sirris manufacturing day 2013 dti denmark - olivier jay

Founded 1906 by Gunnar Gregersen

”To support Danish industry, mainly small enterprises, by providing technical assistance in the form of teaching, advice, testing and technological research”

An independent, not-for-profit institution

Approved as a technological service institute by the Danish Ministry of Science, Technology and Innovation.

Status

28%

13%

22%

25%

12%

Performance contracts

Danish business customers

Organisations and public customers

International customers

Research and Development activities Revenue

EUR 131,6 millions

Poland

Hirtshals

Aarhus

Kolding Odense

Taastrup

Gothenburg

Warsaw

Roskilde

Danish Technological Institute

Teknologisk Institut AB (Sweden)

FIRMA 2000 Sp. z o. o. (Polen)

Dancert A/S

Danfysik A/S

DTI Robotics US, Inc. (USA)

Te

ch

no

log

ica

l un

ce

rtain

ty

Resource depletion

Market

Idea

Is it attractive ? Is there a need ? How are all the markets demands fulfilled ?

Is it possible?

8-15 years

Is it feasible?

3-8 years

Basic/strategic Research

Can it be improved?

0-2 years

New/emerging Technologies

Commercial/proven Technologies

DTI’s area of operation

Area of Operation

It s just a tool ……

……not the solution !!!

AM

Economy and Environment

Design

Production

Finish

Quality

control

Education

Industry: Widex (Denmark), for their invention of a computer-aided method to manufacture individually-fitted hearing-aid devices;

EPO's European Inventor Award 2012 goes to outstanding inventors from Germany, France, Denmark and Australia

The beauty of Rapid Manufacturing.

”The RM technology has given us a bigger creative designing space, because we

are no longer limited by a particular geometric shape.

We do not produce tools, which means that the production process is reduced to

a few weeks where it before took between 4 to 6 months.

The time factor means that we can now try out our ideas, and it gives us

an enormous amount of freedom”

Leif Johannsen, Chief Officer of Acoustics and Technology

40

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100

0 50 100 150 200 250

Rela

tiv

e d

en

sit

y (

%)

Laser power (W)

Qphase density for a scan velocity of 23 cm/s

21/01 test cubes

22/01 test cubes

Pumps and the world's electricity consumption

• Today pumps account for no less than 10% of the world's electricity consumption.

• Two third of all pumps use up to 60% too much energy.

• If every business switched to a high efficiency pump system there could be global savings of 4% of the total electricity consumption- comparable with the residential electricity consumption of 1 billion people

Sustainable

Parts with complex internal channels • Demonstrator part: crossing manifold

a manifold to let 2 hydraulic lines cross each other in limited space

Conventional manifold design

230x230x54 mm 20,15 Kg

0,95 Kg

80x80x50mm

Additive Manufacturing

Støbeteknologi

Funktionsmodellering

Svingnings- dæmpning

Styrke- optimering

F•MAT

www.fmat.dk

The STL Legacy

CAD STL Sliced

Then What?

CAD ? Sliced

VTK

Mesh

FRep STL

Comparing mechanical properties of different cellular structures experimentally and

theoretically

BCCz FCCz BCC F2CCz Tryl1b

Compression test of different cellular structures

(7x7x14) with same size and density

Cellular structures: • Nylon PA2200 • 4 highly ordered structures and 1 unordered • Same outer dimensions (40 x 40 x 80 mm3) and

density (19 vol%) • Different bar thickness in different structures

(same thickness within same structure) • 7x7x14 unit cells • Built with two different set of machine parameters

Plast 250 Kg.

0

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1200

BCC BCCz F2CCz FCCz Solid Tryl1b

Elas

tic

Mo

du

lus

(MP

a)

Parameters 1

Parameters 2

Fe simulation

Compression tests and FE simulations:

BCC

BCCz

FCCz

F2CCz

Tryl1b

Solid

0

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BCC BCCz F2CCz FCCz Solid Tryl1b

Stre

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axim

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Pa)

Parameters 1

Parameters 2

Max stress in FE simulation (arb. units)

0

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BCC BCCz F2CCz FCCz Solid Tryl1b

Stra

in a

t M

axim

um

(%

)

Parameters 1

Parameters 2

5703Hz Structure

Skærmklip taget: 12-06-2012; 09:09

Graphene-based Thermoplastic Masterbatches for Conventional & Additive Manufacturing Processes

The NanoMaster Concept • Develop processes for large-scale rapid production of graphene, expanded graphite and

nano-graphite

• Develop machinery and processing methods designed for efficient, high-throughput production of masterbatches and compounds

• Develop material systems which can be incorporated into current conventional and additive manufacturing processes quickly, easily and safely.

• Reduce the amount of polymer required to produce components by 50%, whilst still meeting performance requirement

• Open up an extensive field of applications for plastic mouldings with significantly enhanced functionality

• For the first time, make industrial-scale quantities of graphene-filled compounds and masterbatches available to European industry

• Place European companies in a position to exploit the rapidly growing US and Asian markets

Expanded Graphite Development Graphene Functionalisation and

Development

Compounding and Dispersion Method Development

Composites Development and Case Study

Environment, Health and Safety Assessments

Additive Manufacturing Process Development

Nanocomposite Development and Project Coordination

Pilot-scale Compounding and Injection Moulding

Additive Manufacturing Process Development and Case Study

Conventional Moulding Process Development and Case Study

Production

Production and Testing of Demonstrators

FDM Process Development Nanomaterial Compounding and

Formulation Development

Preliminary results

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It s just a tool ……

……not the solution !!!

98% of all ideas are old

Thank You!

Olivier Jay, Head of Additive Manufacturing section