Sustainability approach by design optimization for advanced layer manufacturing

This presentation may contain confidential and/or privileged information.
Any unauthorized copying, disclosure or distribution ofthe material in this document is strictly forbidden.
Sustainability approach by Design Optimization
for Advanced Layer Manufacturing
Udo Behrendt
Business Development
Manager Aerospace

E-Manufacturing_May2012_UB.pptx | EOS | 2
~ 1200 systems thereof ~ 450 M-systems
EOS is a ''global organization'' with a significant
installed machine base
EOS installed base
Customers in more than 50 countries
EOS sales/service/applicationin
11 countries
Revenue 108 Mio € (FY 2011/2012)
Worldwide ~ 450 HC
Strong patent portfolio
EOS global footprint
EOS sales/services offices EOS technicalcenter R&D/application office Distributors
AMS RMS EM-PI-ES PROTEC 3D DESIGN LRPS PROMECH ALPHA
DETEKT
DIGITAL-
CAN
NDES
FREEFORM
BIBUS-MENOS
TEMACONSULT
AB-UNIVERSAL YING FENG
SNC
DOYANG
ROLAND-SINGER
Europe:
~750
Asia: ~200
ROW:~120
NA: ~150

Focus industries
Lightweight
components
Substitution metal
by plastic
Footwear
Web platforms
Jewelry / Interior
Micro electronics
Micro tooling
EOS is focusing on selected industries
MedicalAerospace/
Turbines
Tooling
Automotive/
IndustrialApplications
Consumer
Goods & Lifestyle
Micro
Laser Sintering
Dental applications
Implants
Medical devices
Aero engine parts
MRO applications
Airplane
components
Injection
molding tools
Packaging
components

Strong focus on engine and interior market
Focus markets M – Aerospace
Selective growthInvest & Growth Further investigation
AM is established at jet engines
High temperaturesuper alloys
Different applications
Already used in severalaircrafts
Low weight solutions
Cost reduction
Customizing/VIP
High value through AM
Most UAV's already containing AM
parts
Fast growing market
Test bench for new technology
Jet Engine Interior UAV
Focus markets M – Aerospace

Industry view
Source: Press
Citation´s
“….in ourlifetime, at least 50% of the
engine will be made with additive
technologies…” - Robert McEwan, General
Manager, Airfoils and Manufacturing, GE Aviation,
2011
“On a 6,000-pound engine, we expect to
save 1,000 pounds….” Todd Rockstroh, GE
Aviation in Modern Machine Shop, March 2012
“I truly believe that additive
manufacturing will develop to become
the most important, the most strategic
and most usefulmanufacturing
technology ever…”–T. Wholers, Wholers
Associates Inc., August 2012

No Tooling
Long product life cycle
Low quantities / Modifications / Upgrades
Spare parts on demand
Higher flexibility
Lose Weight
Light weight structures
Highintegratedsubsystems
Improved functionality
Reduced Cost
Investing in parts not tools (Just intime investment)
Less part counts
Reducedassemblyandqualitycontrol
Novel Materials
Higher melting points
SOURCE: EOS
ALM – Benefit´s for the aviation industry
Source: 4dsysco.com
Source: medicom.de
Source: ewstvlowcost.com

Hydraulic Manifold
(Oil block with lattice structure)
Source: 3T RPD, Within
Design study for a medicalinstrument
Special surfacestructure with grooves or cavities for
defined positioning
Hollow and thin-walled design
EOS StainlessSteel PH1
Building time: 25 h
Project: 3T RPD, Within

From block to advanced solution…

From nature to product….
Source: IPA, Messe München
Project partner:
The gripper is able to withstand 2 bar permanently
(>15.000.000 cycles in fatiguetesting)
End stops for angle limitation are realised
High gripping power
Extremely low weight
Walter Reis Innovation Award for Robotics 2006

Integrated functionality
Source: HP
Complex plastic parts in small quantity for EOSINT Systems

Production Applications – Multi-Functional
Designs reduce cost and weight
Attach Straps Eliminated
Part Count Reduction
Quick & EasyInstallation
Multiple Ducts Combined
to Single-Piece Duct
PA 2210 FR / PA 2241 FR
UL 94 V0 confirmed
FAR/JAR qualification
Testedon:
Flammability
Smoke Density
Smoke Toxicity
Heat Release
ConformalShapes Achieved and InternalFlow Features Added
Previous (Kevlar/Rotomold)Configuration New (SLS) Configuration

Southampton University Laser Sintered Aircraft
SULSA - UAV
− Projectcreated in aboutone month
− Builtin five parts with ~ 3 kg weight
− Wingspan ~ 2 meters
− Flapswith hingesintegrated (no fasteners or screws
used)
− Snap fit techniques for easy and quick assembly
− Geodetic structuresand elliptical wings
The world first printedAircraft with historical Design´s
Source: 3 T RPD

Complex Metal Parts
Source: EOS GmbH

CobaltChrome MP1 superalloy for fully-
functional aircraft engine parts
Source: PEP/Turbomeca/Best in Class
Prototypes forTest Rigs
Requirement
Functional prototypes for developing helicopter gas-
turbine engine components
Capable of running in test-bed conditions, e.g. high
strengthat high temperature
Solution
EOSINT M 270 with EOS CobaltChrome MP1
superalloy
Result
Can be built fully dense in 82 hours
Can be automatically polished
Properties fulfill requirements for running on test-bed
Straightener for an helicopter gas-turbine engine.
PEP/Turbomeca/Best in Class

E-Manufacturing_May2012_UB.pptx | EOS | 15Source: Materials Solutions
Aerospace applications
Demonstration part
EOSINT M enables product optimization
For aerospacedevices
New design concepts
Aerospace part design
High complexity
Thin walled
Largesize(max Ø 248mm ~10 inches)
New materials
EOS Nickel Alloy IN718
EOS Nickel Alloy IN 625
HastalloyX
Thin walled turbine combustion chamber, produced on
EOSINT M 270, material EOS Nickel Alloy IN718

With the design freedom of EOSINT M you can
integrate all sorts of functionality into products
Source: 3T RPD, Assystem
Integralinstrumentation with curved
pathways
Cooled aerofoils
Flange design for weight saving and
load distribution
Enclosed and perforated honeycomb
structure
Weight saving internal cavities oil
ways and service channels Complex bosses

Door hinge build with DMLS
Source: Evo Maganize and EADS IW Filton, from:
http://www.evo.co.uk/features/features/261526/3d_printing_is_this_the_future.html
Challenge
Create a "light weight" nacelle hinge
Solution
Stress and load path proved design by EADS engineers
Highly complex design built as "one piece" with
integratedfunction
Built on M270 Xt
Material: Ti64
Benefits
A 60% weight saving was achieved through topology
optimization
Significant cost reduction
Optimized A320 Nacelle Hinge – DMLS and Conventional
EOS Ti64 produced on EOSINT M 270Xt at EADS IW

P3 used EOSINT M 270 to produce a bionic
bracket that is 40% lighter than the original
Source: EOS GmbH, P3
Project summary
Requirements
Reduce weight by keeping product requirements for
use in aerospaceindustry
Solution
Innovative designed bionic bracket
Manufactured on EOSINT M 270 using aluminum
material
Result
Weight reduction by 40% (23g)
Concave bionic bracket weights only 33g
(original bracket weights 56g)
Built full automatically in one piece
Integratedthreadand thus reduction of
assembly parts
Original milled and new designed bracket manufactured
on EOSINT M 270
Project partner

Fuel Injection & Swirlers
Challenge
Improve fuel efficiency of jet engines
Optimize airflow and fuel swirling
Cooling with integratedfuel channels
Solution
Laser sintered on M 270
Material: EOS CobaltChrome MP1
Benefits
Highly complex design built as "one piece"
Cost - < 50%
Weight reduction - < 40%
Increasedrobustness – no joining sections

Gas – Turbine development with EOSINT M 270
Source: Sturzkopf
Project: R. Sturzkopf, Munich
Gas Turbine TJ 42
Turbine wheels in IN 718
Maximum RPM: 100,000
Maximum EGT: 750°C
Turbine weight: 3kg
Thrust @ max. rpm: 420N
Thrust-weight-ratio: 14
(note: Typical values areabout 8 for standard
aircraft engines)
So far 5 test cycles completed, no creep, …
Application: UAV, auxiliary engine for glider
Gas turbine TJ 42 on a engine test rig
Gas turbine TJ 42
EOS NickelAlloy IN718
turbine wheel

Tel:
Fax:
eMail:
web:
+49 89 89 336 2220
+49 89 89 336 2288
Udo.behrendt@eos.info
www.eos.info
Contact
EOS®, EOSINT®, DMLS®, DirectPart®, DirectTool®, DirectPattern®, DirectCast® and Alumide® are registered trademarks of EOS
Udo Behrendt
(Business-Development-Manager Aerospace)
EOS GmbH
Electro Optical Systems
Robert-Stirling-Ring 1
D-82152 Krailling (Munich) Germany

Sustainability approach by design optimization for advanced layer manufacturing

Recommended

Recommended

More Related Content

Similar to Sustainability approach by design optimization for advanced layer manufacturing

Similar to Sustainability approach by design optimization for advanced layer manufacturing (20)

More from Alberto Garcia Romera

More from Alberto Garcia Romera (20)

Sustainability approach by design optimization for advanced layer manufacturing