Metal 3D Printing(AM) 효율적 활용 from Prototyping to ProductionE1... · 2018. 7. 20. · SLM Solutions is leading the Evolution of Metal Based Selective Laser Melting (SLM)

SLM Solutions is leading the Evolution of Metal Based

Selective Laser Melting (SLM) Manufacturing

from Prototyping to Production

김인명 / ㈜퓨전테크놀로지(FusionTechnology Co., Ltd) Tel : 031-342-6901, www.fusiontech.co.kr

위상촤적화와 Metal 3D Printing(AM) 제조기술의 융합과 효율적 활용

Understanding of 3D Printing Technology

피라미드의 건축 (적층조형방식의 시작 ; 3D프린팅의 시초??)

3D 프린팅기술??

Additive manufacturing : layer by layer ( by quad lasers )

Additive manufacturing : layer by layer

Basic understanding of Topology Optimization

4

Lessweight shape &

Lightweight structures are

inspired by nature:

1. Minimize the weight while

maintaining the stiffness

2. Create a better bone ingrowth

for medical purposes

This forms the basis for Altair’s topology (& morphology) optimization technology

Company Intro. SLM Solutions & FusionTechnology

Lübeck, Deutschland, 53° 52´ N, 10° 42´ O, MEZ

Germany´s city of science in 2012 !

Welcome to North Europe!! SLM Solutions Group AG

1996 – 1998 Basic Research F&S Stereolithography GmbH, Trumpf GmbH and Fraunhofer Institute for Laser Technology (ILT)

1998 – 2002 Fockele & Schwarze (F&S) research leading to IP with today more than 30 own patents and applications

2002 F&S/SLM Solutions(a) partner to develop, produce and market the SLM Technology to industrial requirements

2003 Launch of first Fibre Laser technology with the MCP SLM 250

2006 Launch of SLM 100 as an entry model

2007 Launch of the 400 Watt technology

2009 Launch of the new SLM 250HL

World Wide cross license agreement with Trumpf, EOS and Fraunhofer ILT

2011 Launch of SLM 125HL and SLM 280HL with hull and core (400W & 1000W) technology and 3D laser technology

2012 Introduction of SLM 500HL and the multi laser technology

2013 ~

Launch of SLM 500HL with additional automated powder handling devices, Quad Laser Technology for high productivity applications High Powered (multi) laser(s) for AM performance, Enhancing monitoring systems for secured AM production. -. 700W and high temperature heated patform (550℃), Small Volume Reduction Platform supplied

(a) In 2002 SLM Solutions Group was known as MCP. MCP changed its name to MTT Technologies Group in 2008. MTT Technologies GmbH, Lübeck was renamed into SLM Solutions GmbH in 2010

Source: Company information

SLM Solutions Group – History of Innovations

Powder bed fusion Thermal energy selectively fuses

regions of a powder bed Key technologies:

Selective Laser Melting, EBM

Prototyping, direct part

Metals, polymers

Directed energy deposition Focused thermal energy is used

to fuse materials by melting as the material is deposited

Direct part, repair

Metals

Sheet lamination Sheets of material are bonded

to form an object

Prototyping, direct part

Metals, paper

Binder jetting Liquid bonding agent is selectively

deposited to join powder material

Prototyping, direct part, casting molds

Metals, polymers, foundry sand

Material jetting Droplets of build material are selectively deposited

Prototyping, casting patterns

Polymers, waxes

Material extrusion Material is selectively dispensed

through a nozzle or orifice Prototyping Polymers

Vat photopolymerization Liquid photopolymer in a vat is

selectively cured by light-activated polymerization

Prototyping Photopolymers

(a) Powder bed fusion technology accounting for 77 % of metal based 3D systems sold as per CODEX Partners analysis Source: ASTM International Committee F42 on Additive Manufacturing Technologies; Roland Berger, CODEX Partners

Me

tal t

ech

no

logi

es

Technology Materials Typical markets Relevance for metal

Powder bed fusion technology is most relevant for metal 3D printing

Others

77 %(a)

18

Finish part with support structure welded on the

substrate plate

Powder Bed Fusion : SLM process

Powder bed fusion technology is most relevant for metal 3D printing

SLM_process.wmv.mp4

Laser Power: L

Scan Velocity: v

Hatch Distance: Δy

Layer Thickness: Δz

𝑬𝒏𝒆𝒓𝒈𝒚 𝑫𝒆𝒏𝒔𝒊𝒕𝒚 𝑬 = 𝑳/(𝒗 × Δ𝒚 × Δ𝒛)

Picture Source: FhG ILT Aachen

𝒗

Δ𝑦

Δ𝑧

Only need 4 parameters for optimal process!!

Impact on: • surface quality, mech properties, cost per part, detail

resolution, weight, density, build time, hardness, fatigue strength, thermal conductivity....

Key Parameters of the SLM Process

May 09. 2014 : IPO /stock market launch for SLM Solutions Group AG.

Strategic focus on metal based 3D printing, Selective Laser Melting (SLM)

SLM Solutions stands for technologically advanced, innovative and highly

efficient integrated system solutions with focus on part quality & function

SLM Solutions Group is already operating in all key industries

Multi-laser systems 60% of orders

267 installed SLM machines word wide until June 30, 2016

40% orders from existing customer base

70 % orders in the last 12 months for industrial application !

66

102

146

265

62 33

2014 2015

Sales (€) Machine Orders Employees

Machine Orders / Sales & Employees

SLM Solutions: leading provider of metal based of SLM - Selective Laser Melting “3D printing” machines

SLM Solutions Group has exposure to attractive end markets and has longstanding

relationships with blue chip customers

The market continues the shift from rapid prototyping to industrial applications

SLM Solutions Group is well positioned to capitalise on this trend given SLM Solutions'

technology and customer base

SLM Solutions Group is already operating in key industries

Selected blue chip customers

Aerospace Automotive

Healthcare Energy

GE Energy, Emerson, Alstom, Siemens P&W

and etc.

GE Aviation, Airbus, Boeing, Sintavia, Lufthansa

Teknik, Honeywell Aerospace, Safran, NASA

and etc.

BMW, Audi, VW, Toyota, Ford, Mercedes,

Bridgestone and etc.

BEGO, 3D Medical and etc.

More than 70 universities and research institutes

(e.g. RMIT (AUS), GIAT, NRIAM (CN) NTU,

NUS (SGP), Kinki University (J))

Citim, Fruth, Linear Mold, Polyshape, Innoshape

and etc.

KNU, KNUT, GJTP, Ulsan KITECH in Korea

and more worldwide,

Aviation

SLM Solutions Group is already operating in key industries

Headquarters

SLM Solutions – Subsidiary

Distribution partners

Lübeck, Germany

Moscow

Detroit

Shanghai

Singapore

Location and global sales, application and service footprint

Metal 3D Printing Technology : 3D printed car

Metal 3D Printing Technology : 3D printed car

Back to the core: What 3D printing is!!

Source : solidThinking/Inspire from Altair Technology Korea

Back to the core: What Additive Manufacturing is!!


Topology Optimization??

What Topology Optimization is!!

• 주어진 공간내 제품에 주어질 하중등을 고려한 디자인 문제에 대해, 재료 분포를 최적화 하는 수학적인 기법/알고리즘


Work Flow: Topology Optimization

스케치 또는 도면을 불러들이기

디자인 영역을 단순화 연결되는 부분을 설정 (Fasteners, Joints,

Contacts)

물성과 하중 적용

이상적인 최적화 형상 확인 성능 평가 부드러운 형상 생성 지오메트리를 추출하여 CAD에서 개선


from Topology Optimization -> LWS -> metal 3D printing

Design Space FEA TO Cleanup CAD or 3-matic

“Printable” design Topology Optimized Design (rough)

Simulation based redesign combined with in-house experience about AM process (printability)

Traditional CAE Design

Define build orientation

LWS region

Application and cellular sizing

Final stress evaluation

Finished ‘TOPAM’ design Source : Materialise 3-matic LWS

Manufacturing from SLM Solutions’

Metal 3D Printer

For successful applications of SLM metal 3D printing technology: from DfAM(Design for Additive Manufacturing) & SLM 3D printing

Part Integration Design

Topology Optimization Design

Lattice Structure Design

Topology Optimization: Idea of maximizing AM performance!!

디자인 문제를 해결할 수 있습니다. 고성능, 경량화, 보강, 재료 및 비용 절감 다양한 산업분야의 어떠한 제품도 형상을 바꾸고 부품수를 줄일 수 있습니다.


free from manufacturing limitation, needs to catch up by design innovation!!!

Manufacturing technology w.r.t Design technology.

Time

Com

ple

xity

Eff

icie

ncy

Design

Manufacture

BC Medieval Industrial revolution

1900’s 1950’s 2000’s 최근

?


Creative Higher Performance: 3D프린팅 & 위상최적화(solidThinking/Inspire)

이상적인 콜라보레이션 : TO for DfAM & AM 4 higher performance


AM Topology Optimization

자유로운 형상

특성있는 디자인

제품개발의 가속화

+

혁신적 (설계/제조) 기술

Topology Optimization Applications for Additive manufacturing

World air traffic over 24 hours!!

Aerospace projects 10.000,‒ € per Kg

Automobile industry 10,‒ € per Kg

Aircraft design 1.000,‒ € per Kg

The amount of money industries are willing to pay to safe 1 Kg

Challenge of weight reduction potential…

1) Quelle: GE Aviation

Weight

No. Of components

Durability

-25%

-95% 5x

18 components integrated as 1

Industrial revolution: Complexity through SLM Technology

Airbus Defence & Space : Multi-bracket mounting for telemetry & telecommand antennas for Eurostar 3000 satellite.

4 main parts & 44 rivets > 1 single piece, 40% stiffer & 35% lighter; aluminum alloy

SLM 3D printing technology & Optimized design – smart structure

Application

Aircraft: Airbus A380

Upper Deck Cabin Bracket

Connecting Crew Rest with Stringers

Lot Size: 1 part per aircraft

Conventional Design Bionic Design

Source: Airbus

Machined from Solid Block

Buy-To-Fly Ratio: 13 (17kg/1,3kg)

High Set-Up & Span Times

7000 Al Alloy

Source: Laser Zentrum Nord

50% Weight Reduction

Improved Buy-To-Fly Ratio: ~1-2

Build Time for 2 Parts: 41:23h

AlSi10Mg

SLM 3D printing technology & Optimized design: Aircraft applications – Bionic Cabin Bracket

1.2 kg 0.6 kg

1 kg = $3,000 fuel savings/year CO² emission reduced

SLM 3D printing technology & Optimized design: Aircraft applications – Bionic Cabin Bracket

Unlock the lightweight

potential of AM with

concept optimization

and

organic interpretation

at LZN

SLM 3D printing technology & Optimized design – smart structure

43% Mass Reduction

Topology Optimization Applications


55% Mass Reduction

45% Lighter than Original


Topology optimized structures are pretty good,

and lattice structures are able to make better:

Topology Optimization Applications (Morphology)

Walking Running

Topology & Morphology Optimization Applications

Creative Higher Performance: 3D프린팅 & more 위상최적화(solidThinking/more…)

이상적인 콜라보레이션 : D4E & next AM 4 better pleasure

from innovative designing

Source : solidThinking/Inspire & Click2 series from Altair Technology Korea

AM Design4Emotion

자유로운 형상



+


Creative Higher Performance: 3D프린팅 & more 위상최적화(solidThinking/more…)

이상적인 콜라보레이션 : D4E & Process 4 AM 4 better pleasure

from innovative designing

Source : solidThinking/Inspire & Click2 series from Altair Technology Korea

AM Design4Emotion

자유로운 형상



+


주소 : 경기도 안양시 동안구 시민대로 361 에이스평촌타워 1동 406호

TEL : 031-342-6901 FAX : 031-342-8264

Email : [email protected], www.fusiontech.co.kr (available from June 2017)

• Building up as solution provider of 3D printing technology for industry & medical

• 2016년 사무실이전(경기도 안양), “㈜퓨전테크놀로지”로 법인명 변경

• 2015년 “㈜퓨전테크”로 법인 전환

• 2008년 “퓨전테크” 설립 • 산업계 및 의료 및 의공학분야의 S/W & 3D Printer 솔루션 공급지원 업체

• Since 1991 3D프린팅장비 공급 및 활용지원

• SLM Solutions Group AG 3D프린터(SLM) 국내 공식 대리점

• Farsoon 3D프린터(SLS) 국내 공식 대리점

• Qubea 3D프린터(SLA) 국내 공식대리점

• RAISE3D 3D프린터(FDM) 국내 공식 대리점

• Materialise NV Mimics/3-matic S/W 국내 공식 대리점

• 한국알테어 국내 공식 대리점

• 기타 3D Printer 장비 외 관계 소프트웨어 Biz.

감사합니다!!! (주)퓨전테크놀로지

mailto:[email protected]

http://www.fusiontech.co.kr/

Superior Productivity of SLM Technology

Additive manufacturing : layer by layer ( by quad lasers )

Additive manufacturing : layer by layer

Additive manufacturing : bigger ( by SLM500 & SLM800 )

SLM Metal 3D Printers :: Better, Faster, Bigger, Automized,….

Superior factors of increasing productivity from SLM-machines

30 mm overlap

Laser #1

Laser #2

From Build chamber & Recoating process design ; Recoating over only build chamber (no powder feed cylinder)

From Recoating system ; Bi-directional recoating Dynamic powder recoating control Quick stroke recoating movement From Scanning Strategy ;

Scanning of overlapping zone by multi-lasers (SLM280 & SLM500)

From LASER ; Multi-lasers .up to 2x lasers @ SLM280 .hull & core lasers @ SLM280 .up to 4x lasers @ SLM500 Higher power lasers .400W / 700W / 1000W

Thanks to SLM metal 3D printing technologies!!!

C:/Alpha/SLM/SLM presentation/4x400Block.mp4

100%

Monolaser 400W

(a) Productivity accounted without powder deposition time

(b) Productivity depending on number of layers melted with 1000W laser (More suitable 세 build bigger section area part (Thicker part)

Source: Company information

Up to 200%

2x 400W 2 Scanner SLM 280HL

Up to 400%

4x 400W 4 Scanner SLM 500HL

1x 400W 1x 1000W 1 Scanner SLM 280HL

~150 – 300%(b)

2x 400W 2x 1000W 2 Scanner SLM 500HL

~300 – 600%(b)

Build rate(a)

Hull-Core Technology

Multiple laser

SLM Solutions Productivity: Innovations & advantages using multi-lasers technology

7000 m² production floor. Currently, world wide the biggest capacity for metal AM production!

FIT AG : Germany – 14x SLM500 for series mass production

Healthier & Better Safety of SLM Technology

Features

Explosion Protection Zone 21: occasional dust cloud; Zone 22: dust cloud not likely

Health & Safety: Explosion Protection

Features

• Dust free re-filling and sieving

• Safe powder handling

• Closed loop powder handling

Health & Safety: closed loop powder handling

Production Quality Monitoring & Controlling of SLM Technology

360° Quality

Management

Build Process

Operation

Material

Machine

Factory Acceptance Test Site Acceptance Test Preventive

Maintenance & Calibration

Powder Handling Concept Operator Qualification Working Instructions Facility Conditions

Certified Powder Quality Original Spare Parts High Quality Consumables

Process Intervention Control Build Job Documentation

LCS – Layer Control System LPM – Laser Power Monitoring MPM – Melt Pool Monitoring

SLM Solutions QM & QC: SLM 360° Quality Management Approach

Quality Control System

LCS Sensors

MCS monitoring and logging

Documentation

• The QCS includes 6 modules (caustic measurement and dynamic powder control not shown here)

• The modules are already in place, are being tested or in development. (√ : standard, √ : option)

• Display and processing is divided into internal monitoring and logging.

Status

√ √

Laser power

√

Melt pool

√

SLM Solutions: Quality Control System QCS module overview

Quality Control System: Dynamic Powder Recoating Control

5 cm3

5 0 10 20 15

• Reducing powder overdose

• Saving the powder amount to be exposed at atmosphere (minimizing oxydized)

• Cost reduction

• Conserve Mechanical Properties better

Features

More Flexibility of SLM Technology

Features

• Dia. 90 x 100 mm

• 550°C heated platform

• TiAl6V4 baseplate x 19mm thick

• Ceramic recoater

• High temperature material

processing

Flexibility: High Temperature Platform @SLM280

Flexibility: Smaller Chamber Size with same build size

no powder feed cylinders at left/right for recoating only build cylinder existing shorter preparation time to start building less inert gas consumption less possibility to leak to oxygen possible to equip gloves at the front door of the chamber to minimize operator’s direct contact to metal powder minimize the exposure of the recycling powders to atmosphere to avoid oxidization

Smaller build processing chamber size Features

• Open software for full control of

all process parameters

• Optimise scanning and exposure

parameters

• Protection of in-house know-how

Flexibility: SLM Build Processor Software

Benefits of SLM Metal 3D Printer

• Higher production performance (생산효율화) • from multi-lasers with bigger power • bigger building volume • bi-directional recoating ( maximize to save building time ) • efficient powder feeding system by controlling optimized dose of powder and more

• Automation of 3D printing process (자동화) • from powder supply and removal to support cleaning up • feasible to apply for serial production and more

• Security of product quality and healthcare (안정화) • supplying best ambient with good quality of inert gas in laminated flow • many (monitoring &) controlling system provided ( layer, laser, melting pool,…) and

more

• Others (다양화 & 유연화 등) • selectable production options ( build time / material consumption / saving laboring,…) • more flexible with HTH(High Temp. Heating) / SBVR(Small Build Volume Reduction),… • Possible to control build parameter for each individual part on the same layer & more

March 12th 2015

Business Development – Automotive/ Medical/ Aerospace

Source: web

March 12th 2015


Source: web

March 12th 2015


Source: web

주소 : 경기도 안양시 동안구 시민대로 361 에이스평촌타워 1동 406호

TEL : 031-342-6901 FAX : 031-342-8264

Email : [email protected], www.fusiontech.co.kr (available from June 2017)

• Building up as solution provider of 3D printing technology for industry & medical

• 2016년 사무실이전(경기도 안양), “㈜퓨전테크놀로지”로 법인명 변경

• 2015년 “㈜퓨전테크”로 법인 전환

• 2008년 “퓨전테크” 설립

• 산업계 및 의료 및 의공학분야의 S/W & 3D Printer 솔루션 공급지원 업체

• Since 1991 3D프린팅장비 공급 및 활용지원

• SLM Solutions Group AG 3D프린터(SLM) 국내 공식 대리점

• Farsoon 3D프린터(SLS) 국내 공식 대리점

• HP 3D프린터 국내 공식 대리점

• Qubea 3D프린터(SLA) 국내 공식대리점

• RAISE3D 3D프린터(FDM) 국내 공식 대리점

• Materialise NV Mimics/3-matic S/W 국내 공식 대리점

• 한국알테어 국내 공식 대리점

• 기타 3D Printer 장비 외 관계 소프트웨어 Biz.

감사합니다!!! (주)퓨전테크놀로지

mailto:[email protected]

http://www.fusiontech.co.kr/

Metal 3D Printing(AM) 효율적 활용 from Prototyping to ProductionE1... · 2018. 7. 20. · SLM Solutions is leading the Evolution of Metal Based Selective Laser Melting (SLM)

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