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LPW TechnologyIntelligence in powders

Rybinsk Forum

April [email protected]

+49 1525 540 96 77

mailto:[email protected]

lpwtechnology.comlpwtechnology.com

To view AM from the perspective of the powder

LPW PowderRange powers >50% global metal AM install base90% of sales outside the UK

LPW powders advancing AM in over 74 countries

PowderRange off-the-shelf rapid delivery solutions– Over 50 AM metal powders available for dispatch in 24 hours

PowderLife production solutions – Custom powders, pioneering software, hardware and process solutions

for AM production

Quality certification AS9100, AS9120 for aerospace, ISO9001 & ISO 13485 for medical

Servicing safety-critical sectors such as Aerospace, Defence, Medical, Automotive, Energy, Tooling

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Worldwide network

UK powder manufacturing plant

USA powder processing facility

Local stockholding

EU commercial offices

Global team of professional, trained resellers offering worldwide support LPW Technology LPW Joint-VenturesLPW reseller

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Worldwide network

State of the art powder manufacture– 7 acre site in Widnes, Liverpool, UK

– 90,000 sqft² (9,700 M²)

– Full material traceability

– Digital Integration

– Strict contamination control

LPW Technology LPW Joint-VenturesLPW reseller

High-tech, low contamination manufacturing:– Climate controlled - regulating humidity

– Air showers / airlocks / positive air pressure

– Sealed powder containment

– Allocated cells for individual alloys

– Dedicated operators for specific processes

– State-of-the-art laboratory

– Testing certified to ISO 17025 and NADCAP

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Worldwide network

12,000 sq. ft. (1,115 m2) site near Pittsburgh, Pennsylvania, USA – Metal powder processing facilities

– Sieving and blending lines

– Analytical and reconditioning capabilities

– Orders shipped within 24 hours of receipt of order

LPW Technology LPW Joint-VenturesLPW reseller

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LPW powders power >50% global metal AM install base

Comprehensive range of metal powders

Off-the-shelf rapid delivery solutions

Over 50 products available for dispatch within 24 hours

Developed specifically for AM– optimised for use on all AM machines

– Every powder supplied with a certificate of conformance

Custom alloys– Characterised to your specification

– Developing new powder chemistries to deliver specific properties

Explore novel alloys

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PowderRange

Titanium

Aluminium

Cobalt

Tungsten Carbide

Copper

Refractory metals (Ta, W, Mo)

XLC

Steels– Maraging

– Stainless Steel 316L

– Stainless Steel 174/155

Nickel superalloys– LPW 718

– LPW 625 NiCr

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PowderTrace

Powder AM Laboratory– In-house AM

machine

– Process parameter development

– Powder degradation studies

– AM feasibility studies

– Root cause analysis of failed builds

Adding materials assurance

Powder Analysis Laboratory– Full range of powder

analysis techniques

– Operating to ASTM as standard, ISO available on request

– Testing in UK & US labs

New Material Development– Atomisation of

powder

– AM machine builds, testing of built parts

– Complete project delivery

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LPW Lab Testing Services - Analysis

Contamination

Chemistry

LECO Analysis

Oxygen, Nitrogen & Hydrogen

Full Chemical Analysis by ICP, all

elements

Energy Dispersive X-ray

Spectroscopy -EDX

Size

Laser Size Diffraction

Sieve Analysis

Shape

Morphology G3 Analysis

SEM Scanning Electron

Microscopy

Density

Apparent Density

Tap Density

Pycnometry –

True Density

Powder Cross Section - Porosity

Flow

AM machine simulation

Hall / Carney Flow

Angle of Repose

Moisture Analysis

Karl Fischer Titration

Powder Rheometry by Freeman FT4

SEM-EDX

Scanning Electron Microscopy with Energy Dispersive

X-Ray Spectroscopy

Micro CT

Contamination

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Any metallic powder could be plasma treated to improve

morphology, flow and packing density, regardless

• Chemistry and melting point

• High meting point refractories (e.g. W, Ta, Mo, etc.

and their alloys)

• Lower melting point metals and alloys (e.g. Ni-

based, Ti based, Cu-based, etc.)

• Shape and form

• Agglomerates

• Spongeous

• Angular

• Manufacturing method

• Water Atomisation

• Chemical Process Routes

• Mechanical Methods

Plasma Spheroidisation

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Titanium Spheroidisation

Before Plasma Treatment After Plasma treatment

Product Ti-64 feedstock (HDH and mechanically crushed) Ti-64 spherical

Particle Size, µm 45-105 µm 45-105 µm

Hall Flow rate,

sec/50g47.31

22.3

App. Density,

g/ccN/A

2.6

Tap Density, g/cc 2.2 3.0

Shape analysis Circularity: D10: 0.556, D50: 0.774, D90: 0.937

Elongation: D10: 0.083, D50: 0.260, D90: 0.428

Circularity: D10: 0.81, D50: 0.989, D90: 0.995

Elongation: D10: 0.008, D50: 0.044, D90: 0.366

Morphology SEM

- x1000 mag

• Most commonly used Ti-based alloys: Ti6Al4V Grade 23

• Starting powder, produced by mechanically crushing “embrittled” ingots via a Hydride-De-Hydride (HDH) process, is angular and elongated

• Post Spheroidisation particles are almost perfectly spherical i.e. with a circularity close to 1

• Flow time is improved by a factor of two

• Tap density is increased to almost 60% of the theoretical bulk density

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Tungsten Spheroidisation


Product W feedstock W spherical


Hall Flow rate,

sec/50g

7.5 5

App. Density,

g/cc

11.2 14.3

Shape analysis Circularity: D10: 0.70, D50: 0.89, D90: 0.95

Elongation: D10: 0.05, D50: 0.17, D90: 0.36

Circularity: D10: 0.80, D50: 0.95, D90: 0.98

Elongation: D10: 0.02, D50: 0.15, D90: 0.33

Morphology SEM

- x1000 mag

• Refractory metal tungsten at 3422 °C

has the highest melting point of all

metals in its pure form

• Feedstock was produced by reducing

Tungsten oxides and demonstrates

angularity

• After plasma treatment

• the majority of the powder particles are

shown to be highly spherical

• flow and packing (~74% of the theoretical

bulk density) are improved

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Tantalum Spheroidisation


Product Ta feedstock (dendritic) Ta Spherical


Hall Flow rate,

sec/50g17.4 5.2

App. Density,

g/ccN/A N/A

Tap Density, g/cc8.32 11.16

Shape analysis

N/ACircularity: D10: 0.790, D50: 0.989, D90: 0.996

Elongation: D10: 0.007, D50: 0.050, D90: 0.276

Morphology SEM

- x1000 mag

• Refractory metal tantalum, melting

point 3017 °C

• Feedstock produced by electrolysis

of a solid feedstock and has a very

irregular, dendritic shape

• After optimised Plasma

Spheroidisation powder particles

become:

• highly spherical

• flow and packing (~67% of the

theoretical bulk density) are significantly

improved

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LPW AM Consultants will work closely with your team to tailor a project that perfectly meets your requirements

• Supporting the development of AM processes with new or untested materials

• Laser AM processing feasibility studies

• Process parameter development – densification

• Spheroidisation plus AM feasibility

• Alloy development/design for optimum AM processing

• Powder degradation studies (onsite or offsite)

• High temperature bed studies <700°C (with research partner)

• Machine platform comparison studies

• Metals, and cermets (WC-CoCr)

Expertise in metal AM processing, alloy design, metallurgy and powder behaviour

powder AM laboratory

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Magnitude Innovations

Full AM application development - helping manufacturers to overcome production challenges

Working together to deliver a full AM production solution

Part design

Process development, qualification and implementation

Troubleshooting and education

Independent AM consulting services

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LPW Industrial Advisory Board

To advise on design & capability of LPW’s new powder processing facility

To ensure LPW can support demanding aerospace, defence, & power applications

To enhance the UK supply chain to globally competitive levels

Industrial Advisory Board

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Traditional Powder Reuse – the challenges

Powder degradation

Oxygen pick up

Humidity

Contamination

Introduction of foreign particles

Mixed batches

Lose material traceability

No effective recall system if a failure occurs

Mechanical Testing

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Degradation of Ti-6Al-4V Powder

Ductility has decreasing trend with build number

Ductility in AM influenced by:– Porosity

– Impurity content

Ductility has is heavily correlated to oxygen content in present study

Mechanical Properties – Ductility

0,15

0,2

0,25

0,3

0,35

0%

1%

2%

3%

4%

5%

6%

B2 B3 B4 B5 B6 B7 B8 B9 B10

Oxy

gen

Co

nce

ntr

atio

n [

%]

Elo

nga

tio

n a

t B

reak

[%

]

Build Number

Elongation at Break

Solid Sample Oxygen Concentration

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Mechanical Testing

PowderLife – Adding Control to the AM Process

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LPW manufactured powder - Designed to engineer out contamination

Separate processing areas for each alloy category (Al, Ti, Ni/Co, Fe, Other)

Dedicated 90,000 sqft (9,700 sqm) facility operating on clean room principles & 5S principles

Reducing potential for contamination from:- Powder Manufacturing Processes

- Powder Processing

- Sizing

- Blending

- AM Recycling

- Multi Material Machines

- Sampling and Testing of Powders

Test certification focused on contamination & statistical confidence through repeated sampling

World leading lab with a range of analytical techniques for identifying contamination

The Devil Particle

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AM powder lifecycle management

software

Analytical testing AM consultancy

Materials development

Powders, products and solutions to support AM in production

Smart hopper for controlled metal powder

storage and transport

Sensors to measure powder condition

Simple powder flow measurement kit

Comprehensive range of

off-the-shelf AM metal powders

• Steel• Nickel• Titanium• Aluminium• Cobalt• Tungsten

Carbide• Copper• Refractory

metals• Custom alloy

development

Case StudiesWhy we need control

Adding powder control reduces risk in AM

Working with Industry

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Impact of In-process Powder Control - Traceability

Powder can be allocated for a specific build

Easy location of powder batch and sub-batches

Material used for any build is fully traceable– Testing (mechanical or chemical) relating to the powder batch available with a single

mouse click

Certificate of conformance can be generated for any powder batch at any time during its lifecycle

Fully auditable data trail

Minimise product recall

Any powder can be interrogated for suitability for production at any time

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Impact of In-process Powder Control - Contamination

Atomisation & powder processing

Containers used during transport and storage

Environmental contaminants: skin, hair, dust, O2, moisture

Cross contamination with other powders

Degradation of powder through repeat builds

Mitigate contamination originating from:

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Impact of In-process Powder Control – Stock control

Real time stock control of powder across single or multiple locationsAt any time a report can be generated within the software for all powders • In stock

• On machines as Work In Progress

Fool proof audit trailReduced stock levels

Minimising time required for stock take

Automated alerts for powders dropping below the pre-determined minimum stock levels

Automated alerts for powders dropping out of specification

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PowderTrace

Puts you in control of your powders

Medical grade stainless steel hopper

Transports and stores AM metal powders in a controlled environment

Reduces the risk of contamination

Minimises manual handling and the potential for human error

Connects with all standard metal AM machines, sieves, and powder blenders

All surfaces, valves and flanges easily dismantled and cleaned

Seamless use at every stage of your manufacturing process

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Wireless monitoring of the controlled environment in real-time with PowderEye– Temperature, humidity, pressure and oxygen content of powder

environment

Load cells monitor the powder mass – know when your powder is low

Fully integrated with PowderSolve AM software to provide a full powder lifecycle management system– Powder storage/transport data recorded and analysed in PowderSolve

– QR codes for scan and move accuracy, powder traceability

The smart way to store and transport metal powders

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Casters for ease of movement

Decanting stands for safe powder dispensing into all standard AM machines

Range of adaptors and connectors enables use with all standard AM machines

Forklift and gantry crane compatible

Protective frame available for transportation of hazardous material

Add the PowderEye sensor for real-time monitoring of powder environment, stock levels and material location

Integrate with PowderSolve AM Quality Control software

Customise PowderTrace for your production process

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Primed with argon to create an inert environment– limiting exposure to oxygen, nitrogen and moisture

Positive pressure prevents powder storage environment from degrading over time

Material specific name plates and QR codes simplify material identification– enables powder traceability and avoids cross contamination

Large volume units minimise the storage footprint

Equipped with tamper-evident fittings

120 L model UN tested for transportation of hazmat material

When integrated with PowderEye, PowderTrace is ATEX certified for use in hazardous environments

Metal powder control & management

Alloy Std 120L model

Steel 440kg

Titanium 290kg

Nickel 450kg

Cobalt 440kg

Aluminium

Aluminium

150kg

280kg (230 L)

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PowderEye

Maintain comprehensive, real-time update of powder status– proving transport, storage and handling environment is controlled

Monitor environment in which powder is transported, stored and used– temperature, pressure, oxygen and moisture content

– simple traffic light system to alert you of significant change

Connect to your sieves and blenders, monitor production area

Record powder weight in a PowderTrace hopper giving confirmation of material available for build

Use data to audit and optimise your AM production process

Adding certainty to the AM powder environment

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PowderEye

Encrypted wireless connection to PowderSolve

100 m wireless range, internal data storage capacity, automatic transmission when back in range

Complete data records wherever your powders are located

Four-month battery life, recalibration every two years, for long-term ease of use and minimal maintenance

Designed and manufactured by LPW specifically for metal additive manufacturing

Certified for safe operation in critical environments

Adding certainty to the AM powder environment

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Powder Recycling Powder Cycle (Laser Bed)

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The digital solution

A clear overview of metal powder status at the click of a button– A complete record of material in production

– Manages all metal powder data

– Tracks powder through repeated builds, blending, across multiple machines

– records powder specifications and test data

– warns if the powder is out of specification

– Track powder history, confirm test results from individual material batches and optimise processes

Integration via an API to MES/ERP system

Secure, encrypted cloud based software suite – manages all powder and build material data in one safe, easy-to-use

database

PowderSolve - secure AM quality control software

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Powder Specification for all parameters (e.g. sizing, chemistry, flow) revision control

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Family-tree of powder from starting feedstock to repeated use and blending

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Detailed breakdown of a batch of powder that has been blended several times

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Powder and component certificate is automatically generated within PowderSolve

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Measure powder flow the easy way

Simple, fast confirmation of material quality – Avoid failed builds, the risk of damage to machine parts,

and costly downtime

– Portable for quick, on-site testing wherever and whenever you need it

Full range of equipment to conduct a comprehensive suite of tests– Hall Flow - ASTM B213, ISO 4490

– Carney Flow – ASTM B964

– Apparent Density - ASTM B212, ISO 3923-1

– Angle of Repose - LPW standardised internal procedure

Upload results into PowderSolve

Safely stored in a robust plastic case – Includes funnels, reference powder, stopwatch and

calculation software

S A M P L

SECURE ADDITIVE MANUFACTURING PLATFORM

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© SAMPL Project 2018 | Alle Rechte vorbehalten / All rights reserved 41

In a wider sense, Industry 4.0 means the intermeshing of the value chains in

• development,

• production,

• sales and service

……using state-of-the-art information and communication technologies. The force driving this

development is the increasingly rapid digitalization of business and society.

Industry 4.0

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To do this, all the product parameters relevant to production must be available in digital form.

The 3D master model provides the foundation for drawingless processes and is a first step on the road to an entirely digital product model, the Digital Master

Industry 4.0

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Challenges

Protection of intellectual property; protection against pirated copies/counterfeits; encryption of print data

Copyright

Distinction between original and counterfeit; enforcement of copyrights Original vs. Counterfeit

Warranty and product liability; defense of unjustified claims Liability

Only authorized access; secure identification and authorizationSecurity

No unapproved changes of product data; no changes of product featuresSafety

43April 2018; Martin Holland

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SAMPL – Challenges and Solution Components

• New challenges in copyright and product liability law

• Security in product data exchange

• Granting and traceability of printing rights

• Distinction of original parts from counterfeits

• Interaction with product liability and warranty

• Support of new business models

• Modular platform for the establishment of a Chain of Trust - from copyright holder to end user

• Blockchain-Technology for the supply of licence and copyright information

• Marking and traceability by means of innovative technologies such as “Imprint” of RFID-chips, starting or recording of “fingerprints”

• Inclusion of printer control into the Chain of Trust => trusted 3D printer

3D printed A350 XWB Bracket, Source: Airbus

Key Components SAMPLSecure Additive Manufacturing Platform

-> secure Information exchange -> digital licence management

-> Chain of Trust-> Blockchain-Krypto-Technology-> Authenticity, copyright protection


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PLM for the Additive Process Chain• For an integrated Process Chain asuitable PLM Solution must be implemented.• PROSTEP has more than 20 Years of PLM Experience

Blockchain ready!• also for other Use Cases; Software update in for Cars; CAD-Files with related usage rights

….

SAMPL-Industrialisation

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SAMPL Project on a pageSecure Additive Manufacturing Platform ( www.SAMPL-3D.de )

Partner

Challenges

• Copy- and product liability law

• Distinction of original parts from counterfeits

• Support licensing and printing rights

• Support of new value added and business models

Objectives

• Trusted 3D printers and Chain of Trust

• Marking and traceability by RFID-chips

• Development of a reference platform

• Blockchain-Technology for the supply of licence information

47© SAMPL Project 2018 | Alle Rechte vorbehalten / All rights reserved April 2018; Martin Holland

http://www.sampl-3d.de/

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Manufacturer/Copyright Owner

(Airbus/Evobus)

supply of product data

Initiates print job

Contract DataProduct Data-Files

3D Blockchain Licence Data / Smart Contracts

Service provider or in-house production with

trusted 3D printer

Print Process

Control with Secure

Element

Realization: Blockchain ready!

Contract DataProduct Data-

Files


Licence Data

Licence Data

Licence Data

48

Printed Product 1

Printed Product ….

Printed Product n

RFID 1

RFID …

RFID n

April 2018; Martin Holland

lpwtechnology.com

49

pvinoiM3498vmv945dmc8u39s98vp8w349fa98938uz587b

3D-Print Licence

4

4711-A4-58572

NzudjJK%VBt5hJc045218w23ßKXuyztr8ldf42db66c8d842

Licence:

Hash-Key of Part001.prnPart001.prn

Jc045218w23ßKXuyztr8ldf42db66c8d84269d4b7157b92a4

Wallet-Address of Alice (Public Key)

We8ßcvxxüy9u34PH9ivJc045218w23ßKXuyztröldf42db66

Wallet-Address of Bob (Public Key)

4

Number of licensed components

Licence Database

4711-A4-58572

Licence number (created by Alice )

Alice Bob Part001.prn 4ID

144thdf4sfgf2db66fn6hncrggfc8d84269d4b7157b92a87be7

Bob shall print 4 components

Part001.prn

Alice OEMAirbus

Smart Contract

Bob/ Print Service Provider

Lice

nce

cre

ated

by

Alic

e

ConfirmedTransactions

Blockchain

© SAMPL Project 2018 | Alle Rechte vorbehalten / All rights reserved April 2018; Martin Holland

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SAMPL: Extended Ecosystem


3D BLOCKCHAIN Licence Data / Smart Contracts

Licence data iscreated and

published in theblockchain

Autonomouslysourced material

and services throughsmart contracts

Hashes of processdata files saved in the

blockchain

Product is registered in Blockchain and tied

to the license

Product is shipped bylogistics partnerTimestamp and

Shipping ID

Hash of usage datasaved in theblockchain

Customer product id

Trusted Devices Registry

License Management

Product Lifecycle

Material dataCustomer dataTracking data

Printed product IDQuality data

Licence data

Material files Quality data files

Print process dataPrinted part ID

Shipment IDLogistics partner

Product Data files Product Data files

CAD/Print files Process filesProduct usage data


IP Owner/Inbound logistics Production/Manufacturing Partner Outbound logistics/End customer


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Approach

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Goals

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SAMPL Demonstrator auf der HMI 2017 und 2018(Hannover Messe Industrie 2018: 23.4 – 27.4.)

• Demonstration along the process chain:

• Uploading CAD data to GlobalX

• Awarding a licence to a print shop

• 3D printing and licence check

• Results:

• Good contacts with potential customersand SAMPL Project Partners

• Next Steps• Integration of additional Partners

• Development of a Demonstrator 2.0 with new functions

• Analysis of potential other blockchains e.g. Hyperledger

• Definition of interfaces for 3D printers


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SAMPL Blockchain


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© SAMPL Project 2018 | Alle Rechte vorbehalten / All rights reserved 56April 2018; Martin Holland

SAMPL Block Explorer

Number of Licences

Licensor

File Hasch

Licence-ID

Licensee

Time Licence issued

Licence-ID

Transaction prize if applicable

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Benefits of the SAMPL Platform

Printer Manufacturer

Key differentiator “trusted” 3D printer; Integration of block chain and Secure Elements; competitive advantage

Owner of IP RightsIP security, prevention of pirated copies, enforceable rights, traceability of use, pay-by-use billing

OEMSecure on-demand-production, reduction of storage and transport costs, lower capital investment, insurance of quality, optimized spare parts business

Print Service Provider

“Trusted” Print Center by means of “trusted” 3D-printers, support of quality control, legal certainty and competitive advantage

End UserVerifiable authenticity, protection against design manipulation, precise and secure billing, confidence in the product, advantages in case of warranty claims


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58

3D BlockchainLicence Data / Smart Contracts

lpw technology - Инновации. Технологии....

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