User conference - part 1


Location: CongressCenter, ground floor, Room Carl Zeiss right

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

The continuing growing and evolving Additive Manufacturing space – A look back and looking ahead

Keynote 2
Scott Crump | Stratasys
10:30 - 11:00
Session 1
Presentation: Dr.-Ing. Sabine Sändig, Thüringer Aufbaubank
11:00 - 11:30

For 30 years, Stereolithography (SLA) has been the gold standard in rapid prototyping and has led the charge in revolutionizing the design-for-manufacturing paradigm. Now, with 3D Systems’ Figure 4 technology, SLA is set to pave the way for additive manufacturing in the automated manufacturing environment. Patrick Dunne will share how Figure 4 offers a step change in productivity by providing a system that is configurable with other automation tools in the factory setting.

Mr. Dunne will discuss the key features that distinguish Figure 4 and prime it to keep pace within automated manufacturing. These features include a short vat life, which frees the chemist to do a more reactive kind of chemistry. This results in 3D printed parts with the physical properties demanded by modern applications, including high temperature resistance, toughness, elastomeric qualities and bio-compatibility.

Attendees of this talk will gain understanding of the considerations required in bringing quality, high-speed, additive processes into conventional manufacturing settings. Mr. Dunne will demonstrate how Figure 4 anticipates and answers these needs while unlocking greater opportunities in part geometry and production speed.

Lecture 1/1
Patrick Dunne | 3D Systems
11:30 - 12:00

Die Exentis Group AG, ansässig in Stetten, in der Schweiz nahe Zürich, ist ein unabhängiger Premiumanbieter intelligenter Serienproduktionslösungen im einzigartigen und patentierten 3D Siebdruckverfahren, dem Exentis 3D Mass Customization®. Individualisierte Geometrien in Grossserie bei freier Materialauswahl. Im Fokus stehen kundenspezifische Produktlösungen in den Bereichen Metallurgie/Keramik wie auch Biomaterialien. Der Vortrag gibt Einblick in die komplexe Corporate DNA, von der Materialentwicklung, über die Herstellung der Pastensysteme, die Produktion der Siebe, die Siebdrucktechnologie und weitere Prozessschritte wie Sinterung oder Produktion unter Reinraumbedingungen. Es erfolgt eine Abgrenzung zu etablierten 3D Druckverfahren und ein Überblick über die produktseitigen Anwendungen.

Lecture 1/2
Srdan Vasic | Exentis Group AG
12:00 - 12:30

The optimal use of the enormous potentials of additive manufacturing requires not only new hardware solutions, but also new materials that increase the areas of applications and the number of customers respectively. The innovative powder generation process at EOS GmbH opens up new opportunities to develop novel plastic materials for laser sintering systems. The polypropylene powder PP 1101 from EOS GmbH was officially launched in November at formnext 2017.
This polypropylene material is the first major milestone in the development of innovative plastic powders using a novel powder generation process designed to be compatible with present and future powder-based systems. With PP 1101, EOS GmbH broadens the application portfolio of additive manufactured plastic parts, especially for the automotive, pharmaceutical and chemical industries, as well as the consumer goods industry.
In this lecture, the current research and customer experiences with the polypropylene powder from EOS GmbH will be presented, as well as the general framework requirements for future materials development based on the new, successful powder generation process.

Lecture 1/3
Dr. Stoyan Frangov | EOS GmbH

Dr. Stoyan Frangov born on 2 June 1975 in Pazardzhik/Bulgaria has been working for more than 11 years as a material and process developer polymer in the research & development department at EOS GmbH.
Currently the main tasks of Dr. Frangov are intensively involved with powder generation process that are strategically important and directly and indirectly affect other focus projects at EOS GmbH. He accompanies the development steps in close cooperation with the external partners and is responsible for the implementation within the company.
As part of material projects develops Dr. Frangov novel and innovative materials for additive manufacturing and is responsible for the technical implementation of the specifications.
In addition to pure technical project management assists Dr. Frangov the monitoring of the competition and analysis of competitive materials, as well as product management in creating sales argumentation.
Over time, Dr. Frangov has proven his considerable expertise and extensive knowledge in many patents, as well as specialist literature.

12:30 - 14:30
Lunch break and visit to the trade show
Session 2
Presentation: Dr.-Ing. Sabine Sändig, Thüringer Aufbaubank
14:30 - 15:00

Additive Manufacturing (AM) of metal components is an emerging technology for oil and gas industry products, offering many new possibilities for future innovation. High-strength materials like cobalt-chromium alloys with high abrasion, erosion, and corrosion resistance are of major interest because tools in the oil and gas industry often operate at high mechanical stresses and in highly corrosive environments. Cobalt-chromium-tungsten alloys promise an enhanced wear resistance and hardness compared to the established ASTM F75 cobalt-chromium-molybdenum alloys. However, these alloys have never been processed using powder bed-based AM technologies. Therefore, investigations covering processing of cobalt-chromium-tungsten alloys have been carried out. The selective electron beam melting (SEBM) technology was chosen to minimize the risk of thermal cracking during processing. Then, available industrial powders were evaluated and a suitable powder material was chosen based on particle size distribution, morphology, and density. Next, an initial test series was performed to determine the density with regards to pores and cracks. These tests were crucial to evaluate the potential of electron beam melting of cobalt-chromium-tungsten alloys and to adjust the parameters related to mechanical properties, abrasion resistance, and erosion resistance.

Lecture 2/1
Matthias Gieseke | Baker Hughes, a GE company

Dr.-Ing. Matthias Gieseke studied mechanical engineering at the Leibniz University of Hannover, Germany from 2003 to 2009. After his studies he started working as a research assistant in the Surface Technology Group of the Laser Zentrum Hannover e.V., Germany in the field of Additive Manufacturing. There he focused on process and material development especially in Laser Cladding and Selective Laser Melting (SLM). In 2015 he earned the doctoral degree of the Leibniz Universität Hannover, Germany for his thesis on Selective Laser Melting of magnesium and magnesium alloys.
Since 2017 Matthias Gieseke is working as a Materials Scientist in the field of Additive Manufacturing at Baker Hughes, a GE company in Celle, Germany. There, he focusses on material qualification and material development for additive manufacturing especially for the Selective Electron Beam Melting process (SEBM).

15:00 - 15:30

Additive manufacturing of metal optics

Lecture 2/2
Nils Heidler | Fraunhofer IOF
15:30 - 16:00

One of the last restrictions AM still has to face today is size which is determined by the size of the build chamber. To meet the rising need for quickly available big-sized plastic parts, the FIT Group has adopted an innovative new technology. GDP technology (Gel Dispensing Printing) can produce xxl parts up to the size 1.8 m x 1.5 m x 1.2 m in one piece by extruding a proprietory gel of high-viscosity which is hardened by UV LED during. Manufacturing speed is up to 10 times faster when compared to similar technologies. This is especially useful for prototyping purposes, e.g. for big objects intended for visual communication and advertising, for concept models, furniture, etc.

Lecture 2/3
Bruno Knychalla | FIT Prototyping

Bruno Knychalla has successfully studied architecture in Munich, Paris, and Sydney and has accomplished his studies in the interdisciplinary ITECH M.Sc. Programme (Integrative Technologies & Architecture Design Research) of the University of Stuttgart, Germany. He is Head of Large Format Manufacturing at FIT and as such responsible for the application development and the manufacturing of big parts from additive manufacturing. Part of his interest is focused on the research of 3D printed composites and their potential for architectural applications. FIT is a pioneer in the adoption of additive manufacturing and has very early recognized the vast potential of this technology. With more than 20 years of experience and 330 employees in 5 countries, FIT today is a synonym for comprehensive knowhow around disruptive AM technologies, materials, and design.

16:00 - 16:30

3D-Printing at Miele - Establishing a new technology in consisting business processes

Lecture 2/4
Pia Gausemeier | Miele & Cie. KG