Forum 3D Metal Printing

WEDNESDAY, 6 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

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

Keynote 2
Scott Crump | Stratasys

Scott Crump is the Chief Innovation Officer of Stratasys, focused on leading and managing Innovation by originating and encouraging new ideas, which result in new solutions and products to market.

Mr. Crump is the inventor of Fused Deposition Technology (FDM) and a co-founder of Stratasys in his home garage along with his wife Lisa Crump. They shipped one system in the first commercial year and now Stratasys has over 200,000 3D Printers at customer sites.

In addition to creating the first 3D printer using FDM, which is 90% of the 3D printers used globally today, his focus is easy to use Additive Manufacturing products, not labor intense products; Including AM automation from front end quote engines, order taking, and slicing, queuing and automatic support removal. Also, including offering all the production grade thermal plastics and many of the thermal set plastics.

Mr. Crump served as the CEO, Chairman, and Treasurer of Stratasys from the 1988 start up through 2012.

He is on the Board of Directors and is currently serving as Chairman of the Executive Committee since February 2015.  Prior to that, he served as the Chairman of the Board since inception in 1988.

From 1982 to 1988, Mr. Crump was co-founder and Vice President of Sales of IDEA, Inc., a premier brand manufacturer of load and pressure transducers. Mr. Crump continued as a director and shareholder until its sale to Vishay Technologies, Inc. (NYSE: VSH) in April 2005.

Mr. Crump holds a B.S. in Mechanical Engineering from Washington State University and attended UCLA’s Business Management Development for Entrepreneurs.

10:30 - 10:45
Break
Session 1
Presentation: Udo Burggraf, GE Additive
10:45 - 11:15

Metal 3D printing has the potential to have a profound impact on the way companies manufacture metal parts. Yet, existing methods today are expensive, slow and require the use of dangerous lasers and metal powders. This presentation will share major advances in metal 3D printing that make it safer, more affordable and more accessible, while producing near-net-shape parts in a variety of alloys, including stainless steels, copper and H-13 tool steel.  With metal 3D printing solutions that cover the full product life cycle – from prototyping to mass production – Desktop Metal is addressing the unmet challenges of speed, cost and quality to make metal 3D printing an essential tool for engineers and manufacturers around the world.

Lecture 1/1
Peter Jain | Desktop Metal
11:15 - 11:45

Get insights into the additive joint project of TRUMPF, Heraeus and Bosch Rexroth. As one of the leading specialists, Bosch Rexroth stands for mobile applications, plant construction and engineering as well as factory automation. In this broad application field, Additive Manufacturing opens many opportunities for industrial applications. The example of an hydraulic application shows how Additive Manufacturing makes its way to industrialization. The example is showing how design freedom in Additive Manufacturing contributes to savings in construction time and material. Furthermore it shows how the smart combination of different technologies (conventional and additive) contributes to savings in construction time and material and that Additive Manufacturing enables new functionalities.
The results are based on a joint project in which the optimal manufacturing process with the ideal results for Bosch Rexroth were evaluated. Project partners has been Heraeus as a powder specialist with comprehensive knowledge of materials, and TRUMPF as th plant manufacturer and laser specialist with its industrialization expertise for Additive Manufacturing.

Lecture 1/2
Frank Nachtigall | TRUMPF Laser- und Systemtechnik GmbH

Frank Nachtigall, MBA, B. Eng, is industry manager within the Additive Manufacturing team at TRUMPF, located at its headquarter in Ditzingen. He focuses on the market development of general industries and automotive. He joined the company already in 2011 handling different positions.

11:45 - 13:30
Lunch break and visit to the trade show
Session 2
Presentation: Udo Burggraf, GE Additive
13:30 - 14:00

One remaining technical restriction in additive manufacturing to-date is size which is defined by the size of the build space. To overcome
this restriction, FIT has introduced the new WAAM technology (Wire Arc Additive Manufacturing) for big metal parts. The resulting massive raw parts are to be finished by CNC milling. It is also possible to work on a pre-fabricated corpus. The WAAM build rate is significantly higher than that of any comparable powder-based technology; usable material includes all welding wires. Complex parts can be realized by the 5-axis system. In our practical every-day use the technology is continually improved.

Lecture 2/1
Philip Emmerling | FIT AG

Philip Emmerling (M. Sc.), originally a trained mechatronics technician, successfully studied Materials Science and Engineering at FAU Friedrich-Alexander University Erlangen-Nürnberg. He specialized in General Materials Properties and Metals. Today, Philip is working as a R&D engineer at the FIT Group, a leading international provider for additive manufacturing services. Philip is dedicated to the company’s technology integration, with special focus on the WAAM technology. His range of interest includes the evaluation of the technology and its integration into the processes of industrial manufacturing, especially considering project planning, parameter study, part programming and layout, software management, and quality control.

14:00 - 14:30

Das Ziel des Vortrags ist es einen Einblick in unsere Weiterentwicklung im Bereich Additive Manufacturing den Zuhörern zu gebe, es geht hierbei um den großen Zuwachs an Möglichkeiten der uns erhalten bleibt wenn wir in stets das Ganze im Blick behalten.
 Hierbei steht unsere blueffect® Vorkammerbuchse im Vordergrund es ist unser erstes individuell gefertigtes Serienteil in unser Sortiment. Durch das AM-Design sind uns viele Möglichkeiten offenbart und ebenso viele Grenzen gezeigt worden und wir haben das Ziel diese zu sprengen. So ist es unser Antrieb nicht nur mit den Maschinen und Materialien zu arbeiten, sondern auch mit beispielsweise der Software, so konnten wir eine Automation in NX erschaffen die eine Konstruktionszeit der blueffect ® Vorkammerbuchse von drei bis vier Stunden auf 15 Minuten herunterbricht. Des Weiteren haben wir die Farbtabelle neu entwickelt so das uns der Kunde ohne weitere Erklärungen mit einem Blick, seine Prioritäten mitteilen kann. Wir sind über das reine Prototyping weit hinaus. Serienteile, Automation und die Verbesserung der Kommunikationsabläufe sind Meilensteine auf unserem Weg in eine Zukunft, die wir heute schon spüren können, zumindest einen Teil.

Lecture 2/2
David Svoboda | JELL GmbH & Co. KG
14:30 - 15:00

Das Fraunhofer IGCV befasst sich mit pulverbettbasierten additiven Fertigungsverfahren, wie dem LBM, zur
Herstellung von metallischen Hochleistungsbauteilen. Derzeit können mit diesem Verfahren Bauteile aus einem
Werkstoff, sog. Monomaterialbauteile, hergestellt werden. Multimaterialbauteile hingegen zeichnen sich durch
mindestens zwei unterschiedliche Werkstoffe aus, die fest miteinander verbunden sind. Die Fertigung von 2-DMultimaterialbauteilen,
bei welchen ein Materialwechsel zwischen aufeinanderfolgenden Schichten erfolgt, kann
bereits heute bei vielen marktüblichen LBM-Anlagen durch einen manuellen Materialwechsel erfolgen. Dies ist
bei einem 3-D-Multimaterialbauteil heute nicht möglich, da hier innerhalb einer Schicht beide Werkstoffe vorliegen
müssen. Zur Fertigung dieser Bauteile ist es notwendig, den Pulverauftragsmechanismus anzupassen,
um die Ablage eines zweiten Werkstoffes in der Pulverschicht zu ermöglichen. Daher wurde am Fraunhofer
IGCV ein neuartiger Auftragsmechanismus in eine LBM-Anlage soft- und hardwaretechnisch integriert, sodass
nun der Aufbau von 3-D-Multimaterialbauteilen in einer kommerziell verfügbaren Laserstrahlschmelzanlage
möglich ist.
Dieser Vortrag gibt einen Überblick zu dem Stand der Arbeiten zur Multimaterialverarbeitung in Augsburg, die
seit Juli 2017 im Rahmen des 10-Mio.-Euro Projekts MULITMATERIALZENTRUM Augsburg gebündelt werden.
Der Fokus des Vortrages wird auf den realisierten Anwendungsbeispielen liegen und den identifizierten
Herausforderungen im Bereich Prozesstechnik und Werkstoffe.

Lecture 2/3
Dr.-Ing. Christian Seidel | Fraunhofer IGCV

Dr. Seidel is an internationally recognized expert on Additive Manufacturing. His current activities related to Additive Manufacturing are:

  • Head of Main Department (since 03/18) and Head of Additive Manufacturing (since 03/18) at
    Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
  • Management Board (since 07/14) at
    Institute for machine tools and industrial Management (iwb) of Technical University of Munich
  • Management consultant on Additive Manufacturing (since 12/14) independent Munich-based consultant with a focus on M&A
  • Guest lecturer (since 10/14) at
    University of Applied Science Augsburg
  • Convenor to

    • ISO TC261/AG1 Coordination Group (since 09/17) and
    • ISO TC261/ASTM F42 JG 57 on Design Guidelines for Powder Bed Fusion (since 07/15)

  • Convenor to
  • German Association of Engineers (VDI) Committee on Environment Health and Safety Issues in Additive Manufacturing (since 04/16)
  • Appointed expert in committees of

    • VDI (since 01/12)
    • DIN (since 01/12)
    • CEN (since 01/15)
    • ISO (since 07/12)
    • ASTM (since 07/14)

From 07/14 until 2018 he was Head of Department “Components and Processes” at Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV focussing on Additive Manufacturing as well as Quality and Technical Cleanliness.


He holds a PhD in mechanical engineering for his submitted doctoral thesis in the field of simulation of laser-based powder bed fusion of metals from Technical University of Munich and has published more than 40 scientific articles and co-authored 4 books related to additive manufacturing and production technology. He studied Mechanical Engineering with a focus on production technology and thermo-fluid-dynamics at University Stuttgart, Technical University of Munich and Stellenbosch University (South Africa). He gathered industry experience at Gebr. Heller Maschinenfabrik GmbH (machine tool manufacturer, Nuertingen, Stuttgart area) and MTU Aero Engines (aero engine components manufacturer, Munich).

15:00 - 15:30
Break
Session 3
Presentation: Udo Burggraf, GE Additive
15:30 - 16:00

Gases represent only a very small part of the production cost structure, but they play a crucial role for safety, process stability and for the final quality of products. Although the influence of the gas in the process is sometimes considered to be secondary during the laser beam melting process, its protective function is essential, as well as the evacuation of generated smokes and spatters in order to limit pollution of the powder bed.
In this work, our study on the influence of gas atmosphere on the process and on the quality of the manufactured parts is presented. Usually, argon or nitrogen is used to inert the chamber during the process. In this study, realized in collaboration with Poly-Shape company and the Process and Engineering in Mechanics and Materials laboratory (PIMM, Paris), various atmospheres have been studied including helium/argon mixtures as well as nitrogen with defined quality and from machine-integrated nitrogen generator. Modifications of the process have been observed, on the melt pool stability and wettability, and on the generation of particles and spatter. The atmosphere of the chamber have been controlled (oxygen, moisture and nanoparticles), powder and generated particles analyzed and their impact on the part properties quantified.

Lecture 3/1
Markus Effinger | Air Liquide Deutschland GmbH
16:00 - 16:30

Additive manufacturing is increasingly used for producing high performance parts, such as turbine blades, medical implants and tools, and for these reasons quality control is an essential part of it. Hereby X-ray computed tomography (CT) adds value at different stages of the whole process chain as it offers non-destructive testing at high precision. For instance, prior to manufacturing, powder for metal printing is analyzed in terms of size distribution, sphericity, foreign particles and porosity inside the grains. Furthermore, manufactured samples and components are controlled by three-dimensional (3D) failure analysis and dimensional measuring. An iterative process of X-ray CT control and printing parameter changes help optimizing the final product. Later in the manufacturing process, powder residues in the interior structures is easily detected as well. The X-ray CT is also used to regularly verify the system performance of 3D printing machines.
In summary, there is an increasing tendency for Additive Manufacturing for larger series as well as for critical products which requires new quality control methods in the whole productive chain. Therefore, high precision and non-destructive techniques like X-ray CT are in growing demand. This contribution shows several case studies highlighting the power of various X-ray CT analytics.

Lecture 3/2
Gerhard Zacher | GE Sensing & Inspection Technologies GmbH
16:30
End
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