“3D PRINTING & ADDITIVE MANUFACTURING”

HYPE ELLER FRAMTID?

SP-Dagen: Digitalisering & Industri 4.0 2016-03-09

BACKGROUND: EVERYBODY IS TALKING ABOUT IT…

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HYPE WARNING!!! Gartner's 2015 Hype Cycle for Emerging Technologies

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WHAT IS THE MEANING OF ”3D PRINTING” The term "3D Printing" may apply to: • Printing text and pictures on a 3D substrate • An AM process based on the original patent ”Three Dimensional Printing Techniques” (MIT, 1993, see also "binder jetting")

• An AM process based on a traditional printing operation, (such as "binder jetting" + "material jetting") • A low cost AM system that private people can have at home, like a home printer • A general term for the whole field of AM; -This is mainly due the recent media exposure of low cost home AM…. 4

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IN PERSPECTIVE: Principal methods of shaping materials: • Subtractive shaping: Shaping a raw material by successive subtraction of pieces of the original block of material; i.e. machining, grinding drilling • Formative shaping: Shaping a raw material by the application of pressure to the material; i.e. forging, pressing, bending, casting, etc. • Additive shaping: Shaping by the successive addition of material(s); i.e. Additive Manufacturing technologies

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UNDERSTANDING AM Definition (ASTM & ISO): 2.1.2 additive manufacturing, noun AM process of joining materials to make parts (2.6.1) from 3D model data, usually layer (2.3.10) upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies Note 1 to entry: Historical terms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, solid freeform fabrication and freeform fabrication. Note 2 to entry: The meaning of "additive-", "subtractive-" and "formative-" manufacturing methodologies are further discussed in Annex A.

The different AM processes are characterized by how the material is "added" ; i.e. brought and joined together! 6

LET'S TAKE A STEP BACK… Additive Manufacturing; shaping objects by successive addition of material… New Technology?

First modern system: Stereo Lithography: patent 1986, first sold machine in 1987 -The technology may be fairly new, but the principle is just natural and ancient! 7

EARLY APPLICATIONS: "Rapid Prototyping": several systems launched through the late 1980s and the early 1990s "Rapid Tooling" (1990's to early 2000's) ; producing tools based on "RP" technology ex. Keltool, Wibatool, early DMLS… "Rapid Manufacturing" (late 1990's to mid 2000's): producing end-use parts based on "RP"technology, -found some applications but did not really take off

-Well, perhaps it wasn't that "Rapid" after all… 8

WHY? SOME AM FUNDAMENTALS Operation by successive addition of material...

• Properties depend the process conditions

• In conventional machining, succesive removing of material cost time and money • In AM, successive addition of material cost time and money

Cost of machining

• The additive process builds a material in the shape of a product

Removed material Added material

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10% 20% 30% 40% 50% 60% 70% 80% 90% 90% 80% 70% 60% 50% 40% 30% 20% 10%

COMPLEXITY MADE EASY Conventional injection moulding

• 16 different parts assembled to one component 10

Manufactured by AM

• The component made in one piece

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A THREAT TO MACHINING INDUSTRY? Not necessarily.... • Part material and surface is shaped by the additive process. Successive addition by fusion of melted metal produces a fine chrystalline structure, -and surface • F1 suspesion mounting (TiAl6V4) Part built by AM, surface finished by machining • Material waste if milled from a block: 87% • Milling reduced to critical surfaces with specific requirements for surface quality

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AM IS AN ENABLING TECHNOLOGY: Successive addition of material brings new opportunities • ”Game changer” for materials technology • Minimized material consumption

• More complex geometries- reduced number of components and operations • More intelligent designs and improved functionalities • Individual variation at (almost) no additional cost 12

COMPLEX GEOMETRIES ENABLE VARIATION OF PROPERTIES IN THE "MATERIAL"!

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FROM "RAPID PROTOTYPING“ TO INDUSTRIAL MANUFACTURING Need for a different perspective:

• This is NOT a single process (-or technology for that matter…) • 7 different process categories identified….

• AM does not produce final products in a single process step • AM as a part of a larger manufacturing system • AM in itself is not necessarily a “Rapid” process…! 14

MORE THAN A NEW TECHNOLGY A NEW PARADIGM FOR MANUFACTURING

• A different manufacturing principle changes the rules of the game: − New geometries − New materials − New production chains

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• Flexibility, versability, but also a new way of thinking: − Design − Material: is formed, -and can therefore be manipulated during the manufacturing process − Product development...! − Intellectual Property Rights (IPR) − The value creation in products and services

THE ROAD TO INDUSTRIALIZATION THE CAPABILITY AND APPLICATIONS ARE THERE • For example: tools for assembly, jigs and fixtures, tooling inserts with conformal cooling for injection molding….

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MEDICAL AND DENTAL • Implants: Customized, Complex geometries • Craniomaxiofacial implants: complex and customized • Orthopaedical implants • Trabecular Structures may built in to the part and optimized for improved primary fit and osseointegration • A growing number of CE-certified and FDA-cleared implants produced by AM on the market

• Dental implants crowns and bridges: • Up to 450 units can be produced/machine/day • No machine supervision needed: manual operations reduced to loading and unloading the machine 17

ENERGY, OIL AND GAS Siemens Turbo Machinery gas burner tip:

• Material: Hastelloy X, subjected to significant wear, • Conventional repair: Cut off tip, machine a new and weld back on − Lead time 44 weeks

• AM repair: Mill off worn section, rebuild by AM − Lead time 4 weeks.

• Siemens reports more parts

are presently built by AM...

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IT’S IN THE AIR..!

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GE-Aviation developed a fuel injection nozzle, designed to be manufactured in CoCr by AM. (http://www.youtube.com/watch?v=l0SXlkrmzyw) It is planned to be in full production during 2015-16 with an output of 25000/year

AEROSPACE, CONTINUED Topology optimized brackets reduce weight • For Airbus A350 XWB • Replace part made by milling in aluminium • 30-55% weight reduction (-more than 30% compared to the milled aluminium part) • 90% reduction of material used for production

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AEROSPACE, CONTINUED GE Avio, TiAl LPT blades AM for the LEAP, GEnx, GE90 and GE9X jet engines • 40% weight reduction compared to casting

• Significant reduction in machining • New plant built for production in 2013: − 12 000 sqft (optional x2) − Up to 60 AM machines qualified for aerospace production − Gas atomization system

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AEROPSACE, REPAIR Pratt & Witney: repairing worn sealing lips of an oil-air seal from a turbine • Certified for repair of critical part in aerospace application − More than 700 parts repaired and currently used in flight − Certification for 5 cycles of repair: -Lifetime extended from 10 000 to 60 000 hours

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MANUFACTURING AND TOOLING MAPAL is bringning more and more tools made by AM to the market, typical benefits are: • Weight (and vibration) reductions

• Integrated cooling fluid channels Sandvik in progress with R&D... –to be continued!

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MISCELLEANOUS ORTOFON: PICK-UPS FOR VINYL RECORDS High-end pickups for vinyl records made by AM • Improved design freedom • Shorter time to production − ”A few weeks” compared to 4 – 6 months

• Adapted processing and parameters for optimized acoustic properties

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MISCELLEANOUS CROFT FILTERS: CUSTOM FILTERS OPTIMIZED FOR FIT AND FLOWABILITY • Possible to graduate metal thicknesses to give strength only where it is required

• Produce internal features and intimately produce assemblies or finished products in a single production cycle

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MISCELLEANOUS TRONRUD ENGINEERING: SILENCER FOR HUNTING RIFLE • Material: Titanium, - robust and low weight

• Growing sales to hunters in Scandinavia and North America • Tender out for a military version to Norwegian armed forces, UK SAS and others

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TECHNOLOGY ADOPTION LIFECYCLE

Prototyping Polymers Metals

Injection moulding tooling

Manufacturing: End-use products 27

GREAT EXPECTATIONS - MANY CHALLENGES PROCESS AND MATERIAL ARE MORE COUPLED THAN CONVENTIONAL PROCESSES • Many variables -requires standardization across the process chain − Material properties for each alloy needs to be mapped in respect to the different variables in the process window

• Different machine systems, different set-ups, different calibrations, and different conditions produces different results…, stability and traceability! − Variation in process variables for different feedstock batches

• Quality management, traceability, inspection and verification • Process: Repeatability and reliability • Knowledge and technical standards are urgently needed! 28

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STANDARDIZATION AND COLLABORATION: Standards are needed, but we don't necessarily need several competing standards… ISO & ASTM have signed a Partnership Standards Development Organization (PSDO) agreement Guiding principles: • One set of AM standards – to be used all over the world • Common roadmap and organizational structure for AM standards

• Fast tracking ASTM standard to become ISO standard • Formal adoption of ISO standard by ASTM 29

AM STANDARDIZATION ACTIVITIES: OVERVIEW 2009

2010

2011

2012

ISO-ASTM PSDO agreement Oct. 2011

ASTM F42 start 2009

2013 ASTM-ISO joint standards development plan Jul. 2013

ISO/TC261 start 2011

Cen-CENELEC STAIR-AM, 2012-….

SASAM: FP7 Project, 2012-2014 30

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2014

2015

2016

MAPPING MATERIAL PROPERTIES FOR DESIGN AM has proven the ability to produce excellent material properties however there is variability in the outcome: • Different raw materials & feedstock • Feedstock quality: PSD for powders, particle shape, number of repeated cycles, sieving quality, etc., ...

• Differences between machines: models and individual machines • Different processing windows • Calibration State of Equipment / Analytical Instruments

• Environmental Conditions during Test Procedure (i.e. Temperature, Humidity, Vibrations,…) • Influences of operator 31

•…

OPERATOR AND BEST AM PRACTICE… Presently there is no best-practice (or equivalent) to be be applied by local AMservice providers.  This requires the development of a certification procedure, and the corresponding requirements to fulfill an ASTM-ISO AM-certification (“AM-certification label”).  It also requires national AM-certification bodies.

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SOME FURTHER OBSERVATIONS • 2014 the total revenue of the AM business was estimated 4.1 bill. USD

• With present, two digit growth rate it will pass 7.5 bill. USD by 2016; However: − If the most principal issues can be solved the market is could exceed 100 bill. USD by 2020.

• Additive manufacturing is not going to replace all other manufacturing methods" in the foreseeable future, But: − It is a vital, complimentary, technology that enables and stimulate innovation, from business model to actual products and services

• The greatest value of AM, is not in the manufacturing and sales of products, but how they are used − There is hardly a sector of industry that will not be impacted in one way or another

• AM is growing fast, investments are there, the potential is huge, BUT

• It takes knowledge to be a part of it!

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FINAL REMARKS: We are just in the beginning of exploring the many possibilities of AM technology The full impact can hardly be estimated

Knowledge is critical; This is a learning process for all of us Misdirected expectations leads to disappointments No one benefits from wasted efforts and failed projects

-Please keep an open mind! Let's work together and get this right!

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THANK YOU! Any Questions? [email protected] 35

[email protected] Sandvik Machining Solutions