2011 11-15 themadag am voor metaal en keramiek - ebm and ceramic am - carsten engel - sirris

le centre collectif de l’industrie technologique belge

Department of Additive Manufacturing (ADD)

Electron Beam MeltingOptoform


Direct Manufacturing: Electron Beam Melting

Charleroi

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• Near net shape solution requiring post milling (HSM)• A high energy beam of electrons is generated in the Electron

Beam Gun• The control system allows an extremely fast beam translation

with no moving parts• Vacuum melt process eliminates impurities and yields high

strength properties of the material• High build temperature provides good form stability and low

residual stress in the parts• Low operating costs

Electron Beam Melting - Arcam

04/02/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |

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Electron Beam Melting – Arcam


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Next generation pre-operative manufactured implants:

• Custom implant manufacture :

• CT-Scan• CAD File of the patient is produced• Engineer + Surgeon 3D implant approved• FEM analysis (when needed)• Custom manufacturing (low cost)• Surgery• Follow up

© sirris 2010 Charleroi | www.sirris.be | [email protected] |

Medical applications

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Automotive applications


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Automotive applications


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Other applications


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Released Materials:• Ti6Al4V• Ti6Al4V ELI• Ti-Al• CoCr, ASTM F75• Copper (tested)• Others on demand

Excellent properties for:• Strength• Elasticity• Fatigue• Chemical composition• Microstructure

Lattice & Cellular Structures:• Lattice and cellular structures allow combination of the excellent

properties of solid metal with the extraordinary properties of a cellular or lattice structure

Applications include:• Structures for bone in-growth in medical implants• Lightweight designs component• Filters• Other applications where a cellular structure is an advantage



Application fields:• Medical:

• Implants• Prosthesis• Instruments

• Aerospace:• Functional parts

• Automotive:• Functional parts

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Mechanical & structural properties:



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Indirect Manufacturing: Optoform process

Liège

Optoform

22/11/2011© Sirris | www.sirris.be | [email protected] | 17

Generalities:

• Commercially not available any more• Flexible technology (hybrid SLA):

•Development of very different materials• Possible materials:

•Soft, hard, metallic and ceramic• ISO 13485 certified @ Sirris

Fabrication steps:

• Preparation and fabrication of the bulk material• CAO / CAD File processing• Automated process manufacturing• Cleaning and recycling of the non-used material• Debinding & Sintering process

[Sirris ADD]

Optoform


Features:

• Layer thickness: 20 - 200μm• Argon laser 400-800mWatt at 351nm and 365nm• Max. Size: 250-350-500mm• Several building plates with variable sizes well suited to small parts and expensive materials• Supports needed

Material Requirements:

• Composition :Resin+ Fillers (20% to 70% Vol.) + Photo-initiator + Wetting agent + rheological/ thixotropic Agent

• Consistency : Firmness of a toothpaste (Bingham’s model)• Good Lifetime : the filler should not deposit sediment• No UV absorption by the filler ↔ Layer thickness• Support removal & cleaning: not always easy (isopropanol, water,…)

Optoform


[Sirris ADD] [Sirris ADD]

Materials:

• Alumina• Alumina with 8% of nano Zirconia• Hydroxyapatite• α & β Tri-calciumphosphate• Zirconia• SiC• Stainless steel• Titanium

• Ceramics & metals need a post-process of debinding & sintering

Optoform


[Sirris ADD]

[Sirris ADD][Sirris ADD]

[Sirris ADD]

[Sirris ADD]

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Optoform & medical field: CASE STUDIES

Ongoing statuts:

• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)• Diameter ~= 10mm• Macro-porosity ~= 0,5mm• Tests various scaffold structures for bone integration• In vivo testing (rabbits & rats)• Field: Spinal implants & Maxillofacial Surgery• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)

[Sirris ADD][Sirris ADD][Sirris ADD][Sirris ADD]

22/11/2011© Sirris | www.sirris.be | [email protected] |

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0,5mm



[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

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Summary:

• More than a new RP technology• Development station for new RP materials• Broad range of ceramic and metallic materials• By using a good formulation strategy of the paste, it is possible to respect the chemical composition of the material• Broad range of applications• High speed• Suited to small parts and expensive materials as well as massive tools and cheap materials

• Commercially not available any more

Optoform


2011 11-15 themadag am voor metaal en keramiek - ebm and ceramic am - carsten engel - sirris

Technology