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© LayerWise NV, all rights reserved 2/19/2014
1 www.layerwise.com Click to edit Master subtitle style
New Thinking Unmatched Performance
From pioneering high-end production to a global vision
Let Additive Manufacturing Inspire You
LayerWise 2014
© LayerWise NV, all rights reserved 2/19/2014
2 www.layerwise.com
LayerWise LBM Technology Technology Development Drivers and Applications Future outlook
© LayerWise NV, all rights reserved 2/19/2014
3 www.layerwise.com
Increase your added value through advantages of
Metal Additive Manufacturing
Therefore LayerWise offers its technological expertise realized by being technology developer as well as technology user
LayerWise
© LayerWise NV, all rights reserved 2/19/2014
4 www.layerwise.com
2008 1989 1991 2007 2009 2010 2012
Start of AM Research
Start of METAL Research
Full Dense Metal Samples
2001
Phd P. Mercelis
Phd J. Van Vaerenbergh
SLM SLS Sintering
2014
Thin Wall 0.5MM
Thin Wall 0.3MM
Thin Wall 0.225MM
Thin Wall 0.18MM
RP
0% Manufacturing
10% Manufacturing
50% Manufacturing
80% Manufacturing
90% Manufacturing
Ti Grade 5 Ti Grade 23
Inc 718 Maraging
17-4 15-5 AlSi10Mg
Tantalum Tungsten
316L CoCr
LayerWise
© LayerWise NV, all rights reserved 2/19/2014
5 www.layerwise.com
LayerWise
Service Provider for metal additive manufacturing
Main Goal:
Tools: In house development of the technology In house development of new materials In house development of post finishing techniques
© LayerWise NV, all rights reserved 2/19/2014
6 www.layerwise.com
LayerWise
dental prostheses crowns and copings
standard implants customized implants medical tools medical modeling
Chemistry Pharmaceutic
Semicon High Tech
Aerospace Tooling
Food Mechatronics
Pressure & Gas Consumer
Electronics Automotive
ISO 9001 & 13485 certified
© LayerWise NV, all rights reserved 2/19/2014
7 www.layerwise.com
LBM Technology AM
Polymers Metals
Powder
Bed
Tech
EBM
LBM
Powder
Deposition
Tech
Laser Cladding
Ceramics Glass …
© LayerWise NV, all rights reserved 2/19/2014
8 www.layerwise.com
LBM Technology
Directly from 3D CAD Layer-wise production 3D components by successive
connection of thin 2D layers
© LayerWise NV, all rights reserved 2/19/2014
9 www.layerwise.com
LBM Technology
© LayerWise NV, all rights reserved 2/19/2014
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“Can we apply 3D metal printing for volume manufacturing of critical
components?”
Technology Developments
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Technology Developments
1) Developing New materials: • First test samples – Microstructure Analysis • Parameter Optimization
• Density • Mechanical Properties
• Composing Certified MDS
© LayerWise NV, all rights reserved 2/19/2014
12 www.layerwise.com
Build Style
• Laser Power • Scan Speed • Athmosphere
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
13 www.layerwise.com
– Homogeneous microstructure; grain
growth across layer thickness
– Combined α/β phases
– Minimal fraction of rest porosity; may small gas inclusions
100µm 60µm
Ti6Al4V
LayerWise
Metal AM
Technology
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
14 www.layerwise.com
Technology Developments
2) Tuning Existing materials: • Constant monitoring
• Test samples during every AM job • Melt pool monitoring and control
3) Increasing part size • Without the loss of accuracy 4) Productivity enhancement • Reducing Manufacturing costs
© LayerWise NV, all rights reserved 2/19/2014
15 www.layerwise.com
Melt-pool fluctuations • Tracking of melt-zone characteristics
• High speed imaging and data recording
inert atmosphere air atmosphere
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
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• Geometric influences
1 2
1 2 1
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
17 www.layerwise.com
• Feedback control advantages: demonstrator
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
18 www.layerwise.com
Chemical Pharma Food Pressure & gas
Mechanization Semiconductor Electronics Tooling Precision mechanics
Standard implants Customized implants
Dental prostheses Implant supported and cemented
Aviation Space
ISO 9001 and ISO 13485 certified
Materials for critical applications
Technology Developments
© LayerWise NV, all rights reserved 2/19/2014
19 www.layerwise.com
Additive manufacturing Same material Same characteristics
What is the added value?
Drivers and Applications
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20 www.layerwise.com
Drivers and Applications
1) Monolythic Construction
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Drivers and Applications
2) Flow Optimization
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22 www.layerwise.com
Drivers and Applications
3) Miniaturisation
© LayerWise NV, all rights reserved 2/19/2014
23 www.layerwise.com
Drivers and Applications
4) Add Functionality
© LayerWise NV, all rights reserved 2/19/2014
24 www.layerwise.com
Drivers and Applications
5) Mass Reduction
© LayerWise NV, all rights reserved 2/19/2014
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Drivers and Applications
10 mm
6) Others:
- First proto of a MiM-serial production
- Very small complex products
© LayerWise NV, all rights reserved 2/19/2014
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Some more Applications
Flow type Laminar Turbulent
Channel shape Cross section 3D traject
Pressure drop Variable sections restriction
Heatex Conformal Balanced
CFD analysis SLM Manufacturing
© LayerWise NV, all rights reserved 2/19/2014
27 www.layerwise.com
Some more Applications
© LayerWise NV, all rights reserved 2/19/2014
28 www.layerwise.com
Some more Applications
© LayerWise NV, all rights reserved 2/19/2014
29 www.layerwise.com
Some more Applications
© LayerWise NV, all rights reserved 2/19/2014
30 www.layerwise.com
Some more Applications
© LayerWise NV, all rights reserved 2/19/2014
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Future outlook
© LayerWise NV, all rights reserved 2/19/2014
32 www.layerwise.com
Future outlook
Materials : super alloys, heavy metals (18+ materials)
Cost : 2008 -> 2012 - buildrate x 4
Upscaling : max dimenions x 5 to circa 500 mm
Surface control : Ra 5 -> Ra 0.9 & Ra 0.1
Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)
Pardigm shift: DfM-> design for function
© LayerWise NV, all rights reserved 2/19/2014
33 www.layerwise.com
Contact details
LayerWise N.V. Kapeldreef 60 3001 Leuven Belgium tel: +32 16 29 84 20 fax: +32 16 29 83 19 www.layerwise.com [email protected]