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Additive manufacturing of polymers – overview and case studies

20 MARZO 2019 TECNOLOGIE ADDITIVE, UN’OPPORTUNITÀ DA COGLIERE

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EOS: A Growing Company

Source: EOS. Installed base (includes purchased and rented systems) and staff figures as per 10/2017.

Some 1,200 employees worldwide (70% Germany, 30% International)

Strong patent portfolio: more than 750 active and pending patents in more than 175 patent families

EOS global footprint

3,000 systems EOS worldwide installed base

37 44 49 55 62

73 63 67

99 113

130

178

265

318

345

0

500

1000

1500

2000

2500

3000

0

50

100

150

200

250

300

350

2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17

Gross sales in m€ (left-hand scale)

Accumulated no. installed base

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Production capacity >1,000 systems per year

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EOS Polymer Systems

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Polymer push – image film

Source: https://www.youtube.com/watch?v=bqABiRV8ckA

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Metal and Polymer processing are different

Polymer Metal

warm process cold process

CO2 Laser Fiber Laser

low laserpower high laserpower

powder partly reusable all powder reusable

… …

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EOS Polymer Portfolio Fa

cto

ry L

ine

EOS P 800

EOS P 500

EOS P 770 EOS P 396 FORMIGA P 110 Velocis EOS P 810

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High temperature composite laser sintering. By EOS.

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Lowest cost-

per-part

Industrial Additive

Manufacturing

Best & desired

part quality

Enabling new materials & applications

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Polymer high quality materials

15 materials: the largest OEM-portfolio of Laser Sintering materials

Family Material name

PA 12 unfilled

PA 2200

PA 2201

PrimePart® PLUS (PA 2221)

PA 12 colored PA 2202 black

PA 2105 (gum colored)

PA 12-GB PA 3200 GF

PA 12-AL Alumide®

PA 12-CF CarbonMide®

PA 12-FR PA 2210 FR

PrimePart® FR (PA 2241 FR)

PA 11 unfilled PA 1101

PA 11 black PA 1102 black

Elastomer (TPE) PrimePart® ST

Polystyrene (PS) PrimeCast® 101

Polyaryletherketone (PAEK) EOS PEEK HP3

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EOS Additive Manufacturing is an established and efficient way of industrial production – today

Automotive: Exciting announcements in 2018!

Images: Courtesy of Under Armour, Wittmann/ABB/Kuhnstoff, Boeing/OPM, MINI, BMW, Daimler, Audi

Footwear

Automation

Aerospace

12 Source: EOS; Logos: Respective companies

We have a unique ecosystem to further accelerate innovation

Start Ups powered by

EOS GROUP

External Partners

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More than 80% of all OEMs use Additive Manufacturing. EOS is #1 in Automotive

Source: Official OEM press material

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How can we improve this gripping device to leverage the full potential of AM technology?

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A conventional handling device was redesigned leveraging the possibilities of AM

Source: Kuhnstoff, EOS, https://www.youtube.com/watch?v=Coo-bE7q1fg

Example for functional integration and lightweight design

Gripper solution

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KuhnStoff Lightweight Gripper Solution

Source: https://www.youtube.com/watch?v=Coo-bE7q1fg

EOS_Company-Presentation.pptx | EOS | 17

Patient Specific Instrument Cut and drill guides

Source: https://www.materialise.com/

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Various orthopedic companies produce patient matched surgery guides for their implant systems

Example Smith & Nephew

Source: Smith & Nephew, EOS

Cut and drill guide

Application

Patient specific knee surgery guides

Based on data generation by CT

Single-use instrument

Biocompatible polyamide material

FDA 510(k) approval

Advantages

OEM: less inventory, additional offer to surgeons

Surgeon: facilitates precision

Patient: less stressful (shorter anesthesia, less replacements)

Hospital: faster surgery (1min ~ 600$), no re-sterilization costs

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Disposable medical instruments are a perfect fit to polymer laser-sintering

SLS Focus Area for Instrumentation

Source: Smith & Nephew (picture)

Additive Manufacturing Advantages

Productivity advantage

Cost advantage

Freedom of design

Customization

$ Patient-specific disposable instruments

Reduced instrument inventory

Less cleaning and sterilization effort

Faster surgery

More precise surgery

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From DICOM acquisition to custom guide

Instrument design and optimization

CT/MRI based design (e.g. Materialise Software)

Design rules

Define part orientation in the building volume

DESIGN

Instrument building process

Different system solutions according to part dimension and production batch

Biocompatibility tests available

Quality assurance of the process

BUILD

Instrument post-processing

Cleaning

Dimensional and quality control

Packaging and Sterilization

FINISH Source: EOS

e.g.

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The disposable instruments can be produced using the integrated EOS portfolio

1)Including system list price with standard configuration, 5 years machine depreciation, 3% interest, maintenance contract, medium user (3500 h/year) and standard list price PA2200 .

2)Full job would be 112 sets/job in 29 hours , BUT due to workflow and processing time it is recommended to build max 5 layers (= 80 sets) per job! Source: EOS

BUILD Layer thickness can be adjusted to find the

right balance of detail resolution and cost per part

EOS application team can consult to optimize work flow

Sample calculation for knee guide set:

P110, 120µm:

24 sets/job

18 h/job

23 €/set1)

P396, 120µm:

80 sets/job2)

21h/job

18 €/set1)

EOS economic production

Sample geometry set consisting of Disposable guide and corresponding bone

section

24 guide sets packed into one P110 job

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New customers and markets can be addressed by manufacturing with 3D technology

Source: Mykita, https://www.youtube.com/watch?v=9u_Dm4NvTd0

Mykita Mylon – 3D printed glasses

“Additive Fashion”

Challenge

Address another customer group by offering a similar product manufactured with 3D technology

Solution

“Additive Fashion”

The “MYKITA MYLON” is produced using 3D technology

A whole new customer group is addressed with this product

Key benefits

Win new customers and gain new markets

Differentiate from competitors

Light weight and robust

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Mykita Mylon Image Film

Source: https://www.youtube.com/watch?v=9u_Dm4NvTd0

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MINI - British premium automobile manufacturer lifts individualization, digitalization and 3D printing to a new level

MINI Yours Customised

Source: https://www.press.bmwgroup.com

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Strong cooperation with DyeMansion on the post-processing of polymer parts

+ =

Print-to-Product Workflow From 3D-printed raw-part to high-value product in three hours cycle time

Polymer Portfolio Systems, Material, Software, Services

Step 1 Cleaning

Step 2 Surfacing

Step 3 Coloring

Entry level

.

.

.

Factory line

High-value product with unlimited coloring options

Source: EOS; DyeMansion; BMW; Daimler EvoBus

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Case Study: MINI - British premium automobile manufacturer lifts individualization, digitalization and 3D printing to a new level

Video Link: https://www.youtube.com/watch?v=r-p6f9Jfdu0