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New Opportunities For Aerospace With DED 3D Printing Technology

New Opportunities For Aerospace With DED 3D Printing Technology

5-axis DED 3D printing is opening new possibilities and finding its own niche in the manufacturing industries. ModuleWorks deep dives into its software technology and the applications. 

Directed Energy Deposition (DED) refers to any additive manufacturing process that uses a focused energy source, such as a plasma arc, laser or electron beam to melt and deposit material from a nozzle onto a surface. 

5-axis DED technology is opening new possibilities and finding its own niche in the manufacturing industries. The aerospace industry, for example, relies on DED for cost-effective repair of moulds and turbine blades, and tool makers use DED for manufacturing and repairing sheet metal forming tools. 

Here, ModuleWorks provides an insight into the software technology (toolpath generation, simulation and post processing) that is making DED an increasingly attractive manufacturing option and shares how the technology opens new production possibilities.

Understanding the Software Technology

Multi-Axis Tool Path Generation

Like other CAM techniques, DED uses sophisticated tool path calculation algorithms to generate efficient, collision-free machining operations from the initial CAD or mesh data. Taking a free-form machining surface as input, the volume is generated and divided into 3D slices according to the desired layer thickness. Tool paths within the layers are generated using path patterns which can be defined by path curves, intersections of guide surfaces or by automatically generated center axes. 

Propagation of the weld pool layers can be controlled by various sorting parameters. Further parameters optimise the tool path accuracy, point distribution and orientation of the laser head [CIRP Vol. 68/1, 2019, pp. 447 – 450]. The combination of the individual additive paths and the layers is automatically collision-free.

Additional features assist operators with both complex and everyday manufacturing tasks:

  • Path planning on scanned data
  • Orientation along wall structures to print areas with large overhangs
  • Fixed 6th axis to keep the orientation of the nozzle in the direction of movement for WAAM applications
  • Buildup of arbitrary curved shapes such as tube geometries

DED tool path generation software combines these features and takes the operator-defined parameters to automatically generate an additive toolpath optimised for DED manufacturing.

 

Multi-Axis Additive Simulation

Machine simulation is essential for catching collisions and other potential machining problems that would otherwise halt production and require operators to adjust the machining process (e.g. to redefine the workpiece zero point or reset the machine modules). Using an integrated machine simulation prevents this expensive downtime by detecting and avoiding collisions before they occur. Collisions between the part and print head, as well as printing errors, can be predicted and avoided.

DED simulation allows operators to define the shape of the tool (powder nozzle, laser) for each simulation job, and the operator-defined test points ensure a robust in-process model for the machine simulation which can be used for subsequent simulation steps. The simulation also checks for collisions between machine components, clamping devices and the in-process state of the workpiece.

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Hexagon And Authentise Partner To Deliver First Open End-To-End Software Solution For AM

Hexagon And Authentise Partner To Deliver First Open End-To-End Software Solution For AM

Hexagon’s Manufacturing Intelligence division and Authentise have partnered to extend the Additive Manufacturing (AM) control loop from the machine level to connect the end-to-end value chain from design, manufacturing operations and quality assurance to make additive manufacturing more predictable, repeatable and traceable.

Data from shopfloor manufacturing operations, engineering data from the design phase, materials properties and quality data from validation and inspection processes hold the key to automating serial production improvements and enabling design improvements. However, the technical challenge of connecting these silos and applying these data have inhibited the ability to consistently apply AM to new designs. New solutions delivered through the partnership will apply Statistical Process Control (SPC) with Machine Learning (ML) and Artificial Intelligence (AI) methods to mitigate waste and quality issues during the design phase and improve the repeatability of additive manufacturing processes within a site or between global locations.

Through the partnership, Hexagon and Authentise will build solutions to industrialise AM technology by digitising every step of the workflow from part design through production to final product and quality assurance utilising their unique stack of technology capabilities to connect the digital thread of a part and trace its pedigree. This is made possible by a shared commitment to open architectures that integrate data and automate workflows between Hexagon´s best-of-breed applications for AM and the third-party equipment and software manufacturers chose to use.

Mathieu Pérennou, Global Business Development Director Additive Manufacturing, Hexagon’s Manufacturing Intelligence division says, “Together with Authentise, we are building a next-generation framework for our customers to manage flexible, fully digitised production workflows in private cloud environments. For manufacturers, AM is a complex and changing market with many excellent tools, printers and materials to apply. We believe our open and flexible systems will enable us to respond quickly to customer’s needs and integrate with their unique environments. This will connect the data flow and help streamline their workflows in all stages of the AM process – before, during and after production and support their specific standards or compliance needs.”

Authentise is a key partner in Hexagon´s open AM ecosystem, having built an open manufacturing execution system tailored to the specific needs of additive manufacturing methods. This growing ecosystem provides a broad solution portfolio that allows Hexagon to build solutions tailored to the specific needs of customers from different industries and any level of complexity – from achieving high volume production of precision metal gears to first-time-right production of bespoke aerospace parts from composites.

Andre Wegner, CEO, Authentise says, “We are excited to combine Hexagon’s solutions with our open workflow management engine to offer a unique end-to-end solution platform. Integrating data from Hexagon’s best-of-breed software and sensors helps deliver a seamless experience for users, automation across their process, and unlocks the ability to learn from data. This partnership represents a step change for the industry – together we’re delivering the integrated digital thread for additive manufacturing that customers have sought for so long.”

 

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Driving Hard On The Race Track: Wear-Resistant Iglidur Gears In The Gearbox

Driving Hard On The Race Track: Wear-Resistant iglidur Gears In The Gearbox

The iglidur I6 gears from the 3D printer for car racing of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) challenge

Electromobility is a crucial topic of the future. For Germany to be in the pole position, it is important to inspire young minds to take up scientific and engineering professions. Towards this purpose, the annual JET Challenge takes place at the IdeenExpo in Hanover. Students are given the task of building a fast, tough and energy-efficient racing car from a standard, remote-controlled car with a limited budget. Wear-resistant 3D-printed gears from igus made from the high-performance plastic iglidur I6 helped in this endeavour.

Build a fast, energy-saving racing car from an ordinary, remote-controlled car and overtake all other teams in a race – that’s the goal of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) Challenge, organised by the Society of German Engineers (Verein Deutscher Ingenieure – VDI) and the University of Hanover (Hochschule Hannover – HSH). As with the renowned models, the key factor is not speed alone, but also energy efficiency. In June 2019, visitors to the IdeenExpo can see the JET Challenge in action at the HSH trade fair stand. 25 teams compete for victory with their racing cars on a 1:10 scale on a 20-metre race track. The rules are strict. Available to each team is a budget of just 50 euros. Apart from battery, motor and speed controller, all components must be purchased, developed or built by yourself.

Save money with the igus 3D printing service

The teams are currently preparing for the next IdeenExpo. Students of the Eugen Reintjes vocational school are relying on a wear-resistant and tough gear transmission to enhance the performance of their race car. The biggest difficulty with this gearbox was the gear procurement. Due to the small budget, the students couldn’t afford big innovations. Finally, they found what they were looking for at the motion plastics specialist igus in Cologne: cost-effective, low-wear gears from the SLS printer. After a simple online configuration, the gears were printed and provided, made from the high-performance plastic iglidur I6.

High performance plastic makes race cars tough

Laboratory tests prove that the material I6 is significantly tougher than other plastics. In an experiment at our in-house test laboratory, the engineers tested gears made of polyoxymethylene (POM) and iglidur I6 at 12 revolutions per minute and loaded with 5Nm. A machined gear made of POM failed after 621,000 revolutions, while iglidur I6 was still in very good condition after one million revolutions. Thus, the team does not have to worry about potential failures. The gears in the racing car have already successfully completed an initial test run. The car is energy efficient and still reaches the top speed of 60km/h.

The young engineers support from igus promotes innovative projects

Innovative projects such as the race car gears for the JET Challenge are supported by igus as part of the young engineers support. The initiative supports young pupils, students and inventors in the development and execution of their technical projects. Further information on yes can be found at http://www.igus.sg/yes.

 

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3D Printing The Future Of E-Mobility Tools

3D Printing the Future of E-Mobility Tools

Kennametal’s 3D printed stator bore tool meets accuracy, roundness, and surface finish requirements of hybrid and electric vehicles.

Kennametal has developed a 3D printed stator bore tool specifically designed to meet growing customer demand for lighter weight tooling solutions used to machine components for hybrid and electric vehicles.

E-mobility components are typically machined on smaller, low horsepower CNC machining centres that require lighter weight tooling solutions. Kennametal’s 3D printed stator bore tool weighs half that of the conventionally manufactured version, while still meeting accuracy, roundness, and surface finish requirements for aluminium motor body boring.

“The main bore, which houses the stator of an electric motor measures approximately 250 mm in diameter (9.84 in) and approximately 400 mm (15.74 in) in length, with a smaller bearing bore at the bottom,” says Harald Bruetting, Manager, Program Engineering, at Kennametal. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kg (55 lb), far too heavy for the existing machine tool or for an operator working with the tool.”

Bruetting and Kennametal’s Solution Engineering Group turned to the company’s in-house additive manufacturing capabilities to 3D-print a strong but lightweight indexable tool, equipped with proven Kennametal technologies including fine adjustable RIQ reaming inserts for high precision finishing and a KM4X adaptor for maximum rigidity. The tool also features internal 3D printed cooling channels that help maximize productivity and tool life.

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The 3D Printing Market Will Reach $51 Billion In 2030

The 3D Printing Market Will Reach $51 Billion In 2030

3D printing has the potential to significantly disrupt traditional manufacturing, as it is increasingly being used beyond prototypes, moulds, tools, or other one-off parts. The total 3D printing market will reach $51 billion in 2030, driven mainly by growth in production parts, according to new data from Lux Research.

Lux’s new report, “Will 3D Printing Replace Conventional Manufacturing?” highlights the 3D printing market size and growth by application and material, provides an outlook on what 3D printing means for the future of manufacturing, and discusses how strategies and business models will evolve as well.

“3D printing will be a key in the future manufacturing landscape thanks to benefits that it can bring over injection moulding, machining, casting, or other conventional methods,” explains Anthony Schiavo, Research Director at Lux Research and one of the lead authors of the report. “These benefits include customisation and personalisation, the ability to create complex geometries, part consolidation, and in some cases lowering costs.”

The value of 3D-printed parts will rise at a 15 percent compound annual growth rate (CAGR) over the next decade, from $12 billion in 2020 to $51 billion in 2030. “The largest share of this growth will be in end-use parts, which are just 23 percent of the market today but will reach 38 percent share in 2030,” notes Schiavo.

“The medical and dental industries will account for the largest share of end-use parts, reaching $4.5 billion in 2030, followed by aerospace at $3.9 billion.”

As 3D printing for manufacturing matures, strategies will shift. Vertical integration is critical today, but horizontal specialists can capture more profits in the future. Due to the relative immaturity of 3D printing as a manufacturing technology, complete well-integrated ecosystems are needed to help make it competitive.

 

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TRUMPF Unveils New New 3D Printer To Help Fabricators Move Into Mass Production

TRUMPF Unveils New New 3D printer To Help Fabricators Move Into Mass Production

TRUMPF has unveiled the new series of its TruPrint 3000 3D printing system at a virtual customer event. The medium-format machine uses powder-bed-based laser melting to produce parts with a diameter of up to 300 millimeters and a height of up to 400 millimeters. It can handle all weldable materials including steels, nickel-based alloys, titanium and aluminum.

“We’ve improved key aspects of the TruPrint 3000 to tailor it even more closely to the quality requirements, certifications and production processes of various industries,” says Klaus Parey, managing director of TRUMPF Additive Manufacturing.

The new TruPrint 3000 can be equipped with a second laser that almost doubles its productivity. “The multilaser option significantly reduces part costs – that’s how we help our customers make the move into mass production,” says Parey.

Two 500-watt lasers scan the machine’s entire build chamber in parallel. This makes production much faster and more efficient regardless of the number and geometries of the parts. With the Automatic Multilaser Alignment option, the system can automatically monitor the multilaser scan fields during the build stage and calibrate them to each other. With each laser scanning a contour, the process does not lead to any kind of weld seams. This is what allows multilaser parts to meet such outstanding quality standards.

The TRUMPF experts have transformed the movement of inert gas through the TruPrint 3000. The way in which it flows through the machine from back to front is now even steadier and more uniform. As well as boosting the quality of printed parts, this also allows the operator to remove excess powder from the part while it is still inside the machine. Previous models required the operator to take the part out and remove the powder at a separate station. The new machine is designed to process the powder in a shielded environment, using an inert gas to prevent the powder from becoming contaminated during the build. This is a major advantage for sensitive industries such as medical device manufacturing.

 

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A.I. Engineering Pioneer Hyperganic Raises $7.8m Funding For R&D Expansion In Singapore

A.I. Engineering Pioneer Hyperganic Raises $7.8m Funding For R&D Expansion In Singapore

Hyperganic has announced the closing of $7.8m in funding, with a focus on significantly expanding their presence in Singapore. The round is led by German funds HV Capital and VSquared Ventures. Co-investors are US-based tech fund Converge, industrial partner Swarovski and PC pioneer Hermann Hauser, co-founder of ARM.

Hyperganic was founded in 2017 to radically accelerate innovation in design, engineering and production of physical objects. The company drives a paradigm shift, where complex products are created by computer algorithms and Artificial Intelligence. The resulting objects are traded digitally and manufactured in digital factories based on industrial 3D printing (Additive Manufacturing).

The investment will drive a significant expansion of the existing Hyperganic team and the establishment of R&D centers in both Singapore and China.

“Humanity’s biggest challenges can only be solved through a giant leap in technology. We’ve created Hyperganic to fundamentally change how we design and build the things around us. Now we are ready to shift gears. We are happy to have the support of such a diverse team of investors on this exciting journey,” said Lin Kayser, co-founder and CEO, Hyperganic.

Hyperganic will use Singapore as a key pillar of the company’s development strategy. This decision was driven by the country’s investment in a vibrant deep technology ecosystem, specifically for advanced manufacturing technologies such as A.I., robotics and industrial 3D printing. As part of Singapore’s five-year RIE (Research, Innovation, Enterprise) plans, NAMIC, the National Additive Manufacturing Innovation Cluster, was incepted to orchestrate and implement strategies for the future of production.

“Singapore is one of only a few countries which have recognised the seismic shift happening through digital factories based on Additive Manufacturing. The products designed by our Singapore A.I. engineers will be game changers for many industries that are highly relevant to the region. With NAMIC, Singapore has a unique organisation that demonstrates the country’s strategic commitment to transforming an entire industry sector,” said Kayser.

“We have engaged Hyperganic as early as 2018 when it was in stealth mode, after Lin and I met at a conference. Back then, it was extraordinary to me what the company had envisaged — a paradigm shift in the way people design, using algorithms to create functional products with biomimicry designs. We are delighted to be partnering with Hyperganic on their growth journey, and excited by its plans to rapidly expand its footprint in Singapore and Asia,” said Dr. Chaw Sing Ho, Director, NAMIC Singapore.

 

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Safran And SLM Solutions Evaluate SLM Technology For Additively Manufactured Main Fitting Of A Bizjet

Safran And SLM Solutions Evaluate SLM technology For Additively Manufactured Main Fitting Of A Bizjet

In a joint project, Safran Landing Systems and SLM Solutions tested Selective Laser Melting to produce a component of a nose landing gear for a bizjet. A world first for a part of this size.

The joint objective of the project is to demonstrate the feasibility to produce a main fitting by Selective Laser Melting process. The component was therefore redesigned for metal-based additive manufacturing allowing time saving in the whole process, and significant weight reduction about 15 percent of the component.

Due to the stringent requirements of this component, which is one of the parts that transfers the loads from the wheel to the aircraft structure and is retracted after take-off, Safran selected the titanium alloy, as it is a material with high mechanical properties, naturally resistant to corrosion, which does not require any surface treatment. Additionally, it helps increasing part durability.

Thierry Berenger, Additive Manufacturing project leader at Safran Landing Systems says: “We chose SLM Solutions as a partner, because of their expertise and the SLM 800 machine, which exactly meets our requirements in terms of machine size and reliability.”

With a vertically extended build envelope, the SLM 800 is perfectly adapted to produce large components. The machine is equipped with SLM Solutions’ proven quad-laser technology and innovative features, like the patented gas flow and a permanent filter, that ensure highest reliability.

One of the strengths of the SLM technology is its flexibility. Design changes can be quickly modified, printed and tested, then less time is spent during the prototype development.

Gerhard Bierleutgeb, EVP Global Services & Solutions at SLM Solutions explains: “Additive manufacturing contributes to save time in the qualification and certification phases by rapidly providing the parts for testing. We were able to produce the main fitting in few days on the SLM 800, vs few months with the forging process.”

Part Information:

  • Measurements: 455x295x805 mm
  • Material: Titanium
  • Machine: SLM 800

This new design invented by Safran Landing Systems, meeting ambitious resistance and mass reduction objectives, is patented.

 

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Unlocking New Additive Applications In Asia With Chemical Vapor Smoothing

Unlocking New Additive Applications In Asia With Chemical Vapor Smoothing

Additive3D Asia in collaboration with Additive Manufacturing Technologies (AMT), jointly hosted their first webinar for the Asia Pacific region entitled “Unlocking New Additive Applications in Asia with Chemical Vapor Smoothing”.  Speaking at the session were Mr. Jason Joo, Co-Founder of Additive3D Asia and Mr. Joseph Crabtree, CEO and Founder of AMT.

The webinar addressed the current key challenges of 3D printing and the quality issues of 3D printed parts. AMT gave a deeper insight with actual case studies and demonstrated how AMT’s PostPro Chemical Vapor Smoothing patented technology can benefit users. This includes better strength, surface finishing, smoothness, and watertightness to the 3D printed part close like from injection moulding process.

To deliver a better 3D printing experience, Additive3D Asia who is AMT’s authorised PostPro Production Partner offers the Post Processing treatment as a Service to all customers in Singapore and across the APAC region.

Suitable for all Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS) and HP MultiJet Fusion (MJF) and other Powder Bed Fusion (PBF) technology, the Chemical Vapor Smoothing can now process up to 95 percent of the different 3D printing materials available in the open market. Varies industries from Aerospace, Automotive, Medical, Consumer Products, Lifestyles, Industrial and others will be able to experience up to 200 percent of return to their business by switching to this new post processing technology.

“Collaborating with Additive3D Asia is another example of AMT’s commitment to unlock the full potential of additive manufacturing across the globe. We are delighted to have Additive3D Asia as our first official production partner in Singapore and look forward to supporting their business growth and open up new opportunities for high-quality, customised applications,” commented Mr. Joseph Crabtree

To watch the recording of the webinar, visit: https://additive3dasia.com/vapor-smoothing/contact-webinar-recording/

 

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