New product solutions by using WAAM as a new technology in AM · Process Chain @ WAAM Customer CAM toolpathing Shape & deformation control Quality check Simulation Assigning of parameters

Version 2.1 Confidential © 2018 FIT AG

New product solutions by using WAAM

as a new technology in AM

3DMP® FORUM

June 21, 2018 in Berlin

Philip Emmerling

Development Engineer


FIT AG – AM Experience since 1995

• Founded in 1995, 330 employees

• >10,000 m² manufacturing space

• Revenue in 2017: € 25.4 million

• CAGR > 25 % during 2013

• Operating the world’s largest aluminum

additive manufacturing facility

August 1995

Founded as a

Rapid Prototyping

service bureau

1997

First research project

with paper lamination

technique

1998

Starting laser sintering

2003

Successful Rapid

Tooling with DMLS

metal tools

2004

Unique FIT ERP system

installed for quicker quoting

and most efficient prototyping

production

2005

First EBM system

running titanium

2006

First-time presentation

of microstructured parts

at Euromold

2008

Sintermask Sweden

acquired

EN ISO 13485 achieved (medical certification)

2009

netfabb founded

2010

Skin Freeze

2012

FDA complianceachieved

2013

First four laser

metal machines

worldwide installed

(SLM 500)

2014

7 SLM machines dedicated

to metal, including 3 large

frame SLM 500

20154 Electron Beam Guns

20 CO2 Laser

40 Fiber Laser

2018

Implementation of

Center for advanced

AM technology

2016

Operation of the first

FAB@FIT factory

2018

Opening FIT Campus

with Boarding House

2017

Opening new

FIT Office Tower

First 5-axis

WAAM system

GDP system


Motivation: Worldwide Leadership in AM Technologies

AM system forworldwide

high qualitymanufacturing with

FIT certified AM equipment

FIT is theworldwide leading

manufacturer specialized in

Additive Manufacturing

Significantly lower costs and faster execution going into

Additive Manufacturing

for FIT customers

Our mission! For customer success!

Our clients choose FIT as preferred partner due to

proven success.

As a leading AM Company we support our customers

in five strategic fields of business.

Increasing complexityStrategic partnerships for long-term success

Strategic AM

Consulting

Prototyping

Services

Spare Parts

on Demand

ADM

Components

Production

Tools


Business Units

Prototyping

• Concept models

• Functional prototypes

• Pre-production runs

Additive Design and Manufacturing

• Additive engineering

• Component manufacturing

• Volume manufacturing

Research and Development

• System development

• Process development

• Material development


Traditional model making, jigs

and tools

Segments & Solutions

Design & mockups

Functional parts & castings

Pre-production runs

Functional prototypes with

individual quality agreement

Solutions @ Prototyping

ADM-Q

Final part produced under individual

Quality agreement

ADM-V

Volume Manufacturing

ADM-CV

Customized Volume Manufacturing

ADM-E

ADM and 3S Engineering

ADM-W

Additive Design & Manufacturing

Workshops

ADM-S

Spare Parts on Demand

Solutions @ Production Solutions @ R&D

Integrated software(MES, workflow, quality control, statistics…)

Hardware development

Material development

Process automation


Overview: Range of Technologies at FIT

Plastic Metal ADM Measuring Surface Finising

Drop on Powder Investment Casting ADM Workshops CT Scanning Metal Coating

Stereolithography Laser Melting ADM Engineering 3D Scanning Assembling

Fine Layer Technique Electron Beam Melting ADM Quality Optical Profilometry Spray Painting

Full Color Polyjet WAAM ADM Volume Mfg. Metallography Precision Engineering

Gel Dispensing Printing Lathing & Milling ADM Spare Parts Tensile Testing Shot Blasting

Selective Laser Sintering Ceramic ADM Customized

Volume Manufacturing

Optical Microscopy

Fused Deposition ModelingCeramic Printing

3D Coordinate

Measurement

Vacuum Casting / RIM Element Analysis

PA Casting Surface Roughness

Lathing & Milling Powder Analysis

Lamination

Model Building (conv.)

Elastomers

Injection Molding


Always a Step Ahead – Technology Integration @ FIT

More than 20 years of expertise

• Adoption of new technologies

• Evaluation of new technologies

On-going improvements in all available

technologies and application

development for new products


Time Schedule

April: Gefertec

machine arrives

August – October:

- FIT sample parts (hollow sphere, propeller)

- Complex parts (brackets, half-shell)

Since January 2018:

- Constantly incoming customer

orders

2018

2 employees integrate technology

into manufacturing work flow in

FIT facility

May – July:

- Parameter evaluation

- Qualification of material

- Maraging steel, aluminum,

stainless steel

Adoption steps of the technology:

November – December:

- Process optimization

- Copper-aluminum, Inconel

- First incoming customer orders

April 2018:

WAAM team expands by a trainee

and a MSc student

2017

Processing of:

- Multimaterials

- Titanium

Further development:

- Simulation of deformation and

temperature

- Internal structures


Technology and Comparison

RADICLE

Powder bed

WAAM

Laser deposition


Technologies in Comparison

Cost reduction

Material efficiency

Mechanical properties

Post-production

Part size

Build rate

Accuracy

Complexity

Reproducibility

WAAM Powder Bed / Laser Deposition


Process Chain @ WAAM

Customer

CAM toolpathing

Shape &

deformation controlQuality check

Simulation

Assigning of

parameters

Finished

part

Finished Part

WAAM

manufacturing

Challenge @ FIT

Customer

CAD model

CNC

finishing

Design adjustment

for WAAM


Design Adjustment for WAAM

Customer CAD model

FIT offset

Removal of critical

elements, e.g. holes

Adjusting of radii

Removal of undercuts in

building direction



Customer

CAM toolpathing

Shape &


Simulation

Finished

part

Finished Part

WAAM

manufacturing

Challenge @ FIT

Design adjustment

for WAAM

Customer

CAD model

CNC

finishing

Assigning of

parameters


WAAM Buildup Strategies

3-axis buildup

with substrate plateRadial buildup base body 3-axis buildup of flaps

Combination of different buildup strategies within one part

First step: radial buildup of base body

Second step: 3-axis buildup of fittings


Offset

WAAM CAM Toolpathing and Parameter Assignment

Profile

MeanderCombined strategic planning with

various welding parameters

Welding parameter 1

Welding parameter 2

Welding parameter 1

Welding parameter 2

Different strategies depending on part geometry



Customer

CAM toolpathing

Shape &


Assigning of

parameters

Finished

part

Finished Part

WAAM

manufacturing

Challenge @ FIT

Design adjustment

for WAAM

Customer

CAD model

CNC

finishing

Simulation


Complete manufacture of part Buildup on semimanufactured part Hybrid manufacturing

Internal structures

Selective enforcement of

prefabricated part Massive coating of parts / multimaterials

Application samples

Production Process WAAM (Wire Arc Additive Manufacturing)


- Testing of tensile strength

- Measurement of hardness

- Measurement of density

- Microstructural analysis

- Computertomography

Qualification of materials & process monitoring

Cross section Microstructural analysis

Process monitoring




Material properties & benefits

− Material efficiency by targeted material application

− High build rates of up to 600 cm³/h

− Easy storage

− Lower material cost by use of wire material

− Huge variety of usable materials – nearly all weldable wires



Customer

CAM toolpathing

Shape &


Simulation

Assigning of

parameters

Finished

part

Finished Part

WAAM

manufacturing

Challenge @ FIT

Design adjustment

for WAAM

Customer

CAD model

CNC

finishing


CNC finishing


Quality Assurance

ComputertomographyOptical scanning Parameter evaluation


Finished Part: Engine Cover

Preparation time: 10 h

Material: 1.5125 G3Si1

Part size: 442 x 442 x 100 mm

Deposition rate: 350 cm³/h

Welding time: 13 h

Volume of

finished model: 3,080 cm³ (24 kg)

Engine Cover


More Practical Examples

PropellerBrackets


Material: G3Si1 1.5125



Welding time: 1h

Volume of finished

part: 880 cm³ (7 kg)

Motorsport

Aerospace

Machinery


Material: 1.4430 X2CrNiMo19_12



Welding time: approx. 8 h

Volume of

finished model: 1,500 cm³ (12 kg)


Why WAAM?

Conclusion

− Technology leader im in the field of Additive Manufacturing

− 25 years of experience in rapid prototyping

Resources @ FIT:

− Total of 10,000 m² manufacturing space at FIT Campus

− More than 300 employees: 25 employees in R&D / Advanced AM

Technology / Application development

Why FIT?

New technologies: High potential for future

− New materials, new product solutions, hybrid solutions

Benefits of the technology:

− Augmented variety of usable materials

− Spare Parts on Demand

− Material efficiency

− High degree of automatization

− Cost optimization (no tooling costs)


Thank you for your

attention.

Vision Without Execution Is Just Hallucination !

3DMP® FORUM

June 21, 2018 in Berlin

Philip Emmerling

Development Engineer

Documents

New product solutions by using WAAM as a new technology in AM · Process Chain @ WAAM Customer CAM toolpathing Shape & deformation control Quality check Simulation Assigning of parameters