Tips for Additive Manufacturing in Metal
Aug 20, 2015
Tips for Additive Manufacturing in Metal
This webinar will be available afterwards at
designworldonline.com & email
Q&A at the end of the presentation
Hashtag for this webinar: #DWwebinar
Before We Start
Moderator
Leslie Langnau Design World
Presenter
Tom Pasterik ExOne
About ExOne
• ExOne is a leading additive manufacturing
company dedicated to the industrial manufacturing
sector.
• ExOne is a global supplier of industrial 3D printing
systems and offers design and manufacturing
services of 3D printed products.
• ExOne Production Service Centers are located
throughout the United States, Germany and Japan.
• ExOne systems are able to print in a variety of
industrial materials with the largest available build
sizes.
ExOne Global Facility Locations
Products Produced
ExOne Overview
Distinctive Technology Features
• Largest build envelopes available
• Finely detailed complex shapes
• Print Speed
• Final Product Accuracy
• Industrial Grade Materials
Direct Metal Process - ExOne offers digital part materialization in several metals and metal
alloys, including:
- Additional material systems are currently in development, and
partnership opportunities are available for specific materials.
- The 3D printing process in metal includes printing, curing, depowdering,
sintering, infiltrating and annealing.
- Build Volume (WxDxH): 780 x 400 x 400 mm (30.7 x 15.75 x 15.75 in.)
- Build Speed: 6 mm/hr (.24 in/hr)
• 316 Stainless Steel Infiltrated with Bronze
• 420 Stainless Steel Infiltrated with Bronze
• Iron Infiltrated with Bronze
• Bonded Tungsten
In Direct Metal - Sand Process - ExOne offers digital part materialization in various
combinations of sand casting media and chemical binders,
depending on the desired strength and level of detail:
- Digital production of sand molds and cores eliminates the
need for hard tooling and drastically reduces lead times.
- Standard foundry industry materials are used, enabling easy
integration of the molds and cores into existing manufacturing
and foundry procedures.
- This digital process offers design freedoms not possible in
molds and cores produced using the traditional pattern
approach.
- Build Volume (WxDxH): 1800 x 1000 x 700 mm (70 x 39 x 27 in.)
• Silica Sand
• Synthetic Sand
• Other casting media
ExOne Systems
M-Lab M-Flex M-Print
S-Print
S-Max
ExOne’s Process
ExOne’s Process
ExOne’s Process
Optimizing for Manufacturing
• With simple changes such as automated transfers and print run
layout, an additive manufacturing production process can be
optimized to maximize output.
ExOne in a Factory Environment
Advantages of Additive Manufacturing
• The digital process offers design freedoms not possible in
traditional molds, cores and machining approaches
• Endless patterns and part geometry
• Functional working prototypes for real life applications
• Prototyping can turn directly into low or high volume
production runs
• Draft angles can now be eliminated
• No tool paths or tooling required
• Advanced venting schemes and integrated rigging
features are also possible
• Different parts can be built in a single print bed
• Parts can be modified on the CAD file in seconds, and
reprinted without complicated tooling changes.
Project Overview
• Advance optimization of a traditionally manufactured control arm from a domestic super car by using additive
manufacturing processes.
• Push the boundaries of 3D metal printing and design inside a real and applied production workflow with
practical outcomes.
• Examine existing and heavily optimized designs made using traditional methods and see if they can be
optimized even further using new modeling approaches.
• Develop new workflows and processes that can directly capitalize on the many benefits that 3DP offers.
• Reduce weight while still retaining the same structural properties of the what is said to be “already optimized”
traditional control arm.
The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part for three different 3DP
workflows:
• Printed sand mold package for traditional
foundry casting
• Conservative/constrained direct metal
printing
• Unlimited direct metal printing
The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part for three different 3DP
workflows:
• Printed sand mold package for traditional
foundry casting
• Conservative/constrained direct metal
printing
• Unlimited direct metal printing
Unlimited Variable Geometry
Finding the Best Internal Structures
Initial Reference for Cellular Structure
Base Model Control Arm
Indirect Metal Printing Process and Cast
Advanced Control Arm Is Modeled with Free Constraints
Advanced Model Passes Simulation: Export
Direct Metal Printing Process
Direct Metal Printing – Final Product
Direct Fabrication
Project Specifications
Next Steps – Advanced Designs w/ Automatic Closed Loop Simulation Feedback
Services
Questions?
Design World Leslie Langnau [email protected] Phone: 440.234.4531 Twitter: @DW_3DPrinting
ExOne Tom Pasterik [email protected] Phone: 724.765.1361 www.exone.com
Thank You
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