ACAM Additive Manufacturing - how to successfully adopt ... · Additive Manufacturing - how to successfully adopt the possibilities of the manufacturing processes of the future

ACAM

Additive Manufacturing - how to successfully adopt the possibilities of

the manufacturing processes of the future.

Dr. Kristian Arntz

Fraunhofer-Institute for Productiontechnology IPT | ACAM Aachen Center for Additive Manufacturing | WBA Aachen Tooling Academy

Formnext Forum Tokyo 2019

Aachen Center for Additive Manufacturing | RWTH Aachen Campus Seite 2

Engineering Valley - The RWTH Aachen University Campus

A unique research environment

Campus Melaten 2012

Campus Melaten 2016

Broad engineering portfolio tailored to

industrial needs

Trust is the key! Infrastructure and expertise

is not enough

Systemized learning

RWTH Campus GmbH

RWTH Campus GmbH


Additive Manufacturing at the RWTH Aachen Campus

Nowadays – Cluster Photonics

More than 100 researchers dedicated to AM

200+ years of person years in R&D experience

3,000 m² AM lab space

Design, post-machining and testing facilities

25 systems for metal AM, 15 for polymers

L-PBF, DED, SLS, SLA, EBM, FDM

16 Mio. € yearly overall AM budget

40% industry share

RWTH Campus GmbH



R&D Stakeholders

University, research institutes and spin-off companies in Aachen

Primary contact partner for Additive Manufacturing

We pool resources and facilitate the access to the Additive Manufacturing expertise of the

leading scientific and research institutions the RWTH Aachen Campus for the industry

Provides opportunities for joint R&D, a sophisticated training and education program, as well as an

online platform enabling industrial members to build business connections.

Research Partners at the



Highlights in research, development, patent and cooperation

Basic Patent

for SLMFirst Tool

Insert

First Implant

First Hybrid

Machine Tool

1995

1997

2001 2008

2015

Foundation

of ACAM

The cradle of

metal AM

The world‘s most vivid

and multifaceted AM

ecosystem



Some highlights in research, development and cooperation in Aachen

1997: Basic patent for SLM

Development and patent of laser

based powder bed fusion of metals at

Fraunhofer ILT

2015: Foundation of ACAM

With 14 research partners and a

growing number (now 38) of industrial

members AM is being industrialised

2016: LMD ten times faster

Development and patent of High

Speed Laser Metal Deposition (EHLA)

at Fraunhofer ILT

1995: First hybrid machine tool

Development and patent of „Controlled

Metal Buildup CMB“ at Fraunhofer IPT


Technical Perspective

Additive Manufacturing is a huge bundle of technologies

Prototype

mobile phone case

Prototypes drive,

coke bottle

Models for

foundingTools

Tooth crown,

hearing aid jacket

Procedure

Typical application

Application

»Prototyping«

Material

Quality of component properties

»Manufacturing«

3DP

Plastics Plastics Plastics,

wax

FDM

Laser sintering

SL3DP SL

Laser sintering

3DP SLA

FDM

Laser sintering/

-melting

EBM

LMD Laser sintering/

-melting

LMDWax pressure

Polymer pressurePolymer pressurePolymer pressure

Metals Metals Metals

PlasticsPlastics

Sands / ceramicsCeramics

SL3DP

EBMFDM

Laser sintering

Concept models/

geometry modelsFunctional models

Prototype-

tools Direct Tooling

Direct

manufacturing

FDM

Source: 3DP: Binder Jetting, SL: Stereolithographie, FDM: Fused deposition modeling, LMD: Laser metal deposition, EBM: Electron beam melting



What distinguishes this new paradigm of production?

Images: iLAS, Fraunhofer ILT, Fraunhofer IWU, Fraunhofer IFAM; Fraunhofer IPK, Concept Laser, DMRC

Complexity

Light-weight design by optimized topology

Function integration

Individualization

Individual patient implants

The consumer as a designer



What distinguishes this new paradigm of production?

Source: Fraunhofer ILT

Cost

Weight reduction

Conventional

manufacturing

„Weight Reduction for free“

© Fraunhofer ILT © Fraunhofer ILT

Cost

Lot size

„Individualization for free“

Additive

manufacturing

© Fraunhofer ILT © Fraunhofer ILT

Cost

(Product-) Complexity

„Complexity for free“

Additive

manufacturing

© Fraunhofer ILT© Fraunhofer ILT


Economical perspective

The potential of Additive Manufacturing

51%Polymer

Metal19,8%

Metal and

Polymer 29,2%

The global market volume of products and services in the

field of Additive Manufacturing will increase to € 15.8 billion

by 2020.1

15,8 Bi. €UP

20154 Bil. €

20176 Bil. €

202015,8 Bil. €

Quelle: 1Wohlers Report 2019; Bildquelle: trumpf.com


Economical perspective

The potential of Additive Manufacturing

51%Polymer

Metal19,8%

Metal and

Polymer 29,2%

The global market volume of products and services in the

field of Additive Manufacturing will increase to € 10.8 billion

by 2020.1

15,8 Bi. €UP

20154 Bil. €

20176 Bil. €

202015,8 Bil. €

Quelle: 1Wohlers Report 2019; Bildquelle: trumpf.com

It is estimated that AM accounts for 0.077% of all manufacturing, which in turn accounts for $12.8 trillion globally.

As AM is evolving, this market share is expected to reach a few percent over the next decade.

A 5% market share for AM would result in a $640 billion market in today’s numbers.


AM Numbers and Facts

Materials Revenue

Source: Wohlers Report 2018

0

200

400

600

800

1000

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

Re

ven

ue

s i

n M

io. $

Year

Plastics & Other

Metal

The market volume of AM materials is strongly growing and the range

of available materials is constantly broadening.


AM Numbers and Facts

Systems Market after Expiration of Key Patents

Patent: US5121329 A

Published: 30-Oct-1989

Expired: 2009

Over a short timeframe after

the expiration of patents, 29

companies have entered the

market offering FDM

machines.

No comparable development as with FDM. SLS is more complicated and requires expert knowledge in

order to develop new systems.

Patent: US5597589

Published: 31-May-1994

Expired: 28-Jan-2014

FD

MS

LS

SLM Patent: DE19649865

Published: 2-Dec-1996

Expired: 2016

Key patents as well as technological barriers

are relevant for the AM systems market.

Industrial Machine Desktop Printer

… …

Experts expect a considerable increase in market participants due to the high market attractiveness.

Players from Asia and Australia have launched metal L-PBF solutions. From 2016 to 2017 the number of sold units went from 983 to 1768.


Binder Jetting 3,6 %

Company Market share

EOS 25,2 %

Concept Laser 16,2 %

SLM Solutions 10,8 %

Renishaw 6,1 %

Sisma 4,5 %

Trumpf 2,5 %

Realizer 2,4 %

Eplus 3D 1,8 %

3D Systems 0,9 %

Trumpf 3,6 %

Optomec 1,9 %

Beijing Long Yuan 1,0 %

Xián BLT 0,9 %

BeAM/Irepa Laser 0,8 %

Arcam 5,2 %

DMG Mori 1,1 %

Matsuura 1,0 %

Sentrol 0,1 %

LPBF 75,7 %

LMD 9,2 %

EBM 5,2 %

Others 5,1 %

Hybrid 1,3 %

LPBF with 75,7 % has the biggest market share.

Additive Manufacturing Market

Systems Market - Overview

LPBF 75,7 %

LMD 9,2 %

EBM 5,2 %

Company Market Share


Additive Manufacturing Market

Systems Market - Overview


EOS 25,2 %



Renishaw 6,1 %

Sisma 4,5 %

Trumpf 2,5 %

Realizer 2,4 %

Eplus 3D 1,8 %

3D Systems 0,9 %

Trumpf 3,6 %

Optomec 1,9 %


Xián BLT 0,9 %


Arcam 5,2 %

DMG Mori 1,1 %

Matsuura 1,0 %

Sentrol 0,1 %

The three biggest producers for LPBF-systems are German.

Hybrid processes are not yet common, new machines entered

the market (e.g. DMG Mori Lasertec 65).

Arcam is the only supplier of EBM- Systems.

Company Market Share


Binder Jetting 3,6 %

SLM with 75,7 % has the biggest market share.

Additive Manufacturing Market in Germany

Systems Market - LPBF-Systems


EOS 25,2 %



Renishaw 6,1 %

Sisma 4,5 %

Trumpf 2,5 %

Realizer 2,4 %

Eplus 3D 1,8 %

3D Systems 0,9 %

Trumpf 3,6 %

Optomec 1,9 %


Xián BLT 0,9 %


Arcam 5,2 %

DMG Mori 1,1 %

Matsuura 1,0 %

Sentrol 0,1 %

The three biggest producers for LPBF-systems are German.

Source: EOS Source: Concept Laser Source: SLM Solutions

EOS M 400-4 X Line 2000 R SLM 800


SLM with 75,7 % has the biggest market share.


EOS 25,2 %



Renishaw 6,1 %

Sisma 4,5 %

Trumpf 2,5 %

Realizer 2,4 %

Eplus 3D 1,8 %

3D Systems 0,9 %

Trumpf 3,6 %

Optomec 1,9 %


Xián BLT 0,9 %


Arcam 5,2 %

DMG Mori 1,1 %

Matsuura 1,0 %

Sentrol 0,1 %

Hybrid processes are not yet common, new machines entered the market.

????

Additive Manufacturing Market in Germany

Systems Market - Hybrid Processes

Source: Fraunhofer ILTSource: DMG Mori

Additive build-up of local reinforcement by LMD


Change Impact

Ecosystem and Implementation Challenge

Source: Business Models with Additive Manufacturing - Opportunities and Challenges… Piller, Weller and Kleer (2015)

AM Ecosystem

Machine

manufacturers

Machine / System Materials Design / Scanning Production Distribution Consumption / Use

OEMs

Chemical

companies

Systems

Engineers

Material

suppliers

Product

designers

Scanning

services

Design sharing

platforms

Contract

manufacturers

Digital fabrication

workshops

Machine sharing & printing services

Design marketplaces & printing services

Industrial

Personal / Home

User innovators / entrepreneurs and Maker community

Software/IT (e.g. 3D modeling, IP rights management, IT security

Research & Education (e.g. mechanical engineering & materials science, quality / testing standards, workforce skills)

Policies (e.g. IP rights, CO2e regulation)

Organization:

Roles

Structure

Culture

Communication

Workforce:

Skills

Talent

Infrastructure

Quality:

Standards

Regulations

Liability

Feasibility

Planning:

Vision

Roadmaps

Operations

Market:

Products & Trends

Competitors

Stakeholders

Suppliers & Partners

Maturity:

Internal

External

The usual puzzle of

AM implementation


Change Impact



AM Ecosystem

Machine

manufacturers


OEMs

Chemical

companies

Systems

Engineers

Material

suppliers

Product

designers

Scanning

services

Design sharing

platforms

Contract

manufacturers

Digital fabrication

workshops



Industrial

Personal / Home





Organization:

Roles

Structure

Culture

Communication

Workforce:

Skills

Talent

Infrastructure

Quality:

Standards

Regulations

Liability

Feasibility

Planning:

Vision

Roadmaps

Operations

Market:

Products & Trends

Competitors

Stakeholders


Maturity:

Internal

External

The usual puzzle of

AM implementation


Change Impact



AM Ecosystem

Machine

manufacturers


OEMs

Chemical

companies

Systems

Engineers

Material

suppliers

Product

designers

Scanning

services

Design sharing

platforms

Contract

manufacturers

Digital fabrication

workshops



Industrial

Personal / Home





Organization:

Roles

Structure

Culture

Communication

Workforce:

Skills

Talent

Infrastructure

Quality:

Standards

Regulations

Liability

Feasibility

Planning:

Vision

Roadmaps

Operations

Market:

Products & Trends

Competitors

Stakeholders


Maturity:

Internal

External

Thorough understanding of all

aspects in the ecosystem and how

they apply and interact with your

case is essential for success.

The usual puzzle of

AM implementation


Change Impact

Structural Organization and Culture

Implementing AM competitively goes beyond

high-end equipment!

Challenges in materials and design are the

main opportunities to create competitive advantage

in the market.

Clients, technology suppliers,

knowledge partners

Culture and

Organizational Structure

Strategic Roadmap

Materials Design

Processes

Equipment

Technology


AM Today and Tomorrow

Industrial AM Drivers

Man

ag

er

Tec

hn

icia

nD

esig

ner

Partial. Difficult

Material Handling

Unknown

procedure

Design FreedomHigh

individualization

Lack of

know-how

Consistency of the

digital process chain

(e.g. Simulation)

Lightweight

Adjustable

mechanical

properties

Tool-less

productionGraded materials

Flexible

production

Automation Low build-up rates

Rapid

implementation

of changes

Business model

Innovation

Reduction of

production

times

Marketing

High material costsHigh machine

costs

Security against

product piracyMaterials

Added value

for the

customer

Decentralization

of manufacturing

processes

Improving

availability

Part volume

Assembly

Direct part

manufacturing

Functional

integration

Reduction of

faulty

developments

Embedded

electronics

Economic Barriers Economic Drivers


AM Today and Tomorrow

Industrial AM Drivers

Barriers exist for any technology, especially disruptive ones.

A plan is essential to avoid these being used as arguments

to resist change and slow down implementation.

Man

ag

er

Tec

hn

icia

nD

esig

ner

Partial. Difficult

Material Handling

Unknown

procedure

Lack of

know-how

Consistency of the

digital process chain

(e.g. Simulation)

Automation Low build-up rates

High material costsHigh machine

costs

Part volume

Economic Barriers


Topology Optimization Cellular Materials Monolithic Design Integration of Functions

© Fraunhofer ILT © Fraunhofer ILT © Fraunhofer ILT© GE

Design rules must be adhered

Trends and Developments

AM Design Approaches


© Festo

© Materialise© Roland Berger© Roland Berger© Roland Berger

© Materialise© Materialise

© digitalfolien.de


Alternative Problem Solving Techniques – Nature as a Role Model

Bionical Derivated Lattice Structures

Bionic Part Design

Bionic Surface Design

Shape Optimization



Monolithic Design and Integration of Functions

© GE Aviation

© GE Aviation

© GoetheLab for Additive Manufacturing, IwF GmbH

© GoetheLab for Additive Manufacturing, IwF GmbH

Ball Joint & Cardan JointGE Fuel Nozzle



Application Examples

GE's Catalyst Turboprop EngineClassic Line of Genuine PartsENDURO e1 Mountain Bike

Daimler GE Aviation

Low

Medium

High

Applic

ation

Read

iness

GE Reports / Kinazo Design

Low

Medium

High

Applic

ation

Read

iness

Low

Medium

High

Applic

ation

Read

iness

Electric bicycle adjustable to the

rider's arm and leg length

No tooling necessary

Manufactured on a Concept

Laser X Line 2000R

Spare Parts for out-of-

production vehicles

Rearview mirror base for the

300 SL Coupé

Improved design

New design integrates 855

components into just 12 AM

parts

20% more fuel efficient while

delivering 10% more power

ACAM

Thank you for your attention!Dr. Kristian Arntz

Fraunhofer-Institute for Productiontechnology IPT | ACAM Aachen Center for Additive Manufacturing | WBA Aachen Tooling Academy

Formnext Forum Tokyo 2019


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Community

Our Member Network – Join Us!

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ACAM Membership Opportunities

* Basic ACAM Membership also available without AM Knowledge Area (12.000 € / year) € : paid access ,% discounts provided

ACAM Membership

Basic *

20.000 € / year

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40.000 € / year

Community

16.000 € / year

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DevelopmentAnnual ACAM applied R&D projects

Partner matching for public research projects

MembershipSteering Committee Member

ACAM vouchers (each worth 2,000 €) 3 11

Knowledge Area

10.000 € / year

Community Networking in the ACAM Community

Annual ACAM Report

AM Knowledge Area Basic Expert

ServicesProcess, equipment and material

development

ACAM expert hotline for specific questions

AM engineering services and prototyping€ % %

Further Education

Tailored Inhouse Seminars

General seminars and Certificate Courses%

% %

€

€

Platform only

Service Portfolio

€

€


Join ACAM and be part of the community!

Access to AM know-how, R&D, consultancy and education.

Dr.-Ing.

Kristian Arntz

Managing Director and Partner

[email protected]

+49 241 / 9426 1021

Prof. Dr.-Ing. Dipl. Wirt.-Ing.

Johannes Henrich Schleifenbaum

Managing Director and Partner

[email protected]

+49 241 / 9426 1022

Tobias Stittgen, M.Sc.

Senior Advisor Sales and Technology

[email protected]

+49 241 / 9426 1024

GKN Sinter Metals

Oerlikon AM

Erik Feldbaum, B.Sc.

Sales and Technology

[email protected]

+49 241 / 9426 1023

mailto:[email protected]









https://acam.rwth-campus.com/acam-community/




Documents

ACAM Additive Manufacturing - how to successfully adopt ... · Additive Manufacturing - how to successfully adopt the possibilities of the manufacturing processes of the future