2012 11-15-high-value-manufacturing-sirris-gravet

le centre collectif de l’industrie technologique belge

High Value Manufacturing

L’allègement par les techniques additives Une nouvelle manière de concevoir

Denis Gravet Le 15-11-2012

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Additive Manufacturing

- No chips - Freeforms - Complex shapes - Internal shapes - Customization - Materials range - Graded materials

- Lightweight - Internal geometries - Multi-functional - Porosities

High Value Manufacturing

Good opportunity to change the

World by

Accelerate innovation Redesign

New concepts

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Denis Gravet Le 15-11-2012

High Value Manufacturing Why reduce weight ? - less buiding time

- less waste during production (no chips) - less energy during production - less energy during transport - less energy during component using - reduce cost - Carbon footprint ? (Interreg FRED)

Vanguardist sectors

- Aeronautic - Spatial - Automotive - …

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Denis Gravet Le 15-11-2012

High Value Manufacturing How reduce weight ?

Functionalities

Multi-functionality

3D lattice structures

Porosities

Internal freeforms

Topology optimization

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Denis Gravet Le 15-11-2012

High Value Manufacturing

p using: 400b p test: 600b p rupture PM: 1.535b

Pressure resistance Functionalities

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Mass: 1.33kg at 0.8kg) Reduction of 38%

Volume: 171 cm³ at 91 cm³ Reduction of 47%

External size: similar

Pressure resistance OK

Cost 1 unit PM: 450€ (similar conventional) Cost 150 units PM: 43€/unit

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Multi-functionality

Simplification Cooling tube removed and integrated Support integrated Rings and braces removed 12 components 1 part

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Name/Description Part volume Relative Full cube 27.00 cm³ 100 % Circular profile 4.37 cm³ 16 % Spherical 2.75 cm³ 10 % Honeycomb 3.74 cm³ 14 % Double honeycomb 3.25 cm³ 12 % Reduced honeycomb 1.93 cm³ 7 %

Circular profil Honeycomb Spherical

Reduced honeycomb

Double honeycomb 3D lattice structures

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Denis Gravet Le 15-11-2012

High Value Manufacturing

3D lattice structures

Courtesy of OS Orthopedic Services GmbH / inno-shape GmbH

EBM - Oak Ridge National Lab

[Sirris ADD]

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Denis Gravet Le 15-11-2012

High Value Manufacturing Weight reduction with minimal strength reduction Biomedical implants: bone regeneration Graded structures Shock damping Vibration reduction Filtration

Laser Cusing

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Manifolds

Weight Volume Pressure drops Cost Pressure resistance

Internal freeforms

Functionalities

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Volume: 2.900 cm³ Mass: 19.2 kg External size: 210 x 210 x 70mm

Volume: 244 cm³ Mass: 1.2 kg External size: 85 x 85 x 38mm

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Denis Gravet Le 15-11-2012

High Value Manufacturing Pressure drops:

- Very important reduction of pressure drops and also good pressure resistance

3,25b

0,25b

13x

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Denis Gravet Le 15-11-2012

High Value Manufacturing Influence of roughness on pressure drops:

Negligeable regarding previous result and cost of polishing.

0,25b

0,32b

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Mass: 19.2kg at 1.2kg Reduction of 94%

Volume: 2900 cm³ at 244 cm³ Reduction of 92%

External size: much less (210mm => 85mm) Pressure resistance: OK Pressure drops: 3,25 at 0,32b Reduction of 90%

Cost 1 unit PM: 750€ at 538€ Reduction of 28%

Cost 112 units PM: 78€/unit + milling

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Denis Gravet Le 15-11-2012

High Value Manufacturing Internal freeforms

Functionalities

134 drillings

Rounded channels Changing diameters Same functionalities

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Denis Gravet Le 15-11-2012

High Value Manufacturing Pressure drops:

- Very importante reducing of pressure drops

1,4b

0,3b

4,7x

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Mass: 55kg at 20kg Reduction of 63,6%

Volume: 2334 cm³ External size: 265 x 200 x 165mm => 240 x 200 x 150 mm

Pressure resistance: OK Pressure drops: 1,68 at 0,37b Reduction of 78%

Cost 1 unit PM: 2500€ at 3122€ + milling increase of >25%

Cost 6 units PM: 2500€/unit at 2376€ + milling (similar)

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Cooling channels Reduction of cycle time 15% up to 40% (Hipermoulding) Reduction of the energy consumption Improvement of the durability of moulds Improvement of the efficiency of cooling (no warping, good filling…) Carbon foot print

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Complex geometries for multi functionality

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Denis Gravet Le 15-11-2012

High Value Manufacturing Topology optimization (Topol-Samcef)

• Use material only where is needed • Definition of the free space • Define maximum volume • Set of loads • Maximize stiffness

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Free space and set of loads

% volume and max. stiffness

FEM calcul

Design

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Efforts repartition

STL file Smoothing or redesign based on the STL geometry

Free space definition

FEM calcul

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Al

CF PA

AlSi12

Weight reduction: 530g 392g (-26%) 7 components 2 components 3 materials 1 material (1 technology)

Carbon foot print

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Topology Optimisation of a Lever (Images courtesy of JCB)

EADS

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Denis Gravet Le 15-11-2012

High Value Manufacturing

EOS

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Batsheba Grossman

Wim Delvoye / 3DP metal SIRRIS Artistic

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Denis Gravet Le 15-11-2012

High Value Manufacturing Jewelry

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Denis Gravet Le 15-11-2012

High Value Manufacturing Fashion

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Steel part (Concept Laser)

Technical

LayerWise

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Medical

LayerWise

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Added Values

Reduction of assembly and millings Simplification (nbre of components)

Reduction of pressure drops Improvement of stiffness

Reduction of volumes Material optimization Reduction of weigth

Freedom for design Customization Global cost

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Thanks for your attention

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Denis Gravet Le 15-11-2012

High Value Manufacturing

Bruno Verlee Porosities