2012 06-21-inauguration-labo-additive-manufacturing sirris - umberto baraldi
DESCRIPTION
Overview of the Additive Manufacturing technologies available in the Sirris Additive manufacturing division of GosseliesTRANSCRIPT
The collective centre of the Belgian technology industry
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Driving industry by technology
• Mission?
To help companies implement technological innovations
• Why?
Strengthen the competitive position over the long-term
• For whom?
The Belgian technology industry
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The collective centre
Federation for the technology industry
Collective centreof the technology industry• Nonprofit organisation• Industry owned
“Increase the competitiveness of companies of the Agoria sectors through technological innovations”
MISSION
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of the technology industry
Aerospace Automotive Construction products
Contracting & Maintenance Electrical engineeringIndustrial automation Mechatronical engineering
Information and communication technologies (ICT)Metals & materials Metal processing Mounting & cranes
Plastics & composites Security & defence
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Sirris members
2325 SME’s (<250 employees)
2450 companies
125 large companies (>250 employees)
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Mission statement in practice
Making the right technological choicesfor sustainable economical growth
Translating new technologies intangible products for a company
Taking into account the business & technology strategy of the company
value innovationthrough
technology
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What does Sirris mean to you?
From individual services to common research programs
Large partnernetwerk – Optimized projectfinancing (public&private)Intellectual property stays in company
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Domains of competence
•Materials Engineering•Production Technology•Mechatronics
•Additive Manufacturing•Software Engineering & ICT•Technology Coaching
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Local presence, near the companies
LeuvenMechatronics
Technology CoachingSirris Leuven Composites Application Lab
HasseltMaterials Engineering
Production TechnologySmart Coating Application Lab
CharleroiAdditive ManufacturingBiomedical applications
BrusselsSoftware Engineering & ICTTechnology Coaching
GhentMaterials Engineering
LiègeAdditive Manufacturing
Materials EngineeringNanomaterials and plasma
Sirris Microfabrication Application Lab
> 120 technology experts distributed over 6 sites in the 3 Regions
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Partners network
AuthoritiesAcademics
Industrials
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Facts & figures in 2011
5000 interventions per year (advice, projects, services)
whose 75% for SME’s
within 1840 different companies
2000 payed projects and services for 5.4 mio EUR
2900 free advices subsidized
23M turnover
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Group Nanopowders & Plasma
Sirris In Wallonia : 3 competence groups
Rational integration of advanced materials
in Products and processes
• Polymers• Composites / Nanocomposites• Thixo/MIM/PIM• Light metals• Microtechnology
§ Product concept and development§ Thermal Management§ Multifunctional products § Traceability§ Smart products
Additive processes &
specific materials
for tool-less manufacturing
• Rapid prototyping• Rapid tooling• Rapid manufacturing
§ Additive process & post process development § Porous and functionally graded materials § Fast « Time to Market »by direct manufacturing § Medical applications
Nanopowders for demanding applications
§ Nanopowders production by synthesis in a plasma torch§ Nanopowders characterisation
§ Nanopowders production units developments§ Ceramic and metallic nanopowders§ Handling/safety solutions for nanometric materials§nanocomposites
Group Materials Engineering
Group Additive Technologies
the collective centre of the Belgian technological industry
Additive Manufacturing – Layer Manufacturing:à Rapid Prototyping – Rapid Tooling – Rapid Manufacturing
SIRRIS – ADD department
Incubation times
1980-1990
Focus :Main focus on supporting
plastic material processor and plastic material users
Specific issues :Injection moulds cost
reductionNew polymers in productsRecycling
Actions :- Reducing mould costs by beter concept –
- Demonstration of CAD (2D/3D) Capabilities- First applications and demonstration of
mould filling simulation( moldflow / inssight)
- Closed loop control of mould filling- Reduction of mould costs by new
fabrication technology- Polymer casting, low melting point alloy
projection, …-
Recurrent requirement:- Validation of plastic parts before injection mould ready- Availability of model as soon as possible
Starting the activity
1990
Inputs :- Technology watch has put
into light new technologyfor direct part fabrication from CAD files
Stereolithography- Increasing performances of
3D CAD software and related interest in industry
Actions :
- Setting up of consortium with industrialpartners
- FN Browning – Mecasoft – Aspel
- Purchase of SLA machine- 50% cost supported by Sirris
(Crif/Wtcm)- 50% cost prepaid services to the
industrial partners
- Machine installed and running in Septembre 1990
Rapid prototyping years
1990-1996
Activity :- For industrial partners and for
sectors, realisation of demonstration parts
- Stereolithography models are keycommunication tools for the development of plastic parts. It isan unambiguous interface allowing designers, tool makers, molders, users to interact quicklyand efficiently.
- In RD projects (local and EC funded), valorisation of quick model making technology to produce cast or sprayed injection cavities
Conclusions :
- Because of requirements concerning betterpart properties, purchase on own cost of an FDM machine
- Low cost mould production techniques based on SLA models not viable. If the future of Rapid prototyping is RapidTooling then other techniques are required.Recurrent requirements:-Better part properties to provide quick functional validation-More precise processes
Rapid tooling years
1996-2002
Activity :- In 1996 purchase of- - an DMLS machine to produce
metal inserts for injection moulds- - an SLS machine to produce
functional plastic parts in polyamide
- RD projects (local and EC funded), in order to improve the applicatbility of additive technologies in the tooling sector(rapid tooling) (with Materilise)
- Demonstration activity to sensibilise industrial sectors on the potential of thesestechnologies (Dito Materialise)
Conclusions :
- Fairly big success of SLS for the production of parts applied in practice (even smallseries productions !)
- Tooling applications are quite a challenge and widespread applications of additive technologies for this applications is not possible on the short term.
- Nonetheless important potential for solution of critical cooling problems.
Recurrent requirements:-Better part properties, faster production process-Functional metal and ceramic parts
The transition years
2002-2008
Activity :- In 2001 purchase of a
revolutionnary machine allowingproduction of metal and ceramic« green » parts : Optoform
- In 2004 purchase of a 3D printing machine providing multiple foldproductivity increase for small and large metal parts : ProMetal
- RD projects (local and EC funded), in order to develop specificmaterials for aerospace and medical sectors
- Demonstration activity to sensibilise industrial sectors
Conclusions :
- Lots of problems with the equipments !- Beta machines required very important
efforts to get running satisfactorily.- Optpoform out of the market.
- Important interest in the medical and aerospace sectors (customisedbiocompatible applications of short seriescomplex parts)
Recurrent requirements:-Still better part properties, faster production process-Functional metal and ceramic parts still not fully adressed
The Rapid Manufacturing years
2009-…
Activity :- In 2009 purchase of an improved
SLS machine (own costs)- In 2009 purchase of an EBM
machine (medical applications)- In 2010 purchase of an SLM
machine for hi tech metal parts- In 2010 purchase of a 5 axis laser
cladding unit (graded materialsand aerospace applications)
- In 2009 purchase of a multimaterial 3D printer for multimaterial functional parts and medical applications
- Start of dedicated ceramic spinal implants for « real life » use withthe optoform technology
Conclusions :
- In 21 years, the additive manufacturingtechnology qualified from an anecdotic one shot process to an accepted production technique of hig-value technical parts.
- Sirris, always in relation to industrialinterests and inputs, invested a lot to set up a unique competence and capabilitiesteam in this area.
This technology field is moving forward at a constant pace, promising interesting capabilities in micro-manufacturing and mass customisation. These issues interest our sectors, and we will keep up to date.
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SIRRIS – ADD (1990 – 2012)• 15 engineers and technicians • Two locations: Liège (10 p.) and Gosselies (5 p.)
In-house additive technologies• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (2 Optoform)• 3D Printing of plaster and metal powder (Z-Corp + 2 Prometal)• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser Melting (MTT) SLM 250 HL for metal parts and inserts• EBM Arcam A2 (Titanium & CoCr)• Laser Cladding (Irepa Laser EasyCLAD)• 3D Printing of wax (Thermojet)
• Vacuum Casting of alu, bronze, zamak• 3D scanning & metrology (GOM, Metris, Wenzel)
ADD capacities & competencies
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Motor vehicles11% Aerospace
22%
Industrial/business machines
3%Consumer products/electronic
s15%
Medical/dental29%
Academic institutions
14%
Military1%
Architectural 3%
Other:2%
ADD application areas
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Laser Sintering of polymer powder
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Post-milling
3D Printing Prometal
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Laser Sintering of metal powder
• Direct Metal Laser Sintering
• Mould inserts in Bronze/Nickel alloy and steel• Direct Parts • Layers 20 µm. Accuracy 50 µm.
• EOSINT M250 Xtended
Material properties: 15 years evolution
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─ Aerospace: Functional PartsApplications
Heat Reflector
Material: Ti6Al4V ELISize: Ø 140 x 80 mmWeight: 2,5 kgBuild time: 16 hours
Rocket Engine Impeller
Material: Ti6Al4VWeight: 4,5 kgBuild time: 36 hours
Landing Gear Component
Pressure Vessel
With Cooling Channels
Electron Beam Melting - Arcam
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Applications
Ti 48Al-2Cr-2Nb
Ti 6-4Interface
Abrupt transition between Ti 6-4 and Ti 48Al-2Cr-2NbClean, well bonded fully dense microstructure.
A-Impact: Conventional Ti alloy(Ti 6-2-4-2)
B-LC fatigue: Orthorhomic Ti alloy(Ti 22-23)
C-Creep: Gamma Ti-Aluminide (Ti 48-2-2)
Denis Gravet
Functionally Graded Materials (FGM)
Functional surface:tool steel 1.2344 (finished)
Basic material:copper alloy (Ampco 940)
15-03-2009
Topology optimization
Free space definition
Efforts repartition
STL file
Smoothing or redesign based on the STL geometry
Flying Cam example (Compolight project)
Stress verification
Weight reduction with the same mechanical result
FLYING-CAMU N M A N N E D A E R I A L S Y S T E M S
Most of the components produced by AM44 parts in PA + C31 parts in PA (white, black, painted or not,…1 part in Connex500
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Controlled PorosityLightWeight solutions – 3D structures
Quality, Repeatability,
StandardsSustainability
Composites SiC+ alu, Connexdigital materials…
SIRRIS ADD – Actual & Future developments
Titanium, Inconel, aluminium
Nano particles incorporation
Medicalapplications
Functionally Graded materials and
porosity
the collective centre of the Belgian technological industry
Sirris Gosselies
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Sirris – Gosselies
Historical recap.
• Since1997 : Close collaboration started with Technofutur in the field of micro-manufacturing technologies (plastic injection and µSLA), and composite materials processing.
• Support through Feder and Interreg Funding for development of Advanced manufacturing technologies (PIM, Rapid manufacturing) competences and transfer
• 2008 : Strategic focussing of Gosselies dept in the bio-medical field
• BioManufacturing Platform (Feder project support)Arcam – Titanium & Connex 500 – multimaterial Add process
• Team grows to 5 FTE
2012 i li !
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Sirris – Gosselies
• Projet Campus Technologique :• Closer cooperation with Agoria (offices in “Maison de
l’Industrie”) • Sirris Lab in the “ Village Plasturgie & Composite”• Shared workplaces with Technofutur Industrie
(plasturgie) and Cenaero (projet Cilab)
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Sirris – Gosselies - Strategic partnerships
Partnership management :
• Continuation and reinforcement of collaboration with Technofutur(equipement sharing, common projects, training support)
• Renforcing partnership with Agoria (win-win industrial impact)
• Renforcing partnership with local key actors (innovatech, Igretec)
• Continuation of Interreg projects and actions (Pristimat, Ecolaserfact) interreg FRED)
• Develop collaboration with other CRA (Cenaero, Cetic)
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Sirris Gosselies - Value for Industry
Service development : direct industrial support
• More then 150 industrial projects/year most in the province Hainaut/Namur (65%) (direct service income of +/- 200k€)
• Main industrial sectors Manufacturing, Biomedical and Aeronautic area
• Majority of activities oriented towards product developmentsupport, rapid manufacturing technology applicability
• Applications in MIM and µmoulding ( symbiosis with ING/ SMALL/technofutur)
.
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Sirris Gosselies - Value for Industry
Service development : direct industrial support
• Increase industrial impact with 2 guidances based in Gosselies
Guidance SimADD : promote beter use of additive technologies in direct manufacturing of hi-value products by integration of numerical development chain
Guidance Biomediv : in partnership with Centexbel, support companies in innovative projects in the « medical devices » area.
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Sirris – Gosselies - Expertise development
Service development : Projets de recherche en partenariat avec l’industrie
• Plateforme de bioManufacturing Biofact W
• Projet Interreg Pristimat (champagne/ardenne – Hainaut Namur)• Domaine médical• Domaine Transport• PIM-MIM
• Prospective projet Hennuyer « ECOPOLE » (mécatronique/nanos/surface)
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─ Medical: Implants – Prosthesis - InstrumentsApplications
Material: CoCr ASTM F75Build time: 8 knees in 20 hours Material: Ti6Al4V ELI
Build time: 16 cups in 24 hours
Material: Ti6Al4V
Size: 180 x 130 x 5 mmBuild time: 12 hours
Electron Beam Melting - Arcam
[email protected] / #Sirris / Sirris_be
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