Additive manufacturing voor metaal en keramiek

1. Department of Additive Manufacturing (ADD)
Electron Beam Melting
Optoform
le centre collectif de l’industrie technologique belge

2. Direct Manufacturing: Electron Beam Melting
Charleroi
le centre collectif de l’industrie technologique belge

3. Electron Beam Melting - Arcam
• Near net shape solution requiring post milling (HSM)
• A high energy beam of electrons is generated in the Electron
Beam Gun
• The control system allows an extremely fast beam translation
with no moving parts
• Vacuum melt process eliminates impurities and yields high
strength properties of the material
• High build temperature provides good form stability and low
residual stress in the parts
• Low operating costs
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 3

4. Electron Beam Melting – Arcam
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 4

5. Electron Beam Melting - Arcam
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 5

6. Medical applications
Next generation pre-operative manufactured implants:
• Custom implant manufacture :
• CT-Scan
• CAD File of the patient is produced
• Engineer + Surgeon 3D implant approved
• FEM analysis (when needed)
• Custom manufacturing (low cost)
• Surgery
• Follow up
© sirris 2010 Charleroi | www.sirris.be | info@sirris.be | 22/11/2011 6

7. Medical applications
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8. Medical applications
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9. Automotive applications
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10. Automotive applications
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 10

11. Other applications
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 11

12. Electron Beam Melting - Arcam
Excellent properties for: Released Materials: Application fields:
• Strength • Ti6Al4V • Medical:
• Elasticity • Ti6Al4V ELI • Implants
• Fatigue • Ti-Al • Prosthesis
• Chemical composition • CoCr, ASTM F75 • Instruments
• Microstructure • Copper (tested) • Aerospace:
• Others on demand • Functional parts
Lattice & Cellular Structures:
• Automotive:
• Lattice and cellular structures allow combination of the excellent
• Functional parts
properties of solid metal with the extraordinary properties of a cellular
or lattice structure
Applications include:
• Structures for bone in-growth in medical implants
• Lightweight designs component
• Filters
• Other applications where a cellular structure is an advantage
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 12

13. Electron Beam Melting - Arcam
Mechanical & structural properties:
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 13

14. Electron Beam Melting - Arcam
Mechanical & structural properties:
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 14

15. Electron Beam Melting - Arcam
Mechanical & structural properties:
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 04/02/2011 15

16. Indirect Manufacturing: Optoform process
Liège
le centre collectif de l’industrie technologique belge

17. Optoform
Generalities:
• Commercially not available any more
• Flexible technology (hybrid SLA):
•Development of very different materials
• Possible materials:
•Soft, hard, metallic and ceramic
• ISO 13485 certified @ Sirris
Fabrication steps:
• Preparation and fabrication of the bulk material
• CAO / CAD File processing
• Automated process manufacturing
• Cleaning and recycling of the non-used material
• Debinding & Sintering process
[Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 17

18. Optoform
Features:
• Layer thickness: 20 - 200μm
• Argon laser 400-800mWatt at 351nm and 365nm
• Max. Size: 250-350-500mm
• Several building plates with variable sizes well suited to small parts and expensive
materials
• Supports needed
Material Requirements:
• Composition :
Resin+ Fillers (20% to 70% Vol.) + Photo-initiator + Wetting agent + rheological/
thixotropic Agent
• Consistency : Firmness of a toothpaste (Bingham’s model)
• Good Lifetime : the filler should not deposit sediment
• No UV absorption by the filler ↔ Layer thickness
• Support removal & cleaning: not always easy (isopropanol, water,…)
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 18

19. Optoform
[Sirris ADD] [Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 19

20. Optoform
Materials:
• Alumina
• Alumina with 8% of nano Zirconia
• Hydroxyapatite
• α & β Tri-calciumphosphate
• Zirconia
• SiC [Sirris ADD]
• Stainless steel
• Titanium [Sirris ADD]
• Ceramics & metals need a post-process of debinding & sintering
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 20

21. Optoform & medical field: CASE STUDIES
Ongoing statuts:
• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)
• Diameter ~= 10mm
• Macro-porosity ~= 0,5mm
• Tests various scaffold structures for bone integration
• In vivo testing (rabbits & rats)
• Field: Spinal implants & Maxillofacial Surgery
• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)
[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 21

22. Optoform & medical field: CASE STUDIES
[Sirris ADD] [Sirris ADD]
0,5mm
[Sirris ADD] [Sirris ADD] [Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 22

23. Optoform & medical field: CASE STUDIES
[Sirris ADD] [Sirris ADD]
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 23

24. Optoform
Summary:
• More than a new RP technology
• Development station for new RP materials
• Broad range of ceramic and metallic materials
• By using a good formulation strategy of the paste, it is possible to respect the chemical
composition of the material
• Broad range of applications
• High speed
• Suited to small parts and expensive materials as well as massive tools and cheap materials
• Commercially not available any more
© Sirris | www.sirris.be | info@sirris.be | 22/11/2011 24