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                                               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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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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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