Forum Design

TUESDAY, 5 JUNE 2018

Location: CongressCenter, 2nd floor, Room Chr. Reichart


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08:30 - 09:30
Check-In
09:30 - 09:35
Welcome Carl-Zeiss Saal
09:35 - 10:30

Additive manufacturing processes (AM) have been used for prototyping in experimental
vehicle construction and development for almost 30 years, and have become
established techniques in these fields. The BMW Group is not only considered
an early adopter in this area, having used these technologies since the beginning,
but also an established partner when it comes to identifying new potential fields
for the latest AM technologies and materials.
In recent years, the company has been working hard to implement a strategic
roadmap to move both plastic-based and metal-based AM processes on to the
next logical step – from prototyping to series production. The company’s objective
here has not been to create showcase examples, but rather to apply the specific
benefits of the techniques in a targeted way – for substituting tools in small batch
production, for customisation, and for designing components that are tailored to
the loads and processes involved in series production.
A number of pilot projects have already shown where AM processes could be used
in the creation of customer components. Meanwhile, additive manufacturing has
become an important pillar in the digitalisation strategy of the BMW Group’s production
network that will enable it to manufacture products sustainably and efficiently
going forward. By working with new start-ups and innovative partners in the AM sector,
the company is seeing increases in quality, efficiency and in the number of areas
it can use these processes. It is perhaps no surprise that the BMW Group therefore
sees it as essential to remain a pioneer in the field of additive manufacturing.
This talk will explain how the use of AM technologies is gradually being driven
forward into series production. As well as the technical and economic aspects,
it will also discuss strategic productive investments and partnerships, and show
how client projects in this field are being developed and supported with a focus on
delivering end customer-quality components.

Keynote 1
Dr Dominik Rietzel | BMW Group

Herr Dr.-Ing. Dominik Rietzel studierte an der TU München Chemieingenieurwesen mit der Vertiefungsrichtung Werkstoffe und deren mechanische Eigenschaften. Seine Diplomarbeit befasste sich mit der Qualifizierung von Kunststoffen für medizinische Anwendungen und wurde mit dem DIN Preis für Standardisierung ausgezeichnet. Die Dissertation mit dem Titel "Werkstoffverhalten und Prozessanalyse beim Laser-Sintern von Thermoplasten" fertigte er in der Zeit von 2007 bis 2011 am Lehrstuhl für Kunststofftechnik (LKT) der Friedrich-Alexander-Universität Erlangen-Nürnberg an. Die erlangten Erkenntnisse können besonders zur Qualifizierung und Verbesserung der Verarbeitbarkeit neuer Thermoplaste genutzt werden, da sie einen Einblick in die fundamentalen Zusammenhänge des Schmelz- und Kristallisationsvorgangs bei pulverbettbasierten Verfahren geben. Herr Rietzel gehörte diversen Normungsgremien an und konnte als stellvertretender Leiter der VDI Fachausschusses "Additive Manufacturing - Kunststoffe" dazu beitragen die erste Richtlinie zur Güteüberwachung von Laser-Sinterbauteilen (VDI 3405 Blatt 1) zu realisieren.
Nach seiner Promotion sammelte er erste industrielle Erfahrungen in der Automobilbranche bei der MAN Truck & Bus GmbH, wo er zuletzt die "Qualitätssicherung, Korrosionsschutzlinie und Lackdisposition" in der Fahrerhauslackiererei verantwortet hat. Auch in dieser Zeit befasste er sich weiter mit der Additiven Fertigung und war unter anderem als Berater für Anlagenhersteller in AM Bereich tätig.
Mit seinem Wechsel zur BMW Group legte er seinen Schwerpunkt wieder auf AM Technologien und deren Anwendungen im automobilen Umfeld. Dabei war er unter anderem für die Integration neuer Technologien in die Fertigung (z.B. MJF oder CLIP) verantwortlich. In dieser Vorentwicklungstätigkeit konnten die ersten Ansätze geschaffen werden für die Personalisierung von Produkten, wie beispielsweise dem Side Scuttle oder der Dekorblende von MINI, welche in 2018 mit „MINI Yours Customised“ in Serie gegangen sind. Seit 2016 leitet Herr Rietzel im Additive Manufacturing Center der BMW Group die Fachabteilung Nichtmetalle und ist dort für die F&E Aktivitäten, den Prototypenbau sowie die Serienproduktion verantwortlich.

10:30 - 10:45
Break
Session 1
Presentation: Prof. Dr.-Ing. Detmar Zimmer, Universität Paderborn
10:45 - 11:15

With an increasing industrialization of additive manufacturing (AM) processes, topology optimization (TO) as a part of the development process gets more important. Different studies have shown, that there is a high potential in func-tion optimization by combining both. During testing of optimized parts within qualification processes, parts do not achieve their simulated results. The test bench performance differs compared to the simulation. Reasons for that can be seen in simplifications, interpretation of the finite element model and defi-nition of the optimization goal. Based on the already optimized flight crew rest compartment (FCRC) bracket and its test bench results, further optimizations were done to understand the impact of different optimization models and goals. In result, the weight could be reduced by 22 % compared to the con-ventional design while the stiffness is increased. By lowering the importance of “minimizing compliance” and a slight drop in stiffness, a weight reduction of 38 % is reached. At this point, the material properties concerning the strength of the Ti-6Al-4V was not exhausted. Therefore, the compliance goal is ne-glected in an additional iteration. This leads to a weight reduction of overall 75 % compared to the conventional bracket. In addition to that, designs for the aluminium alloys AlMgSc and AlSi7Mg0.6 respectively were developed and compared to the results for Ti-6Al-4V.

Lecture 1/1
Michael Süß | TU Dresden

10/2008 – 03/2015
Diploma degree in mechanical engineering, Technical University Dresden

06/2014 – 03/2015
Assistant researcher at Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Dresden, diploma thesis: “Topology optimization for additive manufacturing”

04/2015 –03/2016
Research fellow at Fraunhofer IFAM, Dresden, PhD: “Design guidelines for Electron Beam Melting”

04/2016 – heute
Research fellow, professorship of engineering design and CAD, Technical University Dresden, continuing PhD in cooperation with the Fraunhofer IFAM, Dresden

11:15 - 11:45

New design processes and potentials in the design of additively manufactured components require a rethink, especially from experienced design engineers. A lack of knowledge about additive manufacturing technology also inhibits this rethinking [HHD06, WC15]. In order to make the relatively new manufacturing technology more accessible, various design recommendations have been developed in recent years. However, the multitude of recommendations makes it difficult for the design engineers to keep a corresponding overview and to sort out relevant and non-relevant recommendations for special applications.
For this reason, publicly available recommendations for laser beam melting were compiled in a database and prioritized. The result includes design recommendations that have a relevant impact on component manufacturing, component quality and function. By further abstracting these recommendations, guidelines could be developed that are used for a software-supported design check. Through this design check, components of any complexity, for example fine grids or topology optimized structures, can already be examined prior to manufacturing for compliance with relevant design recommendations.
The design check uses a database that contains admissible geometrical attributes in quantitative form. These attribute values can be determined experimentally. For this purpose, standardized test specimen jobs have been developed, which contain all the necessary test specimens for the determination of relevant attribute values and whose evaluation enables an expansion of the database with regard to available machines, materials and parameter sets.

Lecture 1/2
Stefan Lammers | Universität Paderborn, Lehrstuhl Konstruktions- und Antriebstechnik

Stefan Lammers received his M. Sc. degree in mechanical engineering from Paderborn University in 2014 after finishing his master thesis in Qingdao, China. He is currently working as a research assistant at the Chair of Design and Drive Technology in cooperation with the Direct Manufacturing Research Center (DMRC) at Paderborn University. His main research topics are design guidelines for additive manufacturing and the feasibility investigations of AM for permanent magnet synchronous machines.

11:45 - 13:30
Lunch break and visit to the trade show
Session 2
Presentation: Prof. Dr.-Ing. Detmar Zimmer, Universität Paderborn
13:30 - 14:00

The goal of the present investigation was to optimize support structures in laserbeam melting of metals and provide yet missing design guidelines for support generation. The latter then set the framework for automated support generation, which is crucial to speed up the data preparation and pave the way for industrialization. Adequate application of supports increases the productivity by preventing buildjob failures and is one key factor to ensure reproducible part quality. The research approach aims at an optimization by adequate selection of various support types rather than a parameter optimization of those. Herefore five different support types have been chosen and characterized with regard to various target figures: Material consumption, removability and tensile strength of the supports themselves, as well as surface influence on and dimensional accuracy of the supported part. Results reveal that proper selection of supports can greatly reduce post processing effort regarding removability of supports and overall material consumption, while the post processing effort for surface finishing is not positively affected.

Lecture 2/1
Melanie Gralow | Fraunhofer IAPT

Education/Studies
? 2009 to 2013 B. Sc. International Studies of Biomimetics, University of Applied Sciences Bremen
? 2013 to 2016 M. Sc. Production Technologies – Mechanical Engineering, University of Bremen
? 2014 to 2015 One year Master project „Developtment, manufacturing and
Evaluation of an energy harvesting system using generative manufacturing technology“ in cooperation with Fraunhofer IFAM Bremen
Three times winning team project:
? 1st place at the Additive Manufacturing Challenge 2015 (Netherlands)
? 1st place at the Stratasys 3D-competition “Extreme Redesign” 2015 (USA)
? 1st place at the Student Design & Engineering Award 2015 (Germany, RapidTech)
? 2015 to 2016 Master-Thesis „Systematic Part Design for Additive Manufacturing following Biomimetic Principles“ Fraunhofer project group RMV (today IGCV) Augsburg

Employment history:
Refer to current employment

Current employment:?
2016 until today
research assistant in the EU-Project BionicAircraft, Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT (Fraunhofer IAPT), Hamburg
Application of biomimetics in combination with additive manufacturing

2017 until today
Head of Bionic Function & Design Team, Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT (Fraunhofer IAPT), Hamburg

14:00 - 14:30

Additive manufacturing processes (AM) for the direct production of metal components, such as laser beam melting (LBM), are costly. One way to reduce these costs while maintaining AM-specific high design freedom is to use combined process chains with molding techniques, starting with AM technology. One such process chain is the combination of Fused Depositon Modeling (FDM) and investment casting. By using the FDM for the produc-tion of complex structures and the subsequent casting for transfer to the metal component, process steps of the manufacturing process are separated according to the advantages of the respective processes. When designing components for this production chain, design restrictions of both production processes must be taken into account. The paper deals with the research question, which design restrictions arise from the combination of FDM and precision casting for the production of metallic components. To answer the research question, a literature-based synthesis of design restrictions of the individual processes is carried out first. The validation of the combined restrictions is based on a test specimen. It is produced from various materials using the FDM process and transferred to a metal component in an investment casting process. The derived design rules and freedom of design are compared with those for the LBM with an economic consideration for possible usage scenarios.

Lecture 2/2
Florian Weiss | Universität Stuttgart

Florian Weiss studied mechanical engineering at the Karlsruhe Institute of Technology in Germany. Since 2013 he is working as a research assistant at the Institute for Engineering Design and Industrial Design under the head of Prof. Hansgeorg Binz at the University of Stuttgart. He works in the working group Methodical Product Development and deals with design methodology in the field of additive manufacturing, in particular, methodical support of the development of additively manufactured parts.

14:30 - 15:00

In the industry rises an upcoming urge to shorter product development times, higher integration of functions and individualized products because of dynamic competition environment. Hence, additive manufacturing processes get more and more industrial relevance. The Laser-Beam-Melting (LBM) as an additive process has to be highlighted for example because it’s an established process in sector of prototyping and short run production which is at the threshold to serial production. Missing methodical exploitation of design freedom and limitations in the overall product development process harm the use of this comparatively new groups of manufacturing processes.
In the product development, the design methodology forms a possible ap-proach to consider design freedom and advantages directly in early phases of the development process. To achieve this, links to existing and general recognized design methods (e.g. VDI 2221, Pahl/Beitz, etc.) are listed, which allow an implementation, especially for the Laser-Beam-Melting. In this pub-lication, a special attention is put on the two design phases conception and design. Concerning this, additions or adaptions to the existing design meth-ods will be presented. Furthermore, advantages of additive manufacturing processes will be exploited.

Lecture 2/3
Thomas Künneke | Universität Paderborn, DMRC

Current activity
06/2014 – now: Scientific staff at Paderborn University
Faculty of Mechanical Engineering
Chair of Design and Drive Technology (KAt)
Direct Manufacturing Research Center (DMRC)

Education
10/2011 – 05/2014: Mechanical engineering, Master of Science, Paderborn University
Specialization: Product development
Project thesis: Concept of a method for measuring damping functions, which were integrated into additive manufactured test specimen. (KAt – DMRC)
Student research thesis: Optimization of the press-in and welding behavior when joining different material combinations by means of self-piercing resistance element welding (LWF)
Master thesis: Systematic development of test technology and specimen for the measurement of damping effects, which have been function integrated into already existing structures of technical systems by means of additive manufacturing processes (KAt – DMRC)
10/2008 – 09/2011: Mechanical engineering, Bachelor of Science, Paderborn University
Specialization: Product development
Bachelor thesis: Development of design guidelines for
additive manufacturing processes (KAt – DMRC)

Study-related activities
10/2011 – 09/2013: Student assistant, Chair of Design and Drive Technology (KAt)
Direct Manufacturing Research Center (DMRC)

15:00 - 15:30
Break
Session 3
Presentation: Prof. Dr.-Ing. Detmar Zimmer, Universität Paderborn
15:30 - 16:00

Powder-bed based Selective Laser Melting (SLM) has already been established in many applications such as injection molding.
This article presents the development of a new mold technology for particle foam processing, which uses the various possibilities of additive manufacturing.
With a focus on economic and industrial aspects, a large number of technical advantages were achieved along the entire process chain. The new tool concept includes additively manufactured nozzle elements, process-optimized grid structures and direct integrated surface structures. This mass-optimized tool is made of high-strength stainless steel and can be used for EPP-parts with complex geometry. In addition, the freedom of design of the additive process shows new possibilities for the appearance of the EPP components. The nozzles defined in the CAD-file guarantee a homogeneous part quality.

Lecture 3/1
Johannes Schütz | Fraunhofer IAPT

Ausbildung/Studium:
Ausbildung: Feinwerkmechaniker (Werkzeugbau Siegfried Hofmann GmbH, 2007)
Studium: Maschinenbau Bachelor+Master (OTH Regensburg, 2009-2014)


Beruflicher Werdegang:
Konstrukteur für Spritzgusswerkzeuge (Werkzeugbau Siegfried Hofmann GmbH, 2007-2008)

Entwicklungsingenieur (Hofmann WZB, 2014-2015)
Entwicklung und Simulation Belastungsoptimierter metallischer Bauteile für die additive Fertigung

Wissenschaftlicher Mitarbeiter (Laserzentrum Nord Hamburg/Fraunhofer IAPT, 2015-2018)
Entwicklung eines neuartigen Werkzeugkonzeptes für die Additive Fertigung zur Verarbeitung von EPP
Lehre an der Technischen Universität Hamburg

Derzeitige Tätigkeit:
Entwicklungsingenieur (Werkzeugbau Siegfried Hofmann GmbH, seit 2018)
Themenübergreifende Vorentwicklungen

16:00 - 16:30

Additive Manufacturing bietet die Möglichkeit zur Herstellung von Bauteilen mit komplexer Geometrie in kleinen und mittleren Stückzahlen. Neue Möglichkeiten, wie beispielsweise das gezielte Einbringen von Porosität oder das Einbetten von mechanischen und elektrischen Funktionselementen erweitern das Anwendungsgebiet additiv gefertigter Bauteile aus metallischen Werkstoffen zudem.
Der Beitrag beschreibt übersichtlich die im Bereich AM verfügbaren Gestaltungsprinzipen und gibt anhand von Beispielen Hinweise auf deren Nutzungsmöglichkeiten. Schwerpunkt liegt dabei auf der Integration mehrerer technischer Funktionen in additiv gefertigten Bauteilen aus metallischen Werkstoffen. Betrachtet werden unter anderem auch hybrid gefertigte Bauteile mit eingebetteten Funktionselementen.

Lecture 3/2
Dr. Jürgen Reinemuth | JUREC Juergen Reinemuth Consulting
16:30
End
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