Industrializing additive manufacturing - proceedings of Additive Manufacturing in Products and Applications - AMPA2017

363 Pages·2018·61.89 MB·English

Mirko Meboldt · Christoph Klahn Editors
Industrializing Additive
Manufacturing —
Proceedings of Additive
Manufacturing in Products
and Applications —
AMPA2017
—
Industrializing Additive Manufacturing
Proceedings of Additive Manufacturing in Products
—
and Applications AMPA2017
Mirko Meboldt Christoph Klahn
(cid:129)
Editors
Industrializing Additive
—
Manufacturing
Proceedings of Additive
Manufacturing in Products
—
and Applications
AMPA2017
123
Editors
Mirko Meboldt Christoph Klahn
pd|zProduct development GroupZurich Inspire AG
ETHZürich Zürich
Zürich Switzerland
Switzerland
ISBN978-3-319-66865-9 ISBN978-3-319-66866-6 (eBook)
DOI 10.1007/978-3-319-66866-6
LibraryofCongressControlNumber:2017952386
©SpringerInternationalPublishingAG2018
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Preface
“Industrializing Additive Manufacturing” is the proceedings of the first scientific
conference on Additive Manufacturing in Products and Applications AMPA 2017.
The conference provides a platform for the exchange of ideas and knowledge
among engineers, designers, and managers. Its objective is to support real-world
value chains by developing additively manufactured serial products.
Additive Manufacturing (AM) often has been referred to as a future production
technology enabling the next industrial revolution. Additive processes offer very
different characteristics when compared to conventional manufacturing processes,
such as almost unlimited freedom in design and an efficient digital process chain
allowing for lot size one manufacturing. Many AM processes were invented
between the mid-1980s and the early 2000s. Researchers all over the world dedi-
cated their work to understanding and improving AM materials and processes.
Thanksto them, we now have access to a large variety of industrial AM machines
and commercially available materials.
Yet still we are just at the beginning of an industrialization of AM. There are
several challenges to face in regard to quality, productivity and robustness of
processes, and a demand for new materials. Nevertheless, it can be clearly stated
that Additive Manufacturing by now is a mature process ready for industrial pro-
duction. Engineers in industry do not question the operational readiness of the
processes anymore. Their concern now is how to benefit from Additive
Manufacturing and how to integrate AM into their existing product development
and production processes. Having a reproducible process delivering parts of suffi-
cient quality and acceptable costs isonly thestarting point for theindustrialization
of AM. Additive Manufacturing is taking the next step on its journey toward a
broadrangeofseriesproduction,andwearefacingmanynewscientificchallenges.
Transformingthepotential benefitsofAdditiveManufacturingintoasuccessful
industrial or end-user product is a challenge to all disciplines along the product
developmentprocess.Designersandengineersneedstrategiestohelpthemidentify
the right applications, tools, and methods for an efficient design process using the
freedom of design to create benefits for users as well as the manufacturer.
Production engineers have to assess Manufacturing Readiness Levels, implement
v
vi Preface
AMmachinesintotheexistingproductionchain,ensureanefficientoperation,and
establish quality assurance and control mechanisms. Examples for AM-specific
topics ontheeconomicsidearemake-or-buy decisions,supplychain organization,
new business models, and converting Unique Selling Propositions in additional
revenue.
The topics of Additive Manufacturing in Products and Applications cover all
topics necessary to develop and produce successful products.
(cid:129) Design Tools & Methods: Identifying and designing AM parts
(cid:129) Process Chain Integration: Setting up a safe and efficient production
infrastructure
(cid:129) Business Cases of AM Applications: Quantifying the benefits of AM
(cid:129) Unique Customer Benefits: Learning from good and unusual examples
(cid:129) Teaching and Training: Bringing knowledge and experience to new users
WewouldliketothankeveryonewhocontributedtothesuccessoftheAdditive
ManufacturinginProductsandApplicationsconference:Thankstotheauthorsfor
their valuable papers and talks, to the members of the industrial and scientific
committees for their hard but fair reviews and for chairing sessions, to the partic-
ipants of the sessions for the fruitful discussions, and last but not least to all those
who supported the conference in the background.
Mirko Meboldt
Christoph Klahn
Organization
Organizing Committee
Mirko Meboldt ETH Zürich, pd|z
Christoph Klahn inspire AG, ipdz
Filippo Fontana ETH Zürich, pd|z
Martin Stöckli inspire AG
Petra Kahl inspire AG
Daniel Türk ETH Zürich, pd|z
Kornelia Kunstmann inspire AG, ipdz
Members of the Industrial Committee
Matthias Baldinger Additively AG
Ralf Becker Schunk GmbH & Co. KG
Steffen Beyer Airbus Safran Launchers
Paul Fickel Daimler AG
Klaus Müller-Lohmeier Festo AG & Co. KG
Gonzalo Rey Moog Inc.
Thomas Scheiwiller Bühler AG
Kai Schimanski Premium Aerotec GmbH
Members of the Scientific Committee
Guido Adam Universität Paderborn, Direct Manufacturing Research
Center (DMRC)
Stefano Brusoni ETH Zürich, Technology and Innovation Management
vii
viii Organization
Olaf Diegel Lund University, Product Development
Jens Ekengren Örebro University, Mechanical Engineering
Claus Emmelmann TU Hamburg, iLAS; Laser Zentrum Nord
Paolo Fino IIT Torino
Richard Hague University of Nottingham, EPSRC Centre for Additive
Manufacturing
Russel Harris University of Leeds
Erik Hofmann University St. Gallen, LOG - Research Institute
for Logistics Management
Andreas Kirchheim ZHAW, Zentrum fürProdukt-undProzessentwicklung
(ZPP)
Dieter Krause TU Hamburg, Produktentwicklung und
Konstruktionstechnik
Gideon Levy TTA Technology Turn Around
Mirko Meboldt ETH Zürich, pd|z
Wilhelm Meiners Fraunhofer ILT
Torbjorn Netland ETH Zürich, Production and Operations Management
Alberto Ortona SUPSI, Hybrid Materials Laboratory
Maren Petersen Universität Bremen, Institute Technology
and Education
Manfred Schmid inspire AG, icams
Adriaan Spierings inspire AG, icams
Klaus-Dieter Thoben University Bremen, IKAP
Anna Valente SUPSI, IRoS
Konrad Wegener ETH Zürich, IWF
Gerd Witt Universität Duisburg-Essen
Contents
Design Tools and Methods
Evolution of Design Guidelines for Additive Manufacturing -
Highlighting Achievements and Open Issues by Revisiting
an Early SLM Aircraft Bracket.... .... .... .... .... .... ..... .... 3
Christoph Klahn, Daniel Omidvarkarjan, and Mirko Meboldt
A Design Method for SLM-Parts Using Internal Structures
in an Extended Design Space. ..... .... .... .... .... .... ..... .... 14
Rene Bastian Lippert and Roland Lachmayer
Exploring the Impact of Shape Complexity on Build Time
for Material Extrusion and Material Jetting.. .... .... .... ..... .... 24
Patrick Pradel, Richard Bibb, Zicheng Zhu, and James Moultrie
Novel Optimised Structural Aluminium Cross-Sections
Towards 3D Printing ... .... ..... .... .... .... .... .... ..... .... 34
Konstantinos Daniel Tsavdaridis, Jack Antony Hughes,
Lukas Grekavicius, and Evangelos Efthymiou
Manufacturing Process Chain
Finite Element Modeling of Ceramic Deposition by LBM(SLM)
Additive Manufacturing. .... ..... .... .... .... .... .... ..... .... 49
Qiang Chen, Gildas Guillemot, Charles-André Gandin, and Michel Bellet
Analysis of the Influence of Shielding and Carrier Gases on the DED
Powder Deposition Efficiency for a New Deposition
Nozzle Design Solution.. .... ..... .... .... .... .... .... ..... .... 59
Federico Mazzucato, Andrea Marchetti, and Anna Valente
On-Demand Spare Parts for the Marine Industry
with Directed Energy Deposition: Propeller Use Case .. .... ..... .... 70
Wei Ya and Kelvin Hamilton
ix
x Contents
Macroscopic Finite Element Thermal Modelling of Selective Laser
Melting for IN718 Real Part Geometries. .... .... .... .... ..... .... 82
Yancheng Zhang, Gildas Guillemot, Charles-André Gandin,
and Michel Bellet
Additive Manufacturing of Piezoelectric 3-3 Composite Structures. ........ 93
Miriam Bach, Tutu Sebastian, Mark Melnykowycz, Tony Lusiola,
D. Scharf, and Frank Clemens
Additive Manufacturing of Semiconductor Silicon on Silicon
Using Direct Laser Melting .. ..... .... .... .... .... .... ..... .... 104
Marie Le Dantec, Mustafa Abdulstaar, Matthias Leistner, Marc Leparoux,
and Patrik Hoffmann
Additive Manufacturing of Complex Ceramic Architectures. ..... .... 117
Oscar Santoliquido, Giovanni Bianchi, and Alberto Ortona
Process Chain Integration
An Advanced STEP-NC Platform for Additive Manufacturing.... .... 127
Renan Bonnard
Additive Manufacturing on 3D Surfaces. .... .... .... .... ..... .... 137
Olivier Chandran, Sebastien Lani, Danick Briand, Barthelemy Dunan,
and Guy Voirin
Integrated Platform for Multi-resolution Additive Manufacturing . .... 145
Paul Delrot, Damien Loterie, Demetri Psaltis, and Christophe Moser
Enhanced Toolpath Generation for Direct Metal Deposition
by Using Distinctive CAD Data .... .... .... .... .... .... ..... .... 152
DanielEisenbarth,FlorianWirth,KevinSpieldiener,andKonradWegener
Performance Simulation and Verification of Vat Photopolymerization
Based, Additively Manufactured Injection Molding Inserts
with Micro-Features .... .... ..... .... .... .... .... .... ..... .... 162
Michael Mischkot, Thomas Hofstätter, Ifigeneia Michailidou,
Carlos Herrán Chavarri, Andreas Lunzer, Guido Tosello,
David Bue Pedersen, and Hans Nørgaard Hansen
Additive Repair Design Approach: Case Study of Transverse
Loading of Aluminum Beams. ..... .... .... .... .... .... ..... .... 169
Zghair Yousif and Lachmayer Roland