am magazine 29th issue
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The AM Magazine will introduce and update the latest developments in layer manufacturing and Rapid Product Development technologies.The focus of the magzine is to serve the Design and Manufacturing professionals, Research and Development organisations andEducational Institutions who are particularly seeking to adopt layermanufacturing and rapid product development technologies.
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Publisher
Chief Editors
RAPITECH Solutions Inc. INDIA
Professor Deon de Beer
Dr. Wan Abdul Rahman
Professor Khalid Abdel Ghany
Vaal University of Technology, South Africa
Standard and Industrial Research Institute of Malaysia (SIRIM), Malaysia
Director of CAD/CAE and Rapid Prototyping and Manufacturing Lab.Central Metallurgical Research and Development Institute (CMRDI), Cairo, Egypt
ADVERTISING/OPERATIONS
Jyothish KumarRAPITECH Solutions [email protected] Mob: +91 9901033712
EDITORIAL ADVISORY BOARD
Professor P.Bartolo
Assitant Professor Bahram Asiabanpour, Ph.D
Professor Alain Bernard
Associate Professor Chua Chee Kai
Dr Gurunathan Saravana Kumar
Professor David W. Rosen
Professor Bopaya Bidanda
Associate Professor Yonghua Chen
Professor Manoj Kumar Tiwari
Professor Grier Lin
Professor David L. Bourall
Dr Allan E. W. Rennie
Associate Professor Salih Akour
Dr Rajesh Ranganathan
Dr Pulak M Pandey
Rob Snoejis,
Department of Mechanial Engineering, School of Technology and ManagementLeira, Portugal
Manufacturing Engineering Ingram School of EngineeringTexas State University- USA
IRCCyN, Ecole Centrale de Nantes, France
Nanyang Technological University, Singapore
Department of Engineering Design, Indian Institute of Technology Madras
Rapid Prototyping and Manufacturing Institute (RPMI)Georgia Institute of Technology, Atlanta USA
University of Pittsburg, USA
The University of Hong Kong, Hong Kong
Indian Institute of Technology, Kharagpur
International Leadership Institute, South Australia
University of Texas at Austin, USA
Lancaster Product Development Unit, Lancaster University
University of Jordan, Amman
Department of Mechanical Engineering, Coimbatore Institute of Technology
Indian Institute of Technology, Delhi
Layerwise, Belgium
Additive Manufacturing Society
of India (AMSI)French Rapid Prototyping Association
Portugese Rapid Prototyping Association
Standard and Industrial Research Institute of Malaysia
The AM Magazine is also endorsed by the following associations and organisations as a leading resource for information on the latestdevelopment of Rapid Product Development Technologies
3D Systems, USAVoxeljet Technology Gmbh, Gmbh
Optomec Inc. USA Nikon Metrology Arcam AB, Sweden
EOS Gmbh, GermanySchultheiss Gmbh, Germany
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EDITORIAL
Stratasys Inc, USAFARO, USA
Publisher
RAPITECH Solutions Inc., is a leading edge service provider in Rapid
Prototyping (SLA/ SLS/ FDM /3D Printing), Rapid Tooling (Vaccum
Casting), Rapid Metal Casting and Reverse Engineering.
www.rapitech.co.in
Central Metallurgical Research & Development Institute
ExOne, GmbH
EFESTO LLC, USA
Layerwise, Belgium
RAPITECH Solutions Inc., aims to disseminate the research and development work in the field of Additive Manufacturing Technologies.The Objectives are-
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To network and tie up with best the Additive Manufacturing institutions/Organisations in the world to tap best ideas and transfer best practices from around the world.
Interact and collaborate with international Additive Manufacturing institutions and organisations to pursue research projects.
The AM MagazineThe AM Magazine AM - 14/15 Vol.05 AM - 14/15 Vol.05 Issue Issue 2929
CONTENTS
Latest Updates
15 Press Release - EOS GmbH Marks Its 25th
Anniversary with a move into a new new
technology and Customer Centre at its
Headquarters in Krailling
16 Press Release - ZERO – G PRINTER - A
Historic Revolution in Space Access -– The Sky
is no longer the limit – “The Machine Shop for
Space”
17 Press Release - Reconstructing cylinder
heads for Porsche legends Upcoming event
3D Printing and Additive Manufacturing
Applications Symposium, Bangalore, INDIA
Regulars
04 Editorial
05 Special Article - The metal foundry uses ExOne 3D
Printing processess
07 Defence & Space Case study – Aerospace Company
Airbus Defence and Space Uses Additive Manufacturing for
the Production of Satellite Parts
10 Unmanned Vehicle System – Advanced Aerials removes the mystery from Unmanned Vehicle System development with an assist from Quickparts®
12 Biomedical Applications of 3D Printing – Saving a newborn with the support of 3D Printing
14 3D Printing of Sand Moulds
AM Magazine online www.ammagazine.in
http://issuu.com/rpdmag
3
AMMagazine Nov 2014
Editorial
Pumps being the basic equipment for every sphere of the national economy Pumps are the vital elements in an enormous range of fluid handling applications & range from small household pumps to immense units utilized in the water, chemical and energy industries. Pump performance requirements and duties vary considerably in terms of material of construction, wide range of temperature, pressure, viscosity, density etc.
For many years pump industry have been using traditional manufacturing methods for fulfilling the demands of market and in th is large demand from various sectors it is not easy to cater all the industry fastly and with consistent improving quality. In such a high demanding and competitive environment it is required to move to new advanced fast manufacturing methods and ‘3D Printing is one of them’.
3D printing is an ideal tool for volute shapes like impeller casings etc. For the pump industry, ExOne offers digital part materialization for patternless, digital production of sand molds and cores. Regardless of size or complexity, ExOne provides the fastest and most cost -effective way to produce cores for prototyping, replacements parts, and low volume production using foundry materials. Various other additional benefits of 3D printing technology are impeller Core Accuracy up to +/- 0.3mm, Superior Blade Registration, Better Hydraulic Performance, Ease of Dynamic Balance etc.
All these features of this 3D printing technology make it a versatile tool for Pump Industry. This will enhance the dependability of OEM’s on suppliers for better quality and fast deliveries. In coming future this technology is going to lead the whole pumping industry and will prov e itself a milestone.
- GlobalAxis(PartnertoExOneGmbH)
NewDelhi,India
3D Sand Printing – A Milestone for the Pump Industry
4
SPECIAL ARTICLE
“Schüle foundry partners with ExOne to deliver fast and flexible solutions”
“The main advantage is definitely the time savings,” says Ronald Spranger, Head of Sales and Project at
Schüle GmbH.
The German based foundry company cooperates with three-
dimensional (“3D”) printing specialist ExOne to supply automotive
sector customers as well as other business areas with success.
Automotive manufacturers are faced with the challenge to produce
parts more efficiently and at a lower cost. Meanwhile, the demand
for more complex parts in increasing and development cycles are
decreasing. Automotive manufacturers must keep an eye on every
production step to keep up with this ever-changing industry. The
advantages of the 3D printing process are apparent to automotive
manufacturers as they assess these changes.
ExOne, based in Gersthofen, specializes in the additive 3D printing
technique, which applies consecutive thin layers of sand to a
working platform. The sand is bonded by inorganic or chemical
binders and results in casting molds made without time-consuming
and cost-intensive tool production directly from a CAD-file. This
method is especially suitable for two application fields: to produce
new products via rapid prototyping or low volume production and to
avoid storage whenever possible. Therefore the ExOne™
technology provides an excellent complement to the portfolio of
Schüle.
The aluminum sand casting foundry specializes in complex, core-
intensive parts. Amongst them are ambitious parts, such as
gearboxes or engine blocks, for more than 200 customers in
different locations.
About half of the parts being produced by the Schüle foundry are
prototypes. The foundry employs 80 people and uses 500 tons of
aluminum per year. As a mid-sized company, Schüle can react
flexibly to the needs of the customers. Their company offers,
depending on the customer requirements, a fully automatic core
package molding line down to a furan hand molding line with optimal
results. They also provide pre- and post-processing steps such as
modeling and casting construction, in addition to comprehensive
quality testing.
“Our customers have different requirements," says Schüle. “When it
comes to serial production, the delivery reliability is most important.
What counts in this field, are feasibility and short lead time solutions.
Prototypes should still have all the relevant characteristics of a
production part.”
The metal foundry uses the 3D Printing process
AMMagazine Nov 20145
3D printing suitable for rapid prototyping and small scaleproduction
Designers are completely free to develop an experimental design
without any concerns related to casting production. In fact, the more
complex design of the core, the better it is to 3D print the part. For
example, a highly complex casting such as a twelve bore cylinder
block, where the water jack core often needs to be produced in
various sections, can be 3D printed as one complete part.
The cooperation with ExOne started just three years ago when the
company was looking for a foundry to cast samples with their sand
cores. Since then, Schüle orders more and more cores from ExOne,
30 to 50 pieces per month currently. Most of them are special molds
for complicated and core-intensive casting parts like engine blocks,
gearboxes, compressor housings and heat exchangers. They are
mainly used in pilot tests in the automotive branch and during the
initial prototype assemblies in machine and industrial plant
installations. In this case, Schüle uses ExOne’s so called
“Production Service Center“(PSC). The PSC is part of their core
business in addition to the manufacturing of 3D sand printers.
ExOne has offered the production of parts since the year 2000 and
maintains several PSCs worldwide. ExOne is growing their PSCs to
reduce delivery time and be closer to the customers.
Schüle can react quick and flexible to customer
inquiries
The integration of 3D printing into Schüle’s established casting
processes was simple and without problems. “The cores and/or
mold packages which are delivered by ExOne are very similar to
conventionally produced parts” said Mr Spranger, “This means: The
workflow is comparable and extensive changes were not
necessary.” It is also valid for the materials used.
Rainer Höchsmann is General Manager of ExOne Europa andChief Development Officer of ExOne
The unprinted sand, which contains an activator, can be recycled for
further use. In general, Mr.Schüle has come to the conclusion that,
“The cooperation is very good, thanks to the knowledge of ExOne,
who are world leaders in their field.”
Rainer Höchsmann has developed his expertise since 1999, when
he co-founded the company Generis, the predecessor of ExOne. He
is now the General Manager of ExOne Europe and the Chief
Development Officer. Generis developed world’s first 3D printer for
sand molds that has been in use since 2001 in the automotive
industry. To date, ExOne has installed more than 100 printers and
has become the market leader of 3D sand printing. It offers a large
variety of materials which meet the requirements of various casting
materials, such as aluminum, magnesium, iron and steel. The
company developed furan, phenolic and silicate binder systems
which can be used in conjunction with silica or ceramic sand.
In this year’s exhibition in Hannover, the Europe premiere of the M-
FLEX 3D metal printer took place. In addition to the production of
the 3D printers, ExOne also offers print services in its product
portfolio.
Schüle has considered buying its own printer. 3D printing is mainly
utilized for prototyping, but the technique has been growing in use
for serial production too. One attractive application is the use of
conventional methods for the production of the relatively simple
mold halves and 3D printing of complex cores that would be
expensive to produce by conventional techniques. “We have
already gained positive experiences,” confirms Schüle. “And the
printing of molds and parts will establish itself more and more and
become an inherent part of the foundry business.” One thing that
will not change: The know-how and experience of the casting
experts will still be required even though the design of the
molds/cores will play a key role in future production.
AMMagazine Nov 2014
SPECIAL ARTICLE
6
CUSTOMER CASE STUDY DEFENCE & SPACE
AMMagazine Nov 2014
Telecommunicationsatellite:thethreeadditivemanufacturedbracketseasilywithstandatemperature
rangeof330°Candmeetthehighdemandofpermanentspacemissions(Source:AirbusDefenceandSpace).
Aerospace Company Airbus Defence and
Space Uses Additive Manufacturing for the
Production of Satellite Parts
The literal translation of the word satellite (companion) does
not come close to explaining how complex these technical
devices are and what they do for our daily lives. Their tasks
range from weather forecast to message transport and
navigation information. The Airbus Defence and Space
division is one of the world‘s leading suppliers of satellite and
space transport technology. Its Spanish subsidiary is part of
the satellite business and the largest aerospace company in
its home market.
The portfolio ranges from satellite systems to components for the International Space Station ISS. A competence centre for composite materials is also located at the headquarters in Madrid – because innovative materials and production methods play an important role in the a erospace industry. The requirements for the devices are particularly high because of the tremendous temperature differences and external forces involved. To achieve the best results in component manufacturing, Airbus Defence and Space relies, among other t hings, on Additive Manufacturing technology by the German company EOS.
Facts
Challenge
Cost-effective production of optimized retaining
brackets for the connection of components in
telecommunication satellites.
Solution
Faster production of thermally highly stressed
components by using Additive Manufacturing
technology for metal parts offered by EOS.
Results
• Robust: temperature resist- ance meets
highdemand of permanent space
missions
• Economic: production costs reduced by
more than 20%
• Light: weight reduction of the retaining
brackets is about 300 g
• Paving the way: lighthouse project as
the pioneering role for other
applications in space
Advanced Manufacturing Process by
EOS Optimizes Satellite Technology
Short profile
Airbus Defence and Space is a division of Airbus
Group formed by combining the business activities
of Cassidian, Astrium and Airbus Military. The new
division is Europe’s number one defence and
space enterprise, the second largest space
business worldwide.
Address
Airbus Defence and Space Avda. Aragón
7
Challenge
The current generation of satel- lites includes specific
brackets that serve as a link between the body of the satellite
and the reflectors and feeder facilities mounted at its upper
end. The engineers at Airbus Defence and Space faced two
key challenges with regards to the construction of these
retaining brackets: on the one hand, the brackets must
fix the securely to the body. On the other hand, however, the
task of the brackets is to mitigate the extreme temperature
fluctuations in space. The brackets are very important as a
layer of insulation: the temperature ranges from –180 to +150
°C, so the stress on the material is extremely high.
Very few materials are able to meet these requirements. As
so often in the aviation and aero- space industry, titanium
turned out to be the appropriate cho ice. In addition to its well -
known advantages with regards to weight and thermal
conductivity, it offers an acceptable density. After all, every
kilogram to be carried into space costs many thousand
dollars; the exact amount depends on factors such as the
carrier system and the orbit to be reached. However, six-
figure sums and higher are not uncommon.
The brackets manufactured in the conventional way and
especially their connection with the carbon components of the
satellite –
a function subject to high thermal stress – did not meet the
expecta- tions of Airbus Defence and Space. In addition,
subsequent installati- on on the satellite component was very
time-consuming so
costs needed to be reduced. The engineers therefore began
looking for alternatives. Special attention was paid to the fact
that the design of future components could be optimized
accordingly.
Therobusttitaniumbracketsweremanufacturedusing
anEOSINTM280.Theyeasilyandpermanentlywithstandthehightemperaturesandexternalforcesin
space(source:AirbusDefenceandSpace).
Solution
The choice fell to the Additive Manufacturing technology for
metal parts offered by EOS. This meant that titanium was
still usa- ble as a tried and tested material. It also allowed
the design of the components to be adapted easily. As
Otilia Castro Matías, who is responsible for the area of
antennae at Airbus Defence and Space, explains: ”The
solution now found by us has two advanta- ges. For once
we were able to optimize production itself. In addition, we
have improved the design, so the entire workpiece can be
manufactured in a single step. Hewn from a single block so
to speak, even though technically speaking it is the opposite
of this traditional technique.“
After the design was established, the well established
process followed: the engineers loaded the 3D construction
plans from the CAD software into the pro- duction machine
– an EOSINT M 280 – and started the manu- facturing
process: a laser beam precisely melts and hardens the
deposited metal powder layer by layer, so when the
precision- made workpiece is complete, no excess material
remains except for re-useable raw material.
Results
The new devices meet all expect - ations of the experts
involved. Most important of all is the improved temperature
resistance of the entire structure, which now can easily and
permanently withstand a margin of 330 °C under a force of
20 kN. In addition to this, the Spanish aerospace experts
were able to reduce production time of the brackets during
assembly of feed and sub reflector units by five days.
Production time of the three brackets required for each
satellite is now less than a month.
”These improvements signifi- cantly reduce thermally
induced failure during the qualification test campaign. The
cost of space activities is relatively high, so it is even more
important to protect any hardware from possible failures,“
adds Castro Matías. ”The Additive Manufacturing method
brought measurable benefits to critical aspects of the
project, without requiring cuts to be made elsewhere. No
compromises - this is something engineers like to hear, but
don’t get to hear very often.“ In addition to the technical
advantages, targeted cost reductions were achieved:
savings in production alone amount to more than 20%.
What is more, the engineers success - fully put the part on a
diet: the weight advantage is about 300 g, which means
nearly one kilo per satellite.
Incidentally, European Space Agency (ESA) supported this
program. Its successful completion it allows further use of
this efficient production technology in the aerospace field.
AMMagazine Nov 2014
CUSTOMER CASE STUDY DEFENCE & SPACE
8
”The use of titanium as the material for the retaining brackets of our satellites has proven highly effective. The main
weakness, however, was the connection of the brackets with the carbon panel of feed and reflector assembly because
here the thermal stress was negative factor. Thanks to Additive Manu- facturing, we were able to redesign the bracket
and eliminate this vulnerability. There were other benefits, too, such as shorter, more cost-effective and more lightweight
production.“
- Otilia Castro Matías, COC Antennae at Airbus Defence and Space
CUSTOMER CASE STUDY DEFENCE & SPACE
AMMagazine Nov 20149
12
In an industry typically shut off by red “Top Secret” stamps and
closed-door meetings, Advanced Aerials is doing things a little
differently. They’ve put a welcome mat on their door in an effort to
not only supply Unmanned Vehicle Systems (UVS) but to
perfect their designs and innovate through open-source
collaboration. Think of Advanced Aerials’ work as the launching
point for creating affordable UVS designs that fulfill the exact
requirements of users from military intelligence units to first
responders
“There’s a lot of forcing of designs that aren’t fully baked. We don’t
want to force technology because it inevitably falls short,” says
Advanced Aerials founder Bert Wagner. “We’re crowd sourcing UVS
design by sending prototypes to end users so they can collaborate
and build something that fits a need perfectly. We want to solve
problems, not sell products.”
Wagner, a former professional photographer, taught himself CAD
and vehicle design in order to make drones for aerial photos. Over
the years, that side project morphed into Advanced Aerials. For a
homegrown business like this, it’s sometimes difficult to fulfill
manufacturing requirements: tooling and injection molding are far too expensive and owning a 3D printer would be cost prohibitive at
this point. At the same time, the advantages of 3D printing fit
perfectly with Wagner’s needs. “I had to focus on design intent and
less on how to provide enough clearance for a given tool. I didn’t
want to worry about a machinist.”
What Wagner needed was his own 3 D printing manufacturing unit, a
way to produce parts quickly and iterate design without equipment
and labor overhead. That’s where Quickparts—the on-demand
printing service by 3D Systems—came in. Ten years later, Wagner
still uses Quickparts, which produces Advanced Aerials’ ready-to-
use vehicle components using 3D Systems’ Selective Laser Sintering (SLS®) technology.
“We use Quickparts for anywhere between $3,000 and $10,000
worth of parts per year,” says Wagner. “The beauty is that if I’m in a
rush, I can get parts in a couple of days. You can’t beat that.”
Bear in mind, these are not concept model parts or casting patterns,
as is sometimes the case with robotics developers. Instead, they are
characteristically tough SLS parts, made in Duraform® and
Duraform Flex materials, that Advanced Aerials installs onto their
UVSs for direct field use. “Our parts have held up under crashes.
We’re real happy with that,” says Wagner.
SLSpartsfortheMSEV
Above,BertWagnerassemblestheMSEVBelow,MSEVparts
madewithDuraform®EXBlack
Take the Miniature Surveillance Expendable Vehicle (MSEV), for
instance, a UAV made largely of SLS components from Quickparts
and being developed for one of Advanced Aerials’ DoD customers.
MSEV, a deployable, four -rotor vehicle, will eventually aid in
situational awareness. Other Advanced Aerials vehicles will support
short-range, short- duration counter IED operations. The company is
also supporting software and vehicles that would allow users
to operate UVSs in environments where external guidance signals,
e.g., GPS or RF, are weak, unavailable or actively jammed. These
could drastically improve the safety of soldiers and first responders
as they inspect buildings or other dangerous enclosed areas. And
that’s a huge goal for Advanced Aerials —improving safety and
saving lives.
As Wagner puts it, “We want our vehicles to go from A to B in some
pretty brutal environments.” But there’s so much more to it; they’re
democratizing UVS development, and using the speed and
affordability of Quickparts SLS manufacturing to do it.
Advanced Aerials removes the mystery
from Unmanned Vehicle System
development with an assist from
UNMANNED VEHICLE SYSTEM
AMMagazine Nov 201410
UVSs don’t have to cost so much or be so shrouded in
red tape to be effective, and Advanced Aerials is
proving it. Down the road, they even see educational
opportunities brought about by their open-source
model, giving students the opportunity to discover,
explore and contribute to the emerging science of
robotics. All in all, that’s how you build a better UVS:
accept ideas from all around, appeal to the next
generation of engineers, and find the perfect partner
to help you make it.
UNMANNED VEHICLE SYSTEM
AMMagazine Nov 201411
12
BIOMEDICAL APPLICATIONS OF 3D PRINTING
AMMagazine Nov 2014
Saving a newborn with the support of 3D Printing
Finding out that you are going to have a baby may be one of the happiest days of your life. Sadly for one family in Ne
York, the joy quickly turned to fear and uncertainty when they found out their baby would be born with a complex form
of congenital heart disease. Having already diagnosed the condition in the womb, the doctors at NewYork-
Presbyterian/Morgan Stanley Children’s Hospital had time to plan how they would save the baby’s life before it even
began with the support of 3D printing and Materialise’s Mimics Innovation Suite of software.
In July, a baby boy was born with a complex form of
congenital heart disease in which both the aorta and
pulmonary arteries arise from the right ventricle. Also
present was a large hole in the heart called a ventricular
septal defect (VSD). On the first day of his life, an extremely
low dose chest CT scan was acquired to better understand
the complex 3D relationships of the heart and defects. From
the images alone it was difficult for the doctors to formulate
the optimal surgical plan, especially considerin g that the
baby’s heart was no bigger than a walnut! They turned to
the 3D printing experts at Materialise for a solution.
Starting with the baby’s image data, Todd Pietila,
Cardiovascular Business Development Manager at
Materialise, created a 3D model of his heart using Mimics
Innovation Suite of software. The team at NewYork-
Presbyterian/Morgan Stanley Children’s Hospital worked
closely with Mr. Pietila to achieve an accurate reconstruction
of the heart, which would allow the surgical team to best
visualize the complex defect. The result was a 3D
representation of the heart with the small details of the
congenital defects captured accurately.
The file was then 3D printed at the medical production facil ity
at Materialise’s U.S. headquarters in Plymouth, Michigan.
Only 2 days after receiving the data, a replica of the baby’s
heart was delivered to the hospital!
Supporting an Unprecedented Procedure
The Power of Holding the Tiny 3D -Printed Heart The complex 3D relationships of the newborn’s defects were
not apparent from the ultrasound and scan data
alone. Fortunately, with the 3D-printed model in hand, the
team of clinicians at NewYork -Presbyterian/Morgan Stanley
Children’s Hospital found an ideal solution for repairing all of
the defects during one procedure, instead of three or four
surgeries.
12
The Standard in ‘Engineering on Anatomy TM’
The Mimics Innovation Suite turns 3D image data into high -quality digital models in an accurate and efficient way.
Starting from optical scan, CT or MRI data, the Mimics Innovation Suite offers the most advanced image segmentation,
the broadest anatomical measurement options, powerf ul CAD tools for Engineering on Anatomy and 3D Printing, and
accurate model preparation for FEA and CFD.
“The baby’s heart had holes, which are not uncommon with CHD, but the heart chambers were also in an unusual
formation, rather like a maze,” said Dr. Emile Bacha, a congenital heart surgeon and Director of Congenital and
Pediatric Cardiac Surgery at NewYor k-Presbyterian/Morgan Stanley Children’s Hospital. “In the past we had to stop
the heart and look inside to decide what to do. With this technique [using a 3D printed model], it was like we had a
road map to guide us.”
Dr. Emile Bacha performed the surgery when the week-old baby weighed just over 7 lbs. His single procedure approach
allowed the baby to avoid the typical series of palliative operations which can be life threatening. The clinical outcome was
ideal and the baby is on his way to a healthy life.
The 3D printed heart model also allowed the surgeons’ to explain the baby’s condition and their plan to the worried parents.
By seeing the model and understanding what needed to be done, the parents became as confident as the surgi cal team.
The baby’s father commented, "In discussing the necessary surgery with the doctors it was unclear how it would be
performed and if it would be accomplished with one or two surgeries. We were told that they are working on getting
a 3D-printed model of our son’s heart, which the team hoped would clarify the surgical plan. Upon receiving the
model, everything changed. After studying the model, the surgeon got a clearer picture of what needed to be done
and was very optimistic that he could do the repair in one surgery. Our baby was saved from subsequent surgeries
and interventions and all the side effects and developmental delays that come with it. This is truly an amazing
advancement in surgical planning and outcome. We are so thankful!"
The Future Looks Bright
The 3D printed HeartPrint® model proved to be so valuable that the clinicians at NewYork -Presbyterian/Morgan Stanley
Children’s Hospital are already working with Materialise on additional cases. Dr. Bacha added, “After the success of this
surgery, it’s hard to imagine entering an o perating room for another complex case without the aid of a 3D printed
model. It’s definitely going to be standard of care in the future and we’re happy to be leading the way.”
12
BIOMEDICAL APPLICATIONS OF 3D PRINTING
AMMagazine Nov 201413
12
AMMagazine Nov 2014
3D PRINTING OF SAND MOULDS
CAD-file of the wheel carrier Sand casting form of the wheel carrier Race Tech in action Mounted wheel carrier
Sandcasting: fast, patternless, close-to production
voxeljet produces moulds for casting from dataset. Through implementing the Generis Sand Process the user benefits from
crucial time and cost savings. Based on 3D CAD data the moulds are made fully automatically without tools using the layer
building method in the required mould material. The laborious and costly route to the otherwise necessary mould set -up is
dispensed with. Our ability to produce moulds with dimensions of 4 x 2 x 1 meters is unique worldwide.
SandMoulds Castings
Totalsize(mm) 697x523x353 Totalsize(mm) 520x205x390
Weight(kg) 1.2 Weight(kg) 3.4
Individualparts 1 Material AIuminium
Material Sand Leadtime(weeks) 3
Layerthickness
(mm)
0.3
Leadtime(days) 5
Buildtime(hours) 3.5
Project description:
The car must be faster, and also lighter. Also in the formula student projects is the focus on the weight optimization of the new racing cars. In this case, a magnesium and an aluminum wheel carrier were compared.
• Purpose: Prototyping
• Challenge: Production of complex wheel carrier in a few weeks
• Solution: Production of 2 sand casting molds for the aluminium and magnesium castings
14
PRESS RELEASE
Dr.HansJ.Langer,founderandCEOEOS
Customers and long-term companions over the
last 25 years congratulate the company on its
anniversary:
• Christoph Weiss, Managing Partner of the
BEGO Group: "We have enjoyed a good and
close partnership with EOS since 2008. Their
systems represent the current benchmark in
selective laser-melting system engineering in
the dental market and have facilitated our great
success over three continents – Europe, Asia
and America. contact that we have to the
developers in Finland.
EOS GmbH Marks Its 25th Anniversary with a move into a new new technology and Customer Centre at its Headquarters in
Krailling
EOS Additive manufacturing (AM) now allows industrial applications in series production
Krailling, 17 July 2014 – EOS, the technological and market leaders
in design-driven, integrated e-manufacturing solutions in the field of
Additive manufacturing (AM), has now moved into its new Technology
and Customer Centre in the Krailling Innovation Mile (KIM). Dr. Hans
J. Langer, founder and CEO of EOS comments: "This new building
represents a further milestone for EOS and is an expression of our
company's growth and success story over the last twenty-five years.
We operate in a market that is high ly dynamic and which offers a huge
potential. In the past we almost exclusively served the area of Rapid
Prototyping, whereas now, Additive Manufacturing enables industrial
applications in series production." And he adds: "This new building
gives us more space in which to grow, allowing EOS to continually
adapt to new market conditions and customer segments. Moreover,
the new customer centre gives us the spatial flexibility we need to
allow us to jointly develop current and future application solutions in
Additive Manufacturing together with our customers." A few facts about the new building
With the construction of this new building, EOS underlines its loyalty to its location in the west of Munich. Christian
Kirner, the company's COO, stresses: "With a floor space of 17,000m², the building is able to accommodate an
additional 300 employees, while its design follows specific architectural, spatial and workplace concepts. The
architectural concept renders the three key principles of the company's business strategy – innovation, quality and
sustainability – both visible and tangible. The facility operates on the basis of an integral, sustainable energy
concept." He continues: "In line with our corporate objectives, right from the start the emphasis was placed on the
building's functional and ecological efficiency. Both its construction and operation were conceived with all due
consideration for the efficient use of resources and energy-efficient building. In this way, the EOS building concept
already complies with the requirements of tomorrow –
apt reflection of the nature of the technology offered
NewEOSTechnologyandCustomerCentreinKrailling
• Thanks to the sophisticated EOS technology and our BEGO processes and alloys, we are able to restore the
smiles to the faces of patients worldwide – and it is this that drives us on every single day."
• Bart Van Der Schueren, Executive Vice President Materialise: “We want to congratulate EOS with their
25th anniversary. We have been successfully collaborating with EOS over their entire history, both as a
software partner and as a user of their technology. Looking back over these 25 years it is without saying
that EOS has had a huge impact on the industry. Thanks to the effort of EOS, production is changing in a
fundamental way and is giving unseen new opportunities for new produc ts and businesses.”
• Terry Wohlers, Wohlers Associates: “ EOS has played an important role in the history of Additive
Manufacturing and industrial 3D printing worldwide. Without the company, the landscape of the industry
would be much different today. We expect laser sintering to serve a wide spectrum of organizations in the
future, especially as they uncover the vast potential of the technology.”
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AMMagazine Nov 201415
The Zero-G Printer is the first 3D printer designed to
operate in zero gravity. Launched into orbit on September
21, 2014, the printer was built under a joint partnership
between NASA MSFC and Made In Space. Contracted as
the “3D Printing in Zero-G Experiment,” this first version
of the Zero-G printer will usher in the era of off-world
manufacturing.
This initial version of the Zero-G Printer will serve as a
test bed for understanding the long-term effects of
microgravity on 3D printing, and how it can enable the
future of space exploration. It is a culmination of contracts
and development dating back to 2010 including
microgravity tests with NASA’s Flight Opportunities
Program, R&D contracts under NASA’s SBIR Programs,
and development contracts with NASA MSFC.
This “machine shop for space” will mark the first time that
a multi-purpose manufacturing device will be utilized off -
world to create parts, tools and emergency solutions.
Developed by Made In Space, Inc., under a contract with
NASA Marshall Space Flight Center (MSFC), the 3D
printer is part of a technology demonstration intended to
show that on-site, on-demand manufacturing is a viable
alternative to launching items from Earth. “Everything
that has ever been built for space has been built on the
ground. Tremendous amounts of money and time have
been spent to place even the simplest of items in space to
aid exploration and development,” said Aaron Kemmer,
Chief Executive Officer of Made In Space. “This new
capability will fundamentally change how the supply and
development of space missions is looked at.”
Following delivery to ISS, the 3D printer is scheduled to
be installed in the Microgravity Science Glovebox (MSG)
to conduct its series of prints. The printer will create a
series of test coupons, parts, tools, use case examples
and even STEM project designs by students as part of the
3D Printing in Zero-G Experiment. This experiment,
intended to demonstrate additive manufacturing
capabilities in space, was developed through a
partnership between Made In Space and NASA MSFC.
Made In Space is working with busin ess partners to
formulate additional use case examples to demonstrate
printer capabilities.
www.madeinspace.us
ZERO – G PRINTER - A Historic Revolution in Space Access -– The Sky is no longer the
limit – “The Machine Shop for Space”
Zero-GPrinter
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Reconstructing cylinder heads for Porsche legends
Anyone who owns a legendary Porsche 550 Spider, 904 or
356 Carrera can count himself lucky. These cars have
experienced an enormous increase in value over the last
few years. Unfortunately special parts like cylinder heads
are no longer available. In the event of damage, the only
remedy is through customized parts reconstruction or
reverse engineering, and 3-D printing turned out to be the
cheapest way.
Reconstructing complex components is a challenge for e very
design engineer, because drawings are not available in most
cases and they are not provided by the OEM-manufacturers. In
this particular case, the reconstruction of a Carrera cylinder
head made of aluminum started with measuring and scanning
of the defective head.
Valve guides, seat rings, camshaft bearing, intake and exhaust
ducts, cylinder head screws etc. had to be set up as 3D base
bodies in a meticulous detailed process. The next step was the
transfer to superordinate functional models and the adding of
design features from casting technology like site measuring,
bevels and fillets.
Affordable sand cores from the 3D printer
After the geometric reconstruction made by the company CAD
Support from Mössingen, Germany, the production of the sand
cores was the next item on the agenda. The project
implementation with conventional cores based on core-making
tools was impossible for cost reasons. The only solution was
creating the cores in a 3D printer.
The order for printing the entire core package with eleven cores
in total went to the voxeljet service center in Friedberg which
has many years of experience in project of this kind. Thanks to
the excellent printing quality of the voxeljet printer, it was also
possible to outline the thin-walled cooling rib measuring 2 mm
without additional supporting structure in the inner and outer
cores.
The molding was made by the foundry Rauleder & Rudolf
based in Schwäbisch Gmünd, which specializes in constructing
unique components. The hot isostatic pressing (HIP) treatment
led to a tremendous improvement of the mechanical properties,
as well as a reduction of pores.
The final T6 heat treatment provided the ultimate strength of the
cylinder head. The finishing of the components was made on
the basis of the 3D CAD files in a 5-axis machining center. After
completion, the aluminum cylinder head was ready for
assembly.
CylinderHeads
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Advanced Aerospace Applications:
Production of fully functional, highly
complex parts directly from electronic data.
e-Manufacturing™ means
the fast, flexible and cost-
effective production directly
from electronic data for
product development and
manufacturing. Laser sinte-
ring is the key technology
for e-Manufacturing. With
systems from EOS, the
worldwide leading manu-
facturer of laser sintering
systems, you can achieve
weight and material savings,
turn your most complex
design ideas into reality
and enable functional
integration. Directly by
solidifying metal or plastic
powders.
With e-Manufacturing you
can secure your competitive
advantage in a business
environment that is facing
ever increasing and chal -
lenging targets around
emission reduction and
conservation of natural
resources.
www.eos.info
EOS Additive Manufacturing:
Fuel Injector & Swirler,
Material: CobaltChrome MP1
(Source: Morris Technologies)
EOS e- Manufacturing Solutions