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Tips for Additive Manufacturing in Metal
The document provides an overview of Exone, a leading company in additive manufacturing specializing in industrial 3D printing of metal and sand molds. It discusses the benefits of their processes, including design flexibility, reduced lead times, and the ability to produce complex geometries without traditional tooling. Additionally, it outlines a project focused on optimizing a control arm for a domestic supercar using various 3D printing workflows.
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Tips for Additive Manufacturing in Metal
- 1. Tips for AdditiveManufacturing in Metal
- 2. Before We Start This webinar will be available afterwards at designworldonline.com & email Q&A at the end of the presentation Hashtag for this webinar: #DWwebinar
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- 5. About ExOne • ExOne isa leading additive manufacturing company dedicated to the industrial manufacturing sector. • ExOne is a global supplier of industrial 3D printing systems and offers design and manufacturing services of 3D printed products. • ExOne Production Service Centers are located throughout the United States, Germany and Japan. • ExOne systems are able to print in a variety of industrial materials with the largest available build sizes.
- 6. ExOne Global FacilityLocations
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- 9. Distinctive Technology Features • Largestbuild envelopes available • Finely detailed complex shapes • Print Speed • Final Product Accuracy • Industrial Grade Materials
- 10. Direct Metal Process - ExOneoffers digital part materialization in several metals and metal alloys, including: • 316 Stainless Steel Infiltrated with Bronze • 420 Stainless Steel Infiltrated with Bronze • Iron Infiltrated with Bronze • Bonded Tungsten - Additional material systems are currently in development, and partnership opportunities are available for specific materials. - The 3D printing process in metal includes printing, curing, depowdering, sintering, infiltrating and annealing. - Build Volume (WxDxH): 780 x 400 x 400 mm (30.7 x 15.75 x 15.75 in.) - Build Speed: 6 mm/hr (.24 in/hr)
- 11. In Direct Metal- Sand Process - ExOne offers digital part materialization in various combinations of sand casting media and chemical binders, depending on the desired strength and level of detail: • Silica Sand • Synthetic Sand • Other casting media - Digital production of sand molds and cores eliminates the need for hard tooling and drastically reduces lead times. - Standard foundry industry materials are used, enabling easy integration of the molds and cores into existing manufacturing and foundry procedures. - This digital process offers design freedoms not possible in molds and cores produced using the traditional pattern approach. - Build Volume (WxDxH): 1800 x 1000 x 700 mm (70 x 39 x 27 in.)
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- 16. Optimizing for Manufacturing • Withsimple changes such as automated transfers and print run layout, an additive manufacturing production process can be optimized to maximize output.
- 17. ExOne in aFactory Environment
- 18. Advantages of AdditiveManufacturing • The digital process offers design freedoms not possible in traditional molds, cores and machining approaches • Endless patterns and part geometry • Functional working prototypes for real life applications • Prototyping can turn directly into low or high volume production runs • Draft angles can now be eliminated • No tool paths or tooling required • Advanced venting schemes and integrated rigging features are also possible • Different parts can be built in a single print bed • Parts can be modified on the CAD file in seconds, and reprinted without complicated tooling changes.
- 19. Project Overview • Advance optimizationof a traditionally manufactured control arm from a domestic super car by using additive manufacturing processes. • Push the boundaries of 3D metal printing and design inside a real and applied production workflow with practical outcomes. • Examine existing and heavily optimized designs made using traditional methods and see if they can be optimized even further using new modeling approaches. • Develop new workflows and processes that can directly capitalize on the many benefits that 3DP offers. • Reduce weight while still retaining the same structural properties of the what is said to be “already optimized” traditional control arm.
- 20. The Idea Take existingproduction part and provide further optimization and modeling in pre-constrained areas of the part for three different 3DP workflows: • Printed sand mold package for traditional foundry casting • Conservative/constrained direct metal printing • Unlimited direct metal printing
- 21. The Idea Take existingproduction part and provide further optimization and modeling in pre-constrained areas of the part for three different 3DP workflows: • Printed sand mold package for traditional foundry casting • Conservative/constrained direct metal printing • Unlimited direct metal printing
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- 23. Finding the BestInternal Structures
- 24. Initial Reference forCellular Structure
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- 26. Indirect Metal PrintingProcess and Cast
- 27. Advanced Control ArmIs Modeled with Free Constraints
- 28. Advanced Model PassesSimulation: Export
- 29. Direct Metal PrintingProcess
- 30. Direct Metal Printing– Final Product
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- 33. Next Steps –Advanced Designs w/ Automatic Closed Loop Simulation Feedback
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- 36. Questions? Design World Leslie Langnau llangnau@wtwhmedia.com Phone:440.234.4531 Twitter: @DW_3DPrinting ExOne Tom Pasterik tom.pasterik@exone.com Phone: 724.765.1361 www.exone.com
- 37. Thank You Thiswebinar will be available at designworldonline.com & email Tweet with hashtag #DWwebinar Connect with Discuss this on EngineeringExchange.com