Forum Contract Additive Manufacturing

TUESDAY, 5 JUNE 2018

Location: CongressCenter, ground floor, Room Carl Zeiss right


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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 - 11:00
Break
Session 1
Presentation: Dr. Eric Klemp, voestalpine Additive Manufacturing Center GmbH
11:00 - 11:30

Viele Unternehmen stellen die Wirtschaftlichkeit von 3D-Druck in der Serienfertigung in Frage und zögern noch bei der praktischen Umsetzung zu additiv gefertigten Produkten. In der Tat ist auch nicht jedes Produkt oder Bauteil additiv besser oder günstiger herzustellen als auf klassischen Wegen. Auf dem Holzweg ist jedoch, wer ein viele Jahre durchoptimiertes und durch den Einkauf nah an die Grenzkosten der Fertigung geprügeltes Projekt alleine durch einen Wechsel des Fertigungsverfahrens noch günstiger produziert haben wollen.
Der Schlüssel zum Erfolg ist, über den eigenen Tellerrand hinauszublicken.
In seinem Vortrag stellt Stephan Kegelmann 10 Punkte vor, die innovative Ingenieure in ihre Gedanken einbeziehen sollten.

Lecture 1/1
Stephan Kegelmann | Kegelmann Technik GmbH
11:30 - 12:00

The company Rolf Lenk Werkzeug- und Maschinenbau GmbH, which exists since 1949 and has grown traditionally, is a medium-sized company based in Ahrensburg near Hamburg. It specialises in contract manufacturing and has developed into a recognised supplier for various industrial sectors.
For more than four years now, the company has also been successfully working in the additive production of metal parts, producing components from the powder bed for national and international customers from various industries.
However, in order to meet the most diverse requirements for end products, such as tolerances and surfaces, intensive preparation and reworking is necessary. For the manufacturer of individual parts and small quantities, some of which have not been optimized for production, there are price-driving costs and risks arising from additional process steps at this point, which are currently very difficult to estimate and calculate in advance and thus hinder the sensible use of additive production.
The company has taken up this problem and developed their own solutions. Dealing with the customer and the component is the key to success.

Lecture 1/2
Matthias Otte | Rolf Lenk Werkzeug- und Maschinenbau GmbH

Matthias Otte has been working for Rolf Lenk Werkzeug- und Maschinenbau GmbH in Ahrensburg since October 2016.

After successfully finishing his mechanical engineering studies at the University of Applied Sciences in Wilhelmshaven, he initially worked as a CAD designer. He then completed a master's degree at the University of Applied Sciences in Hamburg and worked as a research assistant in the field of application of new technologies. This led him to his current passion - additive manufacturing.

Today, he works as a project manager and deals intensively with topics along the value-added chain of "3D printing". He loves to pass on his knowledge to customers or students in lectures and training courses.

12:00 - 12:30

Typical pitfalls in industrial applications of Additive Manufacturing – a best practice presentation

Lecture 1/3
Tobias Stengel | MBFZ toolcraft GmbH

Studium und Ausbildung:
- Allgemeine Hochschulreife
- Duales Studium an der TH Nürnberg
- Auslandssemester in Dundee (Schottland)

Beruflicher Werdegang:
- Traineeprogramm MBFZ toolcraft GmbH
- Vertriebsbeauftragter
- Vertriebsleiter seit 2014

12:30 - 14:30
Lunch break and visit to the trade show
Session 2
Presentation: Dr. Eric Klemp, voestalpine Additive Manufacturing Center GmbH
14:30 - 15:00

Additive Fertigungsverfahren halten Einzug in immer mehr Branchen. Dadurch steht eine wachsende Zahl an Entwicklern vor der Herausforderung in ihrem Produktportfolio geeignete Anwendungen zu identifizieren und Bauteile zu konstruieren.
Für diese Aufgaben benötigen Entwickler Wissen über die AM-Prozesse mit ihren Eigenschaften, Möglichkeiten und Restriktionen sowie Methoden und Richtlinien für den Konstruktionsprozess in der jeweiligen Anwendung.
Um diesen Bedarf zu befriedigen wurde analysiert, welches Wissen konkret in den unterschiedlichen Phasen der Produktentwicklung benötigt wird, um dieses im Anschluss zusammenzutragen, zu strukturieren und für ein breites Publikum zugänglich zu machen.
Dieser Beitrag beschreibt die entwickelte Struktur für das AM-Konstruktionswissen und die Formen mit denen dieses unter unterschiedlichen Rahmenbedingungen vermittelt werden kann. Das Vorgehen ist auf alle AM-Verfahren anwendbar. Für die konkrete Umsetzung wurde sich auf die Prozesse Selective Laser Melting (SLM), Selective Laser Sintering (SLS) und Fused Deposition Modeling (FDM) beschränkt, da diese aktuell die höchste industrielle Relevanz haben.
Dieses Vorgehen hat sich als wirksames Mittel herausgestellt, um die Implementierung der Additiven Fertigung in industrielle Endprodukte zu beschleunigen. Die Strukturierung des Konstruktionswissens erlaubt es, dieses für andere AM-Prozesse und Anwendungsfelder zu erweitern. Somit kann dieses AM-Konstruktionswissen langfristig mit der Verbreitung der Additiven Fertigungsverfahren wachsen.

Lecture 2/1
Dr. Christoph Klahn | inspire AG

Dr.-Ing. Christoph Klahn is the head of the Design for New Technologies group at inspire AG since 2013. The group is closely linked to the Product Development Group pd|z of ETH Zurich. Since 2008, Dr. Klahn has been working in various functions on the potentials of additive manufacturing for series part and the challenges for product development. The aim of his group is to transfer knowledge about additive manufacturing from research to industry and, together with companies, to identify the potential of new manufacturing processes in their products and to realize successful AM products.

15:00 - 15:30

Within "Industrie 4.0" approach 3D printing technology is characterized as one of the disruptive innovations. Conventional supply chains are replaced by value-added networks. The spatially distributed development of printed components, e.g. for the rapid delivery of spare parts, creates a new challenge when differentiating between "original part", "copy" or "counterfeit" becomes necessary. This is especially true for safety-critical products. Based on these changes classic branded products adopt the characteristics of licensing models as we know them in the areas of software and digital media. This paper describes the use of digital rights management as a key technology for the successful transition to Additive Manufacturing methods and a key for its commercial implementation and the prevention of intellectual property theft. Risks will be identified along the process chain and solution concepts are presented. These are currently being developed by an 8-partner project named SAMPL (Secure Additive Manufacturing Platform).

Lecture 2/2
Josip Stjepandic | PROSTEP AG

2.4.1961
Date of birth

1978 - 1983
Study of mechanical engineering at the University of Zagreb

1983 - 1985
PhD study, promotion as Dr. techn. at Graz University of Technology, Austria

1986 - 1988
Simulation engineer at Steyr-Daimler-Puch Fahrzeugtechnik in Graz, Austria

1988 - 1994
Team manager CA Techniques at WABCO-PERROT BREMSEN GMBH in Mannheim, Germany

1994 - 1996
Professor for Applied Computer Science in Mechanical Engineering at the
Dortmund University of Applied Sciences, Germany

Since 1996
PROSTEP AG, Darmstadt, Germany

2000 - 2012
Head of Competence Center CA Technology

Since 2012
Head of Business Unit 3D Product Creation

Membership:

International Society for Productivity Enhancement (ISPE Inc.) – vice president

Publications:

Concurrent Engineering in the 21st Century: Foundations, Developments and Challenges, Springer, 2015 (edited book)

More than 100 papers in conferences and journals

15:30 - 16:00

Induction heating is a safe and energy-efficient heating process that allows
all electrically conductive materials to be heated quickly and effectively.
Depending on the field of application, inductors in different forms will be
needed, as they should be able, as accurately as possible, to adapt to the
component that is to be heated. With the Inductor Generator from PROTIQ,
it is possible to modularly design induction coils to be suitable for many
industrial applications.
The inductive heating process can be precisely controlled and is reliably
reproducible and extremely fast. In the metalworking industry, this heating
method is therefore often used in the (semi) automated series production.
The production of high-output inductors, however, is very complicated: Their
geometry should be adapted as closely as possible to the shape of the
component to be heated in order to generate a defined magnetic field.
Induction coils for different applications, therefore, have to be specially
designed and produced. Weeks or even months can pass from receipt of the
order to the completion of an inductor.
The Inductor Generator, in combination with tool-less production,
significantly shortens this lengthy process through the use of 3D printing.
After selection of the appropriate basic shape for the application it is possible
to define the individual parameters, such as the number of turns, coil
diameter or the position of the connection. There are six basic shapes to
choose from, which can be modularly adapt to personal requirements with
just a few clicks. The inductor will be finished just a few days after the receipt
of the order, since with industrial 3D printing production can start
immediately!

Lecture 2/3
Stefan de Groot & Dr. Ole Bröker | PROTIQ GmbH & trinckle

M. Sc. Stefan de Groot, born in 1987, completed an apprenticeship as industrial clerk at the Symrise
GmbH & Co. KG after he finished grammar school in 2006. Since he worked as account manager and
business support in the sales department after his apprenticeship for two years, he started studying
industrial engineering at the University of Paderborn in October 2010. After five years, he finished his
studies as Master of Science and started working for the Direct Manufacturing Research Center in
November 2015. The DMRC is an institute for additive manufacturing of the University of Paderborn,
where Stefan de Groot was responsible for the laboratories and worked on scientific projects. Since
August 2016, he is working at the Phoenix Contact GmbH & Co. KG, including the transition to the
PROTIQ GmbH as independent subsidiary in December 2016, and acts there as project and
technology manager for additive manufacturing as well as social media manager.

16:00 - 16:30

The AM market is moving from rapid prototyping to serial production and lots of new industrial and consumer applications like 3D-printed eyewear, automotive parts, mid soles or medical orthotics are rising. This leads to an increase in quality standards for the end-use products and requires a new approach in the economical processing of such higher volumes for contract manufactures. Traditional post-processing methods are reaching their limits and often don't meet the expected quality standards of emerging applications, which require valuable end-use products. DyeMansion from Munich offers a variety of high-volume finishing systems for easy ‘Print-to-Product’ workflows that transform raw, 3D printed parts into high value consumer and industrial products. In his presentation, Felix Ewald, co-founder and CEO of DyeMansion gives an exciting insight into the different application fields of these automated solutions for post-processing and how they can be implemented in existing production lines by showing case studies from different contract manufactures and manufacturing projects from the automotive and eyewear sector using DyeMansion technology.

Lecture 2/4
Felix Ewald | DyeMansion GmbH

Felix Ewald is the Co-Founder and CTO of DyeMansion. DyeMansion is world market leader for additive manufacturing finishing and coloring systems that transforms raw, 3D-printed parts into high-value consumer and industrial products. Already during his business informatics studies, Ewald was passionate about developing business models and founded his first company directly after graduation. The 3D printing agency Trindo. While running Trindo, Ewald and his Co-founder, Philipp Kramer (also Co-founder and CTO of DyeMansion), identified an opportunity for a high quality, cost-effective coloring solution for additive manufactured plastics that could scale to meet the needs of high-volume products. Their idea laid the foundation for DyeMansion’s finishing systems and ’Print-to-Product’ workflow. Already trusted by more than four-hundred customers, including leading global manufacturers in diverse industries, such as eyewear, automotive, retail, medical, and sports equipment, DyeMansion is now expanding internationally and establishing operations in the United States and APAC.

16:30
End
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