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Gravity Pull Systems Introduces Industrialised MES Solutions For AM Processes

Gravity Pull Systems Introduces Industrialised MES Solutions For AM Processes

Gravity Pull Systems, Inc., the enabler of industrialisation in additive manufacturing has launched an integrated Schedule Optimiser and MES system that provides a simple solution to a highly complex problem:

While most of existing solutions for Planning/Scheduling and Manufacturing Execution Systems (MES) require a special process design to meet relevant requirements for AM processes, Gravity’s product suite Synoptik provides a technology that enables best economics of scale and supports profound digital transformation in additive manufacturing.

The Synoptik product suite provides an all-in-one solution, enabling

  • Holistic process planning across entire manufacturing processes, including post-processing with the objective to achieve the most optimal levels of material consumption, material re-use and capacity utilisation
  • full transparency and traceability by a 24/7 total view on each & every process step
  • industry-specific Audit & Compliance conformity for Aerospace, Automotive, Automation and Medical industries
  • significant cost savings by reduced manufacturing costs while ensuring sustainability

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Industrial And Manufacturing 2021: The Year For Additive, Digital Threads, And Industry 4.0

Industrial And Manufacturing 2021: The Year For Additive, Digital Threads, And Industry 4.0

In its new whitepaper, 68 Technology Trends That Will Shape 2021, ABI Research identify 37 trends that will shape the technology market and 31 others that, although attracting huge amounts of speculation and commentary, are less likely to move the needle over the next twelve months. “For success in 2021, especially after a very challenging 2020, one must understand fundamental trends early, and take a view on those trends that are buoyed by hyperbole and those that are sure to be uncomfortable realities. Now is the time to double down on the right technology investment,” says Stuart Carlaw, Chief Research Officer at ABI Research.

Additive Manufacturing Software Innovation Will Play Catch Up

“Additive Manufacturing (AM) is an ecosystem starting to open to third-party developers, and we will see this in 2021 with broader support for AM systems in IoT platforms, a much greater emphasis on simulation and integration of process parameters, and a market that will start to realise the disparity between hardware and software innovation and react with new solutions, and new programs that improve awareness, education, and integration. The reason these actions are inevitable is that production AM simply cannot happen without them,” says Ryan Martin, Industrial & Manufacturing Research Director at ABI Research.

Simulation Will be the Needle for Digital Threads

Manufacturers and industrial firms have been focusing efforts on creating a digital thread that keeps data flowing in a continuous loop between the engineering, manufacturing, and fulfillment teams. “However, in the face of the COVID-19 pandemic, digital threads failed to anticipate demand surges because machine learning was looking at historical patterns and did not provide firms with the ability to maintain production. In 2021, simulation will provide firms with an overview of their operations and stress test them to build resilience. Projects will look to simulate scenarios and run what-if analysis that covers both downstream events (in end markets or individual customers) and upstream events to simulate how to accommodate supply chain events in engineering and production departments,” explains Michael Larner, Industrial & Manufacturing Principal Analyst at ABI Research.

Smart Manufacturing Builds Momentum

“Smart manufacturing will continue to build on its momentum in 2021, but not until factory owners embrace 5G for their smart factory connectivity layer will they reap the operational benefits. Factory owners have been deploying industry 4.0 tools, such as condition-based monitoring, inventory management, and building automation using ethernet cable, but deploying wireless-enabled Industry 4.0 tools will bring smart manufacturing to its full potential. Applications like wearables (health and location/safety trackers) and AR are only possible with wireless connectivity,” states Jake Saunders, Vice President at ABI Research.

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Lightning Fast 3D Printing: SLM Solutions Prints E-Drive Housing From Porsche On NXG XII 600

Lightning Fast 3D printing: SLM Solutions Prints E-Drive Housing From Porsche On NXG XII 600

Has metal 3D printing arrived in the manufacturing industry and is the technology ready to enter serial production? What does it take to make the leap to industrialisation?

With its recently launched innovative SLM machine NXG XII 600, SLM Solutions provided an answer to these questions. The machine sets new milestones in terms of productivity, size, reliability and safety and paves the way to the future of manufacturing. Now, SLM Solutions presents application examples, produced on the NXG XII 600, which impressively illustrate the speed and productivity of the machine to reduce part costs.

The NXG XII 600 is equipped with twelve overlapping 1 kW lasers and a build envelope of 600x600x600 mm, enabling the production of large-volume square parts with up to 120 µm layer thickness and even more. Productivity is further enhanced through variable beam spot, bi-directional recoating, laser balance and an optimised gas flow while a closed environment maximises operator safety.

One company that has already tested the productivity of the NXG XII 600 is Porsche. The Porsche advanced powertrain engineering department also focuses on large powertrain applications, such as E-drive housings, cylinder blocks, cylinder heads etc. in additive manufacturing. In a proof of concept with the SLM machine NXG XII 600 a complete E-drive housing with an innovative AM Design was successfully printed. Porsche thereby sets high quality demands on the part: A permanent magnet motor with 800 volt operating voltage delivers up to 205 kW (280 hp). The downstream two-stage transmission is integrated in the same housing and drives the wheels with up to 2,100 Newton meters of torque. This highly integrated approach is designed for use on the front axle of a sports car.

All the advantages of additive manufacturing have been implemented in this housing such as topology optimisation with lattice structures to reduce the weight, functional integration of cooling channels, higher stiffness and reduced assembly time by the integration of parts as well as improvements in part quality.

Falk Heilfort, powertrain development engineer of Porsche states: “This new manufacturing technology is technically and economically interesting for us. Possible use cases are especially prototypes in the development phase, special and small series production as well as for motor sport and classic spare parts.“ The E-drive unit measures 590 x 560 x 367 mm and was built in only 21 hours on the NXG XII 600.

Ralf Frohwerk, Global Head of Business Development of SLM Solutions, is delighted with the excellent results of the Porsche part: “We are glad and proud to cooperate with highly innovate companies like Porsche. The NXG XII 600 achieves unmatched levels of performance and functional improvements of key automotive parts while delivering cost productivity that enables broad use of additive manufacturing technology for true series production. We are thrilled to take this big step towards full industrialisation of metal additive manufacturing for Porsche applications.”

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Review: The Future Of Additive Manufacturing In Southeast Asia

Review: The Future Of Additive Manufacturing In Southeast Asia

Asia Pacific Metalworking Equipment News (APMEN), in conjunction with SLM Solutions, SIEMENS, Universal Robots, Markforged, NAMIC, and GlobalData held a two-part webinar on 24 Nov and 15 Dec 2020 aimed at helping manufacturers understand 3D printing better and gather insights on the way forward for additive manufacturing (AM) in Southeast Asia.

In the first session on 24 Nov with SLM Solutions, SIEMENS and Globaldata, we looked at where the pandemic has left the AM industry in 2020; key considerations towards successful adoption; case studies which showcased the flexibility and agility of AM in the fight against the pandemic. Click here to view its recap as well as watch the playback of the session. 

We picked up from where we left off in our second session on 15 Dec with Gary Tang, Regional Sales Director, at SLM Solutions Singapore; Li Chen, Application Engineer, APAC, at Markforged; James McKew, Regional Director, APAC, at Universal Robots; and Dr. Ho Chaw Sing, Managing Director at the National Additive Manufacturing Innovation Cluster (or NAMIC).

In a lively roundtable discussion, we addressed burning questions like how AM is a strategic differentiator in today’s manufacturing environment, how it presents unique opportunities and the future developing trends. Other discussion highlights include how to justify investments in 3D printing technologies, and the importance of partnering with the right companies or organisations, because AM is a very fast growing technology and no one company knows everything.

View the full webinar here!

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Recap: Additive Manufacturing Deployments In Southeast Asia

Recap: Additive Manufacturing Deployments In Southeast Asia

Amid the ongoing global health issue, additive manufacturing (AM) or 3D printing is proving in real time that it is speeding production and bringing new ideas to the market at a lower cost to deliver the needed healthcare equipment and devices the world desperately needs.

In market research released earlier this year, Grand View Research Inc. reported that the overall additive manufacturing industry is projected to reach $35.38 billion by 2027, growing at a compound annual growth rate of 14.6 percent over the same forecast period. However, the 3D printing industry still has its share of challenges, such as efficiency that the process yields, the machines, and materials.

In line with this, Asia Pacific Metalworking Equipment News (APMEN), in conjunction with SLM Solutions, SIEMENS, Universal Robots, Markforged, NAMIC, and GlobalData held a two-part webinar aimed at helping manufacturers understand 3D printing better and gather insights on the way forward for additive manufacturing in Southeast Asia.

In the first installment of the two-part webinar on 24 November 2020 with SLM Solutions, Siemens and Globaldata, we covered the different AM deployments in Southeast Asia, the process challenges, and the key considerations toward successful adoption.

Watch the round table discussion during the second session held on 15 Dec with SLM Solutions Singapore, Markforged, Universal Robots NAMIC here! 

Where has COVID-19 left us in 2020?

Opening the session with a keynote presentation, David Bicknell, Principal Analyst, Thematic Research at Globaldata gave an insightful overview of where the pandemic has left the additive manufacturing industry in 2020. He discusses the impact of the pandemic, developments in AM and opportunities for ASEAN.

With the pandemic paralysing supply chains, David also highlights how 3D printing can be the solution to building more resilient supply chains and how more companies are embracing 3D printing. He also covered briefly insights from HP which examines the current perception of digital manufacturing.

3D printing has proved to be a source of optimism, and David rounded the session by sharing innovative feats during this challenging environment such as biomimetic tongue surfaces and printed door handles. Where would 3D printing bring us in 2021?

Key Considerations for Successful AM Adoption

Lu Zhen, Lead Application Engineer at SLM Solutions Singapore, speaks about successful AM adoption and projects worldwide—such as the 3D printed titanium brake caliper for Bugati race car—the different stages of AM adoption and market growth, and four key considerations for successful AM adoption: design, in terms of effectiveness and weight; material strength and compatibility; process scalability and repeatability; and economics or cost.

Lu also speaks about factors that would enable increasing adoption and industrialization of AM, such as systematic qualification processes and standards, specialised knowledge, IP, and having a mature supply chain.

Finally, he presents some of the AM projects in Southeast Asia, such as the anti-cavitation trim for EMERSON; core insert for plastic injection mould, for OMNI MOLD; impellers for maritime application, for ShipParts.Com; motor mount base and clutch for race cars, in collaboration with Nanyang Technological University (NTU) of Singapore; and a battery hull for submarine robots, developed in collaboration with the National University of Singapore (NUS).

3D Printed Face Shield

While the ongoing COVID-19 pandemic has stalled manufacturing activities worldwide, it has, at the same time, highlighted the speed and flexibility of 3D printing to create and deliver the desperately needed healthcare equipment and devices.

For instance, it has provided Siemens and its Industry 4.0 partners an opportunity to combine their strengths to locally develop and manufacture a face shield designed by Singapore’s Tan Tock Seng Hospital using additive manufacturing. This fully local collaboration saw Siemens’ Advance Manufacturing Transformation Centre (AMTC), supported by the Agency for Science, Technology and Research (A*STAR), HP’s Smart Manufacturing Applications and Research Centre (SMARC), and Mitsui Chemicals come together to design, optimise and manufacture the face shields in an accelerated product introduction cycle of under two months.

Benjamin Moey, Vice President, Advance Manufacturing, for ASEAN, at Siemens Pte Ltd, and also the head of Siemens’ AMTC, talks more about this in his presentation, as well as demonstrated the actual 3D-printed face shield.

Wrap Up

The webinar closed the session with a lively Q&A session between the three presenters—SLM’s Lu, Siemens’ Boey, and GlobalData’s Bicknell—with attendees asking questions on simulation technology related to 3D printing; 3D printing software; injection moulding versus 3D printing (in case of the face shield); availability of material base supply; best ways service bureaus can market themselves to attract AM clients; and whether AM will finally see the day it will be used for mass production.

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TRUMPF Presents New Solutions For Latest Trends In 3D Printing Industry

TRUMPF Presents New Solutions For Latest Trends In 3D Printing Industry

TRUMPF is increasing automation and process speeds in its additive manufacturing technologies – and its “green laser” is fueling new applications by enabling 3D printing of pure copper and precious metals. At the formnext Connect virtual trade fair, the company is showcasing new solutions for three key industry trends: speed, automation and new materials.

“The additive technologies market remains very attractive for TRUMPF,” says Klaus Parey, managing director TRUMPF Additive Manufacturing. “Customers are particularly excited by our TruPrint 1000 machine with a green laser beam source, which is designed for industrial use. Short-wavelength green laser light is the best option for welding pure copper and precious metals.” TRUMPF has made major progress in its products and solutions for additive technologies over recent months, building up a broad portfolio of products that can handle a wide variety of materials.

Process speed: new nozzle doubles coating rate

TRUMPF has developed a new nozzle technology that increases the coating speed to well over 600 square centimeters a minute, even reaching speeds as high as 1,000 square centimeters a minute in certain applications. The secret lies in using more powder, higher laser power and a nozzle designed specifically for industrial use. Applying a coating faster obviously means using more powder. But using more powder only works if it can be melted fast enough. That’s where the second ingredient in the mix comes in: higher laser powers of up to 8 kilowatts. Yet these high laser powers can only be used in tandem with a robust, properly cooled nozzle. And it’s exactly this combination that TRUMPF has brought together in its new nozzle technology, which enables significantly higher coating speeds than ever before – especially for rotationally symmetrical parts.

Automation: new depowdering station gets parts cleaner

To boost the productivity of additive manufacturing even further, TRUMPF is working hard to find ways of improving upstream and downstream work steps in the overall process chain. At formnext, the company will be showcasing a new depowdering station for the powder bed-based additive manufacturing process of laser metal fusion (LMF). This system unpacks and depowders 3D-printed metal parts, combining two process steps in one machine. Previously these steps had to be carried out manually by a machine operator using suction nozzles and brushes. But the new depowdering station makes these steps considerably simpler by introducing a degree of automation. The system turns the printed part upside down and, if necessary, starts to vibrate, until almost all the excess powder has been removed. This new depowdering process does a considerably better job of removing excess powder from the finished part.

Diverse materials: green light for copper, gold and platinum

At the formnext fair held two years ago, TRUMPF demonstrated for the first time how a disk laser in the green wavelength range can be used to print pure copper and precious metals. Conventional 3D printers that use infrared light can’t handle materials such as copper and gold, because their highly reflective surfaces prevent melting from taking place. But because green light has a much shorter wavelength than infrared, it opens the door to 3D printing of pure copper and precious metals. Since its launch, TRUMPF’s TruPrint 1000 Green Edition has carved out a solid position in the market and enjoyed tremendous success.

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SLM Technology Opportunities For Healthcare Applications

SLM Technology Opportunities For Healthcare Applications

Find out why selective laser melting is the ideal production technique to integrate function into medical device components. Article by Gary Tang, SLM Solutions.

Medical device manufacturers are increasingly adopting metal additive manufacturing technology of SLM Solutions—the pioneer and one of the inventors of selective laser melting (SLM) technology—to produce a wide range of medical and dental parts.

In the healthcare sector, SLM technology is used to manufacture functional prototypes for the serial production of surgical implants, to manufacture new designs of instruments and equipment, or utilized for mass customization, i.e. the production of patient-matched implants and prostheses on a large scale. Dental prosthetic components, and orthopaedic, spine and cranio-maxillofacial implants are all common applications of the SLM technology, with clear benefits to patient outcomes. 

Selective laser melting is the ideal production technique to integrate function into medical device components, such as printing surgical implants with lattice structures for enhanced osseointegration and reduced stress shielding. Designs optimized for SLM process, and those custom to patients’ anatomy, often create complex, bionic geometries only able to be manufactured with selective laser melting. The technology thereby provides productivity and cost advantages to users.

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Siemens Collaborates With Morf3D To Accelerate Adoption Of Metal AM

Siemens Collaborates With Morf3D To Accelerate Adoption Of Metal AM

Morf3D is collaborating with Siemens Digital Industries Software to promote the use of additive manufacturing (AM) in advanced design, engineering, and production qualification of metal-based product innovations across a variety of industries. This collaboration equips Morf3D with Siemens’ end-to-end AM software solution from the Xcelerator portfolio and makes Morf3D a preferred Siemens AM partner with access to software in advance of the market. In exchange, Morf3D will provide technical feedback to enhance Siemens’ product development.

“The goal of this agreement is to facilitate the advancement of an end-to-end digital solution and develop new strategies for advanced engineering and design,” said Morf3D CEO Ivan Madera.

“By partnering we can leverage our unique integrated system of work to accelerate the adoption of additive manufacturing for development and production of new applications in a variety of industries. Siemens and Morf3D make a good team to accomplish this goal. Siemens has the end-to-end software to drive applications from design through 3D printing, and Morf3D has the expertise in AM operations to leverage that software so we can qualify and deliver those applications with optimal efficiency.”

“Additive manufacturing is a viable technology for innovation in all industries. But, to achieve truly industrialised AM production takes more than technical capability. The industry needs partnerships like our collaboration with Morf3D, where ideas, know-how, AM technology, software and most importantly, people, come together to advance the art of the possible by rolling up their sleeves and fully delivering on new and inspiring applications,” said Aaron Frankel, Vice President of the AM Program for Siemens Digital Industries Software.

“The COVID-19 pandemic has amplified the importance of additive manufacturing as a technology for rapid-response innovation. However, the financial uncertainties brought on by the pandemic have made it more difficult for companies to invest in AM operations and application development. We want to help those companies by giving them the resources and know-how they need to realise their dreams for additive manufacturing,” said Madera.

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Where 3D Printing Makes Sense

Where 3D Printing Makes Sense

Here’s a look at how Paul Horn GmbH got its start in additive manufacturing. 

Even complicated shapes can be produced relatively easily with 3D printing.

Paul Horn GmbH launched its additive manufacturing project in spring of 2018, which led to the creation of a dedicated “selective laser melting” production area. Now, the tool manufacturer uses additive manufacturing to produce its own tools—particularly prototypes, special tools and tool holders—and to optimise coolant attachments. Having recognised the advanced possibilities offered by additive manufacturing, Horn is making these available to its customers and partners as well.

“We were captivated by additive manufacturing right from the start, and so we kept a very close eye on advances in the area of 3D metal printing. As soon as the technology had matured to the point where we could use it to manufacture precision tools, we bought our very first system,” Matthias Rommel, Managing Director of Horn, explains. “Originally, we purchased the machine for the R&D area so that we could make special tools and prototypes. During the initial period, we found that we were constantly having discussions with our customers about 3D printing. To begin with, these were purely technical; but as time went by, they led to more and more concrete enquiries for 3D-printed components. Due to the strong interest from customers, we eventually came up with the idea of setting up an additional contract manufacturing business unit for additively manufactured components. In terms of technology, we opted for a DMG Mori LASERTEC 30 (2nd generation).”

It makes sense to use additive manufacturing if it generates a technological advantage. However, in many cases, there is no economic benefit to using additive manufacturing for a component that used to be produced by conventional methods. One example would be a turned part that can be produced relatively quickly on a Swiss-type lathe. Not only that, but additive manufacturing would also be too expensive in terms of post-processing. Other disadvantages compared to conventional production include relatively poor surface quality (Rz 30 µm), accuracies down to only ±0.1 mm, and the high cost of powder compared to bar. 

Greater Design Freedom

As the complexity of a component begins to rise, additive manufacturing becomes more relevant. This may be driven by the need for lightweight design, special cooling channel layouts and small batches of components with highly complex geometry. Consequently, the disadvantages have to be weighed against the benefits of greater design freedom, lightweight construction, quick adaptability and speedier production for more complex parts. In the future, it therefore makes sense for this option to be included in the preliminary considerations as part of each design process.

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Simulation Irons Out Metal Binder Jetting Defects To Enable Mass-Production AM

Simulation Irons Out Metal Binder Jetting Defects To Enable Mass-Production AM

Simufact, part of Hexagon’s Manufacturing Intelligence division, has introduced metal binder jetting (MBJ) simulation, that is enabling manufacturers to predict and prevent the distortion that sintering processes will have on parts at the design stage for the first time. The new simulation tool marks a significant step forward for additive manufacturing because it helps manufacturers achieve the quality they require while exploiting the unique benefits MBJ offers for volume production.

Metal binder jetting is an emerging additive manufacturing technology that has several key advantages over common powder bed fusion processes; high volumes of parts can be printed with minimal spacing; no support structures are needed, and larger lot sizes are possible. It has the potential to replace low-volume, high-cost metal injection moulding for everything from automotive and aircraft parts to medical applications. Because high resolution is possible, it could also reduce the cost and lead times for production of complex and lightweight metallic parts such as gears or turbine wheels.

However, early adopters can expect a steep learning curve to learn how to achieve the quality they need to exploit these benefits. One key challenge has been predicting changes during the sintering process. A part can shrink as much as 35 percent and the simple shrinkage models used for other processes cannot predict distortion during the post-build sintering process. Until now, costly physical trials were required to perfect the printing of each part, preventing many manufacturers realising the low cost and flexibility MBJ offers.

Made available to existing Simufact Additive customers in August, the new tool extends its capabilities for MBJ processes. Manufacturers can predict the shrinkage caused by factors such as the thermal strain, friction, and gravity during sintering without specialist simulation knowledge. By compensating for these changes, parts can be 3D Printed as they are designed, and production teams can significantly reduce the proportion of parts that must be scrapped or re-processed. Sintering-induced mechanical stress is also predicted before print, indicating where defects might occur. Manufacturers can use this information to make changes earlier in their product development and reduce the need for costly redesign.

Designed for busy manufacturing professionals, the tool can automate the model setup, preparing the CAD or CAE file for manufacturing simulation and simulations can also be automated through Python scripts. To validate the sintering compensation and increase confidence in quality, the optimised geometry from the MBJ tool can be immediately compared to both the initial design (CAD) geometry and a metrology scan of a manufactured part within user interface.

“We are pleased to introduce the first solution for simulating metal binder jetting sintering process to the market so that manufacturers can take advantage of this important new method. We know customers see metal binder jetting as a pivotal technology for manufacturing, particularly where there’s a need to need to produce intricate parts at high volumes like the automotive industry.

This development was only possible through close collaboration between our manufacturing and printer equipment partners and our highly experienced research & development department,” said Dr. Gabriel McBain, Senior Director Product Management, Simufact & FTI.

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