Transformational Use of
Additive Manufacturing
Jason Barkla GDip(CAD/CAM) BTech(IndDes) MMmDes Dip(CompetitiveManufacturing)
Business Development Manager
A.W.Bell Pty Ltd
Introduction
• A.W.Bell and the Need for Transformation
• A.W.Bell and Additive Manufacturing
• The Transformational Journey Begins
• Additive Manufacturing + ABE Casting Process
• Leveraging the power of Additive Manufacturing
• A.W.Bell Now, the Journey Continues
A.W.Bell and the Need for Transformation
• Founded in 1952 as pattern-maker
• Transformed into an investment casting foundry
• Added tooling, post-machining and sandcasting
• Additive Manufacturing established in 2000
• ISO9001 and ISO14001 accredited
• Automotive, medical, general castings, some defence
A.W.Bell and the Need for Transformation
• From 2005 declining demand for tooling and product
for automotive and other commodity industries
• One of several investment casting foundries in the
region
• GFC in 2007-2008 saw the business contract
• Generally uncertain future in the face of imports
• Time to embark on a transformative journey
• Established in 2000
• Over 1000 projects and many 1000s of parts
• Specialising in complex metal products and
prototypes
• Additive Manufacturing with investment casting
• Many parts in heavy-duty end-use applications
A.W.Bell and Additive Manufacturing
• Proof of concept in the end material
• Complex parts with many features and undercuts
• Enormous range of alloys ferrous and non-ferrous
– A356/A357 aerospace grade aluminium
– Super Duplex and other stainless steels
– High tensile steels
– Alloy Bronze for naval applications
– Other air-melt high-performance metals
A.W.Bell and Additive Manufacturing
A.W.Bell Rapid Parts
3D Systems Thermojets
• First 3D Systems Thermojet commisioned in 2000
• Within 2 years running 3 Thermojets
• Very successful allowing parallel testing of parts
while developing soft tooling concurrent with hard
tooling
• Also became manufacturing process in it own right
• Pros
– Slotted straight into investment casting process
– Reasonably fast at about 1.5hrs per 10mm
– Good surface finish on upward facing surfaces
• Cons
– Poor surface finish on downward or overshadowed surfaces
due to supports
– Fragile
– High maintenance machines
– Envelope size
A.W.Bell Rapid Parts
3D Systems Thermojets
A.W.Bell Rapid Parts
Stratasys Vantage S FDM
• Stratasys Vantage S purchased in 2005 a response
to growing need for complex pattern and tooling
manufacture
• Used in conjunction with zinc spray for tooling
• Used as sandcasting patterns directly or as masters
• Other uses on as need basis
• Pros
– Accurate
– Strong
– Stable
– Robust technology
– Real thermoplastic
• Cons
– Slow
– Expensive materials
A.W.Bell Rapid Parts
Stratasys Vantage S FDM
A.W.Bell Rapid Parts
3D Systems SLA 500
• 3D Systems SLA 500 commissioned at start of 2010
• Replaced ageing Thermojets
• Used mainly for investment casting patterns
• Other uses on as need basis
• Pros
– Accurate
– Strong
– Fast
– Large envelope
• Cons
– Large inventory of resin sitting in vat
– Failed builds can be very messy
A.W.Bell Rapid Parts
3D Systems SLA 500
• Stereolithography process using special algorithm
• Produces hollow resin patterns for investment casting
• Excellent surface finish, robust yet light-weight
• Patterns up to 500x500x580mm, can be joined
• Very accurate and stable, do not warp, grow or shrink
3D Systems SLA Quickcast for Investment Casting
3D Systems SLA Quickcast for Investment Casting
• Good surface finish
• Dimensionally accurate castings
• Large castings from single pattern
• Castings can be welded to create much larger parts
• Incredible choice of metals and properties
The Transformational Journey Begins
• Redefining the vision
• Lean training from top to bottom
• Building and strengthening networks and reputation
• ABE casting process
• Lifting quality standards
• Transform A.W.Bell into a supplier of complex metal
components with high mechanical properties, into the
defence and aerospace sectors.
The Transformational Journey Begins -
Redefining the Vision
• All employees were trained in lean and awarded
certificates and diplomas in competitive
manufacturing.
The Transformational Journey Begins -
Lean training
• A.W.Bell is active in regional organisations and well
engaged with governments
• Inducted into the Victorian Manufacturing Hall of
Fame and winner 2013 Medium Manufacturer of the
Year
The Transformational Journey Begins -
Networks and Reputation
• Advanced investment casting process
• High strength, high quality
The Transformational Journey Begins -
Aluminium Billet Equivalent (ABE) Casting Process
• Pursued and gained AS9100C accreditation
• Cultural shift required throughout organisation
The Transformational Journey Begins -
Lifting Quality Standards
• A.W.Bell has developed a world leading casting
process called ABE (Aluminium Billet Equivalent)
• Developed for Aerospace application
• High strength and high density parts
• Allows sophisticated geometries that cannot be
machined from billet
Additive Manufacturing + ABE Casting Process
• Additive Manufacturing supports complex shapes
• Quick turnaround of patterns, perfect for R&D
• Dimensional accuracy and stability
• Removes the need for very expensive and complex
CNC cut aluminium tooling
• Proof of concept for conservative sectors
Additive Manufacturing + ABE Casting Process
• Advanced shape with challenges for castability
• No funds available for tooling
• Additive Manufacturing + ABE used to attempt FAI
• Results in order for tooling and proper FAI
• Project has now moved to production order
Leveraging the Power of Additive Manufacturing -
Aerospace Component 1
• Complex shape requiring high mechanical properties
• Additive Manufacturing + ABE used to make samples
• Results in order for tooling and FAI components
• FAI now in progress
• Significant export work to be won
Leveraging the Power of Additive Manufacturing -
Aerospace Component 2
• Cylinder head with complex water jacket
• Additive Manufacturing used to make plastic cores for
understanding manufacturing and assembly
• AM sand cores being tested to accelerate FAI
• Potential for AM sand cores to be used in production
• Supports leadtime critical project
Leveraging the Power of Additive Manufacturing -
Engine Component
• Significant progress made in the last 4 years
• Accredited as an aerospace supplier
• Continuing drop-off in traditional product and markets
• Numerous foundries closed throughout the region
• Growing order base and interest from local and
export customers
A.W.Bell Now, the Journey Continues