software Engineering & ICT•...
Local presence,near the companies        Ghent                                                     Leuven        Materials...
Partners network Academics                                         Authorities             Industrials                    ...
Facts & figures in 2011    5000 interventions per year (advice, projects, services)                    whose 75% for SME’s...
Sirris In Wallonia :                                         3 competence groups                                          ...
SIRRIS – ADD departmentAdditive Manufacturing – Layer Manufacturing:à Rapid Prototyping – Rapid Tooling – Rapid Manufactur...
1980-1990   Incubation timesFocus :                        Actions :Main focus on supporting       -   Reducing mould cost...
1990   Starting the activityInputs :                         Actions :- Technology watch has put  into light new technolog...
1990-1996    Rapid prototyping yearsActivity :                                Conclusions :-   For industrial partners and...
1996-2002    Rapid tooling yearsActivity :                               Conclusions :-   In 1996 purchase of-   - an DMLS...
2002-2008    The transition yearsActivity :                                Conclusions :-   In 2001 purchase of a    revol...
2009-…    The Rapid Manufacturing yearsActivity :                                Conclusions :-   In 2009 purchase of an i...
ADD capacities & competenciesSIRRIS – ADD (1990 – 2012)   • 15 engineers and technicians   • Two locations: Liège (10 p.) ...
ADD application areas                  Military Architectural   Other: Academic           1%          3%          2%instit...
Laser Sintering of polymer powder                      © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007   22
3D Printing Prometal              Post-milling                             23
Laser Sintering of metal powder•   Direct Metal Laser Sintering•   Mould inserts in Bronze/Nickel alloy and steel•   Direc...
Material properties: 15 years evolution
Electron Beam Melting - Arcam Applications ─ Aerospace: Functional PartsMaterial: Ti6Al4V ELISize: Ø 140 x 80 mmWeight: 2,...
Applications   Functionally Graded Materials (FGM)                          Abrupt transition between Ti                  ...
Topology optimization                                           Stress verificationFlying Cam example (Compolight project)...
FLYING-CAM             UNMANNED AERIAL SYSTEMSMost of the components produced by AM44 parts in PA + C31 parts in PA (white...
SIRRIS ADD – Actual & Future developmentsLightWeight solutions       Controlled Porosity            Medical   – 3D structu...
Sirris Gosselies          the collective centre of the Belgian technological industry
Sirris – GosseliesHistorical recap.•   Since1997 : Close collaboration started with Technofutur in the field of    micro-m...
Sirris – Gosselies    •   Projet Campus Technologique :         • Closer cooperation with Agoria (offices in “Maison de   ...
Sirris – Gosselies - Strategic partnershipsPartnership management :•   Continuation and reinforcement of collaboration wit...
Sirris Gosselies - Value for IndustryService development : direct industrial support• More then 150 industrial projects/ye...
Sirris Gosselies - Value for IndustryService development : direct industrial support• Increase industrial impact with 2 gu...
Sirris – Gosselies - Expertise developmentService development : Projets de recherche en partenariat avec  l’industrie•   P...
Electron Beam Melting - ArcamApplications ─ Medical: Implants – Prosthesis - Instruments                                  ...
info@sirris.be / #Sirris / Sirris_be     WWW.SIRRIS.BE                                  TECHNILINE.SIRRIS.BE       News & ...
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2012 06-21-inauguration-labo-additive-manufacturing Sirris - Umberto Baraldi

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Overview of the Additive Manufacturing technologies available in the Sirris Additive manufacturing division of Gosselies

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2012 06-21-inauguration-labo-additive-manufacturing Sirris - Umberto Baraldi

  1. 1. The collective centre of the Belgian technology industry
  2. 2. Driving industry by technology• Mission? To help companies implement technological innovations• Why? Strengthen the competitive position over the long-term• For whom? The Belgian technology industry © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 2
  3. 3. The collective centreFederation Collective centrefor the technology industry of the technology industry • Nonprofit organisation • Industry owned MISSION “Increase the competitiveness of companies of the Agoria sectors through technological innovations” © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 3
  4. 4. of the technology industry Aerospace Automotive Construction products Contracting & Maintenance Electrical engineering Industrial automation Mechatronical engineeringInformation and communication technologies (ICT) Metals & materials Metal processing Mounting & cranes Plastics & composites Security & defence © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 4
  5. 5. Sirris members 2450 companies125 large companies (>250 employees) 2325 SME’s (<250 employees) © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 5
  6. 6. Mission statement in practiceMaking the right technological choicesfor sustainable economical growthTranslating new technologies intangible products for a company value innovationTaking into account the business through& technology strategy of the company technology © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 6
  7. 7. What does Sirris mean to you? From individual services to common research programs Large partnernetwerk – Optimized projectfinancing (public&private) Intellectual property stays in company | info@sirris.be | 22/06/2012 © sirris 2011 | www.sirris.be 7
  8. 8. Domains of competence•Materials Engineering •Additive Manufacturing•Production Technology •Software Engineering & ICT•Mechatronics •Technology Coaching © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 8
  9. 9. Local presence,near the companies Ghent Leuven Materials Engineering Mechatronics Technology Coaching Sirris Leuven Composites Application Lab Brussels Hasselt Software Engineering & ICT Materials Engineering Technology Coaching Production Technology Smart Coating Application Lab Liège Charleroi Additive Manufacturing Additive Manufacturing Materials Engineering Biomedical applications Nanomaterials and plasma Sirris Microfabrication Application Lab > 120 technology experts distributedsirris 2011 |6 sites |in the 3 |Regions © over www.sirris.be info@sirris.be 22/06/2012 9
  10. 10. Partners network Academics Authorities Industrials © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 10
  11. 11. Facts & figures in 2011 5000 interventions per year (advice, projects, services) whose 75% for SME’s within 1840 different companies 2000 payed projects and services for 5.4 mio EUR 2900 free advices subsidized 23M turnover © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 11
  12. 12. Sirris In Wallonia : 3 competence groups • Polymers Group Materials Engineering • Composites / Nanocomposites • Thixo/MIM/PIM • Light metals Rational integration • Microtechnology of advanced materials § Product concept and development Group in Products and § Thermal Management Nanopowders & Plasma processes § Multifunctional products § Traceability § Smart products Additive Nanopowders for processes & demanding specific Group Additive applications materials for tool-less Technologies§ Nanopowders production by manufacturingsynthesis in a plasma torch • Rapid prototyping§ Nanopowders characterisation • Rapid tooling • Rapid manufacturing§ Nanopowders production units developments § Additive process & post process development§ Ceramic and metallic nanopowders § Porous and functionally graded materials§ Handling/safety solutions for nanometric materials § Fast « Time to Market »by direct manufacturing§nanocomposites § Medical applications © sirris 2007 | www.sirris.be | info@sirris.be | 21/06/2007 12
  13. 13. SIRRIS – ADD departmentAdditive Manufacturing – Layer Manufacturing:à Rapid Prototyping – Rapid Tooling – Rapid Manufacturing the collective centre of the Belgian technological industry
  14. 14. 1980-1990 Incubation timesFocus : Actions :Main focus on supporting - Reducing mould costs by beter concept – Demonstration of CAD (2D/3D) Capabilities plastic material processor - - First applications and demonstration of and plastic material users mould filling simulation( moldflow / inssight) - Closed loop control of mould fillingSpecific issues : - Reduction of mould costs by newInjection moulds cost fabrication technology reduction - Polymer casting, low melting point alloy projection, …New polymers in products -Recycling Recurrent requirement: - Validation of plastic parts before injection mould ready - Availability of model as soon as possible
  15. 15. 1990 Starting the activityInputs : Actions :- Technology watch has put into light new technology - Setting up of consortium with industrial partners for direct part fabrication - FN Browning – Mecasoft – Aspel from CAD files Stereolithography - Purchase of SLA machine- Increasing performances of - 50% cost supported by Sirris 3D CAD software and (Crif/Wtcm) related interest in industry - 50% cost prepaid services to the industrial partners - Machine installed and running in Septembre 1990
  16. 16. 1990-1996 Rapid prototyping yearsActivity : Conclusions :- For industrial partners and for sectors, realisation of - Because of requirements concerning better demonstration parts part properties, purchase on own cost of an FDM machine- Stereolithography models are key communication tools for the - Low cost mould production techniques development of plastic parts. It is based on SLA models not viable. If the an unambiguous interface future of Rapid prototyping is Rapid allowing designers, tool makers, Tooling then other techniques are molders, users to interact quickly required. and efficiently. Recurrent requirements: -Better part properties to provide quick- In RD projects (local and EC functional validation funded), valorisation of quick -More precise processes model making technology to produce cast or sprayed injection cavities
  17. 17. 1996-2002 Rapid tooling yearsActivity : Conclusions :- In 1996 purchase of- - an DMLS machine to produce - Fairly big success of SLS for the production metal inserts for injection moulds of parts applied in practice (even small- - an SLS machine to produce series productions !) functional plastic parts in polyamide - Tooling applications are quite a challenge and widespread applications of additive- RD projects (local and EC funded), technologies for this applications is not in order to improve the possible on the short term. applicatbility of additive - Nonetheless important potential for technologies in the tooling sector solution of critical cooling problems. (rapid tooling) (with Materilise) Recurrent requirements: -Better part properties, faster production- Demonstration activity to process sensibilise industrial sectors on -Functional metal and ceramic parts the potential of theses technologies (Dito Materialise)
  18. 18. 2002-2008 The transition yearsActivity : Conclusions :- In 2001 purchase of a revolutionnary machine allowing - Lots of problems with the equipments ! production of metal and ceramic - Beta machines required very important « green » parts : Optoform efforts to get running satisfactorily.- In 2004 purchase of a 3D printing - Optpoform out of the market. machine providing multiple fold productivity increase for small and large metal parts : ProMetal - Important interest in the medical and aerospace sectors (customised biocompatible applications of short series- RD projects (local and EC funded), complex parts) in order to develop specific materials for aerospace and medical sectors Recurrent requirements: -Still better part properties, faster- Demonstration activity to production process sensibilise industrial sectors -Functional metal and ceramic parts still not fully adressed
  19. 19. 2009-… The Rapid Manufacturing yearsActivity : Conclusions :- In 2009 purchase of an improved SLS machine (own costs) - In 21 years, the additive manufacturing- In 2009 purchase of an EBM technology qualified from an anecdotic one machine (medical applications) shot process to an accepted production- In 2010 purchase of an SLM technique of hig-value technical parts. machine for hi tech metal parts - Sirris, always in relation to industrial- In 2010 purchase of a 5 axis laser interests and inputs, invested a lot to set cladding unit (graded materials up a unique competence and capabilities and aerospace applications) team in this area.- In 2009 purchase of a multimaterial 3D printer for This technology field is moving forward at a multimaterial functional parts and constant pace, promising interesting medical applications capabilities in micro-manufacturing and- Start of dedicated ceramic spinal mass customisation. These issues interest implants for « real life » use with our sectors, and we will keep up to date. the optoform technology
  20. 20. ADD capacities & competenciesSIRRIS – ADD (1990 – 2012) • 15 engineers and technicians • Two locations: Liège (10 p.) and Gosselies (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) • Vacuum Casting of alu, bronze, zamak • 3D scanning & metrology (GOM, Metris, Wenzel) 20
  21. 21. ADD application areas Military Architectural Other: Academic 1% 3% 2%institutions 14% Motor vehicles 11% Aerospace 22% Medical/dental 29% Industrial/business machines Consumer 3% products/electronic s 15% 21
  22. 22. Laser Sintering of polymer powder © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007 22
  23. 23. 3D Printing Prometal Post-milling 23
  24. 24. Laser Sintering of metal powder• Direct Metal Laser Sintering• Mould inserts in Bronze/Nickel alloy and steel• Direct Parts• Layers 20 µm. Accuracy 50 µm.• EOSINT M250 Xtended © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007 24
  25. 25. Material properties: 15 years evolution
  26. 26. Electron Beam Melting - Arcam Applications ─ Aerospace: Functional PartsMaterial: Ti6Al4V ELISize: Ø 140 x 80 mmWeight: 2,5 kgBuild time: 16 hours Pressure Vessel Heat Reflector With Cooling ChannelsRocket Engine Impeller Material: Ti6Al4V Weight: 4,5 kg Build time: 36 hours Landing Gear Component © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007 26
  27. 27. Applications Functionally Graded Materials (FGM) Abrupt transition between Ti 6-4 and Ti 48Al-2Cr-2Nb Ti 48Al-2Cr-2Nb Clean, well bonded fully dense microstructure. Interface Ti 6-4Functional surface: A-Impact: Conventional Ti alloytool steel (Ti 6-2-4-2)1.2344 (finished) B-LC fatigue: Orthorhomic Ti alloy (Ti 22-23) Basic material: copper alloy C-Creep: Gamma Ti-Aluminide (Ampco 940) (Ti 48-2-2) © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007 27 Denis Gravet 15-03-2009
  28. 28. Topology optimization Stress verificationFlying Cam example (Compolight project) Free space definitionEfforts repartition Smoothing or redesign based on the STL geometry STL file Weight reduction with the same mechanical result
  29. 29. 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
  30. 30. SIRRIS ADD – Actual & Future developmentsLightWeight solutions Controlled Porosity Medical – 3D structures applications Quality, Functionally GradedRepeatability, materials and Standards porositySustainability Nano particles incorporation Composites SiC+ alu, Connex digital materials… Titanium, Inconel, aluminium 30
  31. 31. Sirris Gosselies the collective centre of the Belgian technological industry
  32. 32. Sirris – GosseliesHistorical recap.• Since1997 : Close collaboration started with Technofutur in the field of micro-manufacturing technologies (plastic injection and µSLA), and composite materials processing.• Support through Feder and Interreg Funding for development of Advanced manufacturing technologies (PIM, Rapid manufacturing) competences and transfer• 2008 : Strategic focussing of Gosselies dept in the bio-medical field• BioManufacturing Platform (Feder project support) Arcam – Titanium & Connex 500 – multimaterial Add process• Team grows to 5 FTE © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 32
  33. 33. Sirris – Gosselies • Projet Campus Technologique : • Closer cooperation with Agoria (offices in “Maison de l’Industrie”) • Sirris Lab in the “ Village Plasturgie & Composite” • Shared workplaces with Technofutur Industrie (plasturgie) and Cenaero (projet Cilab) © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 33
  34. 34. Sirris – Gosselies - Strategic partnershipsPartnership management :• Continuation and reinforcement of collaboration with Technofutur (equipement sharing, common projects, training support)• Renforcing partnership with Agoria (win-win industrial impact)• Renforcing partnership with local key actors (innovatech, Igretec)• Continuation of Interreg projects and actions (Pristimat, Ecolaserfact) interreg FRED)• Develop collaboration with other CRA (Cenaero, Cetic) © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 34
  35. 35. Sirris Gosselies - Value for IndustryService development : direct industrial support• More then 150 industrial projects/year most in the province Hainaut/Namur (65%) (direct service income of +/- 200k€)• Main industrial sectors Manufacturing, Biomedical and Aeronautic area• Majority of activities oriented towards product development support, rapid manufacturing technology applicability• Applications in MIM and µmoulding ( symbiosis with ING/ SMALL/technofutur). © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 35
  36. 36. Sirris Gosselies - Value for IndustryService development : direct industrial support• Increase industrial impact with 2 guidances based in GosseliesGuidance SimADD : promote beter use of additive technologiesin direct manufacturing of hi-value products by integration ofnumerical development chainGuidance Biomediv : in partnership with Centexbel, supportcompanies in innovative projects in the « medical devices » area. © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 36
  37. 37. Sirris – Gosselies - Expertise developmentService development : Projets de recherche en partenariat avec l’industrie• Plateforme de bioManufacturing Biofact W• Projet Interreg Pristimat (champagne/ardenne – Hainaut Namur) • Domaine médical • Domaine Transport • PIM-MIM• Prospective projet Hennuyer « ECOPOLE » (mécatronique/nanos/surface) © Sirris | www.sirris.be | info@sirris.be | 22/06/2012 37
  38. 38. Electron Beam Melting - ArcamApplications ─ Medical: Implants – Prosthesis - Instruments Material: Ti6Al4VSize: 180 x 130 x 5 mmBuild time: 12 hours Material: CoCr ASTM F75 Build time: 8 knees in 20 hours Material: Ti6Al4V ELI Build time: 16 cups in 24 hours © sirris 2007 | www.sirris.be | info@sirris.be | 20/12/2007 38
  39. 39. info@sirris.be / #Sirris / Sirris_be WWW.SIRRIS.BE TECHNILINE.SIRRIS.BE News & agenda Weekly technology watch interAction newsletter World of know- how Contacts Quick & easy © sirris 2011 | www.sirris.be | info@sirris.be | 22/06/2012 39

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