Forum AM Science - part 1


Location: CongressCenter, ground floor, Room Carl Zeiss left

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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

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 - 11:00
Session 1
Presentation: Stefan Kleszczynski, Universität Duisburg-Essen
11:00 - 11:30

Studies within the quality assurance of conventionally produced components have shown that monitoring systems based on active thermography result in more stable and detailed information about defect zones compared to passive thermography. Passive thermography was found to be a feasible approach for detecting flaws in components manufactured by laser beam melting (LBM). Based on these findings, the suitability of active thermography as a monitoring principle for LBM was investigated in a preliminary ex-situ study and a subsequent in-situ-arrangement. In the in-situ study, the manufacturing of layers is followed by an excitation with the process laser as an input signal. The response signal, consisting of temperature field data of the test specimen surface over time, was detected by a micro-bolometer camera. This data were evaluated by means of a Fast Fourier Transformation. The analysis of the phase progression was found to represent a suitable approach for the differentiation between defect and sound areas. Combined examinations of the phase for various evaluation frequencies have the potential to specify potential flaws. These insights can serve as a starting point for an in-process, layer by layer monitoring tool, contributing to a more sophisticated total quality management of additively manufactured parts.

Lecture 1/1
Cara Kolb | iwb, Technische Universität München (TUM)


Since 10/2015
Master of Science at the Technological University of Munich (TUM)
Field of study: Mechanical Engineering and Management
Topic of the Master Thesis: Concept & Validation of additively manufactured electrodes for lithiumion batteries (in progress)
Topic of the Semester Thesis: Active Thermography as a Quality Assurance for Laser Beam Melting (LBM)

10/2011 – 04/2015
Bachelor of Science at the Technological University of Munich (TUM)
Field of study: Energy and Process Engineering
Topic of the Bachelor Thesis: Development of approaches to improve the offshore suitability of a novel lifting system for wind turbines

09/2003 – 06/2011
Feodor-Lynen Secondary School, Planegg

Research activities
Since 03/2016
Trainee at the chair for machine tools and industrial management at the Technical University of Munich (TUM)

Department: Additive Manufacturing
Area of responsibility: support of research proposals, projects with industrial partners and support of lectures, project management, public relations
work Work Experience

04/2016 – 09/2016
Internship at BMW SA (Pty.) Ltd., Pretoria, South Africa
Department: Validation, Integration & Analysis of Electric/Electronics, Driving

Dynamics & Powertrain
10/2015 – 02/2016
Tutor at the chair for thermodynamics at the Technological University of Munich (TUM)

03/2015 – 09/2015
Internship at the BMW Group, Munich
Department: Problem and Quality Management of the new BMW 7 series

10/2014 – 02/2015
Tutor at the chair for material science and mechanics at the Technological University of Munich (TUM)

10/2014 – 02/2015
Tutor at the chair for thermodynamics at the Technological University of Munich (TUM)

10/2012 – 10/2014
Student trainee at Alphaform AG, Feldkirchen

09/2012 – 10/2012
Internship at Alphaform AG, Feldkirchen

07/2011 – 08/2011
Internship at Dietl Feinmechanik GmbH, Gauting

11:30 - 12:00

The quality (e.g. surface roughness, density) of L-PBF parts depends, amongst other factors, on the position of parts within the building chamber. One possible cause for the position dependency is the angle of incidence of the laser beam on the powder bed. The experiments are conducted regarding probable interaction of the laser beam with metal plume, the elliptical beam shape on the powder bed (caused by displacement) and the angle of incidence relative to the melt pool. Experiments are conducted using (illuminated) high-speed imaging of a Ti6Al4V L-PBF process which enables the depiction of the laser-process by-product interaction.

Lecture 1/2
Maximilian Schniedenharn | Fraunhofer ILT

After finishing his engineering degree at the end of 2012 at the RWTH Aachen University, Maximilian Schniedenharn has been working at the Fraunhofer ILT´s Laser Powderbed Fusion group. Since then, his research focusses on the influence of the L-PBF machines itself on the resulting part quality. Especially the optical system and the shielding gas flow are within the scope of his work since these have a great influence on the process and their correlation with part quality is not fully understood yet.

12:00 - 12:30

Most additive manufacturing technologies share the similarity in production of parts layer by layer based on physical models created with three-dimensional computer aided design (CAD) models. In contrast to the longer on the market available polymer additive manufacturing methods, the principle of “Arburg Freeformer” process bases on melting of conventional thermoplastic polymer granules as base material with an injection moulding plasticising unit. A stationary discharge unit with an integrated nozzle–valve system applies thin plastic droplets layer by layer to a component carrier using high frequency piezo technology to open and close the nozzle–valve system. In this paper, structural properties are correlated with the mechanical and physical behavior of additive manufactured thermoplastic polymers. The investigations are focused on interlayer structure and mechanical properties of layer wised build specimen and parts with Arburg Freeformer Technology. The effects of a variation of process parameters on impact fracture behavior of Acrylnitril-Butadien-Styrol (ABS) and Polypropylene (PP) materials were studied by means of an instrumented Charpy impact tester which records load–deflection diagrams at impact fracture. Additionally, the structural properties of semi crystalline Polypropylene of discharged polymer droplets at interlayer boundaries are investigated by light microscopically investigations.

Lecture 1/3
Franziska Kaut | Procter&Gamble
12:30 - 14:30
Lunch break and visit to the trade show
Session 2
Presentation: Prof. Dr. Gerd Witt, Universität Duisburg-Essen
14:30 - 15:00

Development of alternative polyamide materials for the laser sintering process

Lecture 2/1
Andreas Wegner | AM Polymer Research UG
15:00 - 15:30

The material choice for the Laser Sintering Process (SLS) is still scarce and therefore the potential to find new application fields for the Additive Manufacturing process. In particular industries like electronics, aircraft and automotive demand high performance plastics showing high strength and temperature resistance. In this work, a new SLS material PA613, developed by Evonik, was investigated. This Laser Sintering powder may be implemented where PA6 is used in conventional manufacturing processes. Due to a higher melting temperature in comparison to standard Laser Sintering material PA12, PA613 may be applied in high temperature applications. Despite the higher melting temperature PA613 is processable on an EOS P396 Laser Sintering system, even if some modifications have to be done. Beside investigations of process relevant material properties first mechanical properties are determined. Different parameters of processing PA613 are varied and robust parameters are found. Therewith, mechanical parameters are correlated to the parameter variation.

Lecture 2/2
Christina Kummert | Universität Paderborn, DMRC
15:30 - 16:00

Influence of the layerwise manufacturing on the mechanical properties of selective laser sintered parts

Lecture 2/3
Andreas Wörz | Universität Erlangen, Lehrstuhl für Kunststofftechnik
16:00 - 16:30

Due to the significant importance of the application of polyamide 12 in laser sintering, the demand for high-quality surfaces is also growing.Glass bead blasting of laser-sintered samples have shown a characteristic mean roughness depths Rz of approximately 76 ?m in the direction of manufacture which is based on different settings. In order to further improve the surface of laser-sintered components and thus to smooth, it is additionally possible to carry out chemical post-treatment. In the experiments conducted in this context, the samples are kept in different acid immersion baths with varying interaction time.
The acids used for this series of experiments are from the groups of strong organic acids, oxidizing acids and strong mineral acids and were determined by a preliminary selection of the chemical resistance of the polyamide 12.By immersing samples in an acid from the group of strong organic acids, interaction times of 10 s, 30 s, 60 s, 90 s and 120 s, the roughness characteristic of laser sintering can be reproducibly reduced to up to 10 ?m.
In addition to roughness as an indicator of successful post-treatment, the dimensions of the samples before and after treatment are determined. The resulting dimensional and shape changes are also evaluated and serve as a further indicator of successful post-treatment.

Lecture 2/4
Livia C. Wiedau | Universität Duisburg- Essen, Lehrstuhl Fertigungstechnik