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Tom de Bruyne - Layerwise
1.
Let Additive Manufacturing Inspire You Themadag Additive Manufacturing Mikrocentrum TNO LayerWise 2012 1 www.layerwise.com © LayerWise NV, all rights reserved Click to edit Master subtitle style 6/4/2012 Who we are “What is the manufacturing potential of Selective Laser Melting” Experiences at LayerWise NV 2012 2 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
2.
Content
About LayerWise Technology Drivers for SLM manufacturing Future outlook 3 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 About LayerWise Increase your added value through advantages of Metal Additive Manufacturing Therefore LayerWise offers its technological expertise realized by being technology developer as well as technology user 4 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
3.
About LayerWise
1989 1991 2001 2007 2008 2009 2010 2011 2012 Phd P. Full Thin Wall Start of Start of Thin Wall Thin Wall Thin Wall Thin Wall Mercelis Dense 0.19MM AM METAL 0.5MM 0.3MM 0.225MM 0.18MM Metal Research Research Phd J. Van Samples Vaerenbergh RP SLM 0% 10% 50% 70% 90% SLS Manufac Manufac Manufac Manufac Manufac Sintering turing turing turing turing turing 5 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 About LayerWise ISO 9001 & 13485 certified chemical mechatronics standard implants dental prostheses pharma mechanization customized implants crowns and copings food solar-lighting medical tools pressure & gas electronics medical modeling automotive aerospace consumer tooling 6 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
4.
Technology 7
www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Technology Directly from 3D CAD Layer-wise production 3D components by successive connection of thin 2D layers 8 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
5.
Technology 9
www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Metal Additive Manufacturing Principle 10 www.layerwise.com © LayerWise NV, all rights reserved 10 © LayerWise NV, all rights reserved 6/4/2012
6.
Technology 11
www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Technology 12 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
7.
Technology 13
www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Technology 14 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
8.
Drivers for SLM
manufacturing Additive manufacturing Same material Same characteristics What is the added value? 15 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 16 www.layerwise.com © LayerWise NV, all rights reserved 16 © LayerWise NV, all rights reserved 6/4/2012
9.
Drivers for SLM
manufacturing Manufacturing Cost Total cost of ownership - performance Type of Driver Mostly small parts Small, medium and large parts part SLM feature Tool-less • Monolythic construction manufacturing • Flow-optimized • Miniaturisation • Customisation • Mass reduction 17 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing CFD analysis SLM Manufacturing Flow type Channel shape Pressure drop Heatex Laminar Cross section Variable sections Conformal Turbulent 3D traject restriction Balanced 18 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
10.
Drivers for SLM
manufacturing 10 mm 19 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing 20 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
11.
Drivers for SLM
manufacturing 200 mm 21 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing 22 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
12.
Drivers for SLM
manufacturing 23 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing 24 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
13.
Drivers for SLM
manufacturing 25 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing 26 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
14.
Drivers for SLM
manufacturing 27 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Drivers for SLM manufacturing Custom made hip implants with porous structure rigidly connected to the implant for a severe pelvic discontinuity (left) and separate parts in a multi component revision (right). Courtesy: Mobelife NV, Leuven, Belgium 28 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
15.
Future outlook
“What is the manufacturing potential of Selective Laser Melting” Experiences at LayerWise NV 2012 29 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Future outlook 30 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
16.
Future outlook
SLM is here to stay Technology will shift – Technology development Purpose-built AM lines – Awareness SLM specific Automation - process control design Cost will decrease Standardization is needed Build rate – Material material – Validation 31 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Future outlook Materials : Stainless, super alloys, heavy metals (18+ materials) Cost : 2008 -> 2012 - buildrate x 4 Upscaling : max dimenions x 5 to circa 500 mm Surface control : Ra 5 -> Ra 0.9 & Ra 0.1 Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11) Pardigm shift: DfM-> design for function 32 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
17.
Future outlook
Sustainable PRODUCTION Sustainable PRODUCTS Sustainable ECONOMICS Material Weight Sustainability is not (ex 1/20 BtoF) (ex 30% payl.) the incentive... Ancilliary consumables Plant footprint (ex tooling) (ex inj. molding) but value creation Re-localized production Process intensification (ex LayerWise (ex flow reactor) comes from sustainable design 33 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012 Contact details LayerWise N.V. Kapeldreef 60 3001 Leuven Belgium tel: +32 16 29 84 20 fax: +32 16 29 83 19 www.layerwise.com info@layerwise.com 34 www.layerwise.com © LayerWise NV, all rights reserved 6/4/2012
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