arcam - general - apr 2012
DESCRIPTION
nuclearTRANSCRIPT
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2012-04-10 1
Additive Manufacturing with EBM® (Electron Beam Melting)
2012-04-10 2
• Overview
• Applications
• Medical Implants
• Aerospace
• Arcam Products
• Materials
Overview
2012-04-10 3
Additive Manufacturing (AM) Benefits
• Unlock design potential
• Reduce time-to-market
• Reduce material costs
• Reduce machining costs
and
• Makes it possible to manufacture partswith lattice and cellular structures!
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EBM®
- Electron Beam Melting
• The electron beam gun generates ahigh energy beam (up to 3.000 W)
• The beam melts each layer of powdermetal to the desired geometry
• Extremely fast beam translation withno moving parts
• High beam power -> high build rate(up to 80 cm3/h) and productivity
• Vacuum process -> eliminates impuritiesand yields excellent material properties
• High process temperature (700 ºCfor titanium) -> low residual stressand no need for heat treatment
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The EBM® Machine
Heat Shield
Powder Rake
PowderContainer
Build Platform
EB Gun
Control Unit
Build Chamber
Build Tank
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• Overview
• Applications
• Medical Implants
• Aerospace
• Arcam Products
• Materials
Medical Implants
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Benefits with EBM®
• Implant manufacturing with EBM®
• Freedom in design
• Cost-efficient production
• Excellent material properties
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• Design your unique trademark trabecular structure
• With CAD or with a Structure generator software
• Optimize for osseointegration
• Pore geometry (no limitation)
• Pore size (down to ~400 μm)
• Porosity (up to ~85%)
• Competitive manufacturing costs
• EBM®
production cost, typical: < 2 €/cm3 trabecular structure
Trabecular Structures™
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Bio-Compatibility
Pictures of bone growing into EBM®-manufactured
titanium implants with Trabecular Structures™
Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials,University of Gothenburg.
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Implant Categories
• Acetabular cups
• Revision cups
• Augments
• Femoral stems
• CMF
• Spine
• Shoulders
• Triflanges
• Tibial trays
• Femoral knees
In productionwith EBM®
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• Single-step production of solid and porous sections,with structural continuity between them
• All-porous implants possible (augments, wedges, …)
• High process temperature gives low residual stress,and no need for heat treatment after the build
• No secondary high temperature process to apply theporous structure that could cause grain growth
Production Benefits
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Post-Build Processing
• Remove and recycle excess powder
• Machine inside with conventional CNC
• Clean parts with ultrasonic and solvents
• Quality Control with EBM® LogStudio™
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• CE-certified acetabular cups with integratedTrabecular Structures™ since 2007
• Implants with FDA clearance since 2010
• > 20,000 cups implanted
• 25% of the global production of cups with advancedporous coatings is now manufactured with EBM®
Adler Ortho, IT2007
Lima-Lto, IT2007
Exactech, US2010
CE-certified & FDA-cleared Implants
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Courtesy of Adler Ortho s.p.a.
CE-certified since 2007
Fixa Ti-Por™ Acetabular Cup
Material: Ti6Al4V
Build time: 16 cups in10 hours
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Material: Ti6Al4V
Build time: 16 cups in10 hours
DELTA TT™ Acetabular Cup
Courtesy of Lima-Lto s.p.a.
CE-certified since 2007
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Material: Ti Grade 2
Build time: 4 cups in16 hours
DELTA TT™ Revision Cup
Courtesy of Lima-Lto s.p.a.
CE-certified since 2007
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FUSE™ Lumbar PLIF Cage
Material: Ti Grade 2
Courtesy of Advanced Medical Technologies AG
CE-certified since 2009
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Summary
• EBM® lets you design and produce unique trademarkTrabecular Structures™ with minimum investment
• EBM® offers a unique single-step productionmethod for solid and porous implants
• EBM® provides structural continuity between solidand porous sections, and requires no heat treatment
• EBM® is a proven and cost-efficient technology,with thousands of implanted CE-certified products
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2012-04-10 19
• Overview
• Applications
• Medical Implants
• Aerospace
• Arcam Products
• Materials
Aerospace
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AM Benefits in Aerospace
• The Aerospace industry’s fundamental characteristics are• Extreme requirements on product performance
• Geometric design complexity
• Extensive use of Ti alloys
• Use of exotic materials
• EBM® is the ultimate Additive Manufacturing solutionfor the aerospace industry with its• High productivity
• Excellent material properties
• Ability to process new materials
• Several aerospace applications in the pipeline
• All major engine OEM’s have ongoing EBM®
initiatives
• First application in series production during 2012
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AM Drivers in Aerospace
• Freedom in Design• Optimize geometry for weight savings
• Optimize geometry for improved function
• Brackets (weight), Vane segments (function), Filters (function)
• Materials Savings• Buy-To-Fly ratios of 15-20 are common in Aerospace
• 95% of the material is machined away as scrap
• For EBM®
the Buy-To-Fly ratio is close to 1
• Materials Flexibility• Many alloys with unique characteristics are difficult to cast and forge
• EBM®
has demonstrated that it can be used to process such alloys
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Turbine Blades
Courtesy of Avio S.p.A.
Material: γ-TiAl
Size: 8 x 12 x 325 mm
Weight: 0,5 kg
Build time: 7 hours / blade
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Aerospace Prototype
Material: Ti6Al4V
Size: Ø 180 x 300 mm
Weight: 5,5 kg
Build time: 40 hours
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Rocket Engine Impeller
Material: Ti6Al4V ELI
Size: Ø 140 x 80 mm
Weight: 2,5 kg
Build time: 16 hours
Courtesy of CalRAM, Inc.
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• Overview
• Applications
• Medical Implants
• Aerospace
• Arcam Products
• Materials
Arcam Products
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Arcam A1
• For Implant production,in titanium and CoCr
• Build size 200 x 200 x 180 mm
• Full EBM® MultiBeam™technology, providing
• High productivity
• Smooth surfaces
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• For Aerospace production,in titanium alloys
• Large build volume
• 200 x 200 x 350 mm and
• Ø300 x 200 mm
• Two alternative build tanks(tall and wide)
• Full EBM® MultiBeam™technology, providing
• High productivity
• Smooth surfaces
Arcam A2
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Powder Recovery System
• > 95% recovery ofunmelted powder
• Minimal dust generationfor safe operation
• Closed circuit until powderrecovery is completed
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Training & Maintenance
• Support & Maintenanceagreements to maximizeuse of machines, incl.
• Application support
• Periodic maintenance
• Spare parts
• Emergency visits
• Support hot-line
• Training packages toensure operator skills
• Basic training
• Advanced training
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Arcam Powder Metals
• Pre-alloyed powder
• Powder fractions selected for safe operation and handling
• Verified material properties
• Chemical composition in accordance with applicable standards
• Optimized process parameters
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• Overview
• Applications
• Medical Implants
• Aerospace
• Arcam Products
• Materials
Materials
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Materials Strategy
• Arcam's customers range from companies in the aerospace andmedical implant industries who use their EBM® systems forproduction, to universities and institutes that focus on research.
• Arcam's materials strategy is to supply our industrialcustomers with the metals they use in their production.
• We simultaneously make it possible for our research-orientedcustomers to work with other materials, by providing additionaltraining that enables them to use EBM® with these materials.
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Materials Portfolio
• With the high power available (up to 3.000 W) the EBM® processcan melt any powdered metal with a melting point temperatureup to 3.400 °C (e.g. W), allowing an extensive range of materials.
• The materials currently supplied by Arcam are:
• Titanium alloy Ti6Al4V (Grade 5)
• Titanium alloy Ti6Al4V ELI (Grade 23)
• Titanium CP (Grade 2)
• CoCr alloy ASTM F75
• For these materials Arcam has
• Established a validated powder supply chain
• Optimized process themes that match powder quality
• Verified material properties of the built material
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Other Materials in EBM®
• Arcam has tested and has customers who use a range of othermaterials in their EBM® machines, including but not limited to:
• Titanium aluminide (γ-TiAl)
• Superalloys (e.g. Inconel 625 & 718)
• Stainless steel (e.g. 316L)
• Tool steel (e.g. H13)
• Aluminium (e.g. 6061)
• Hard metals (e.g. NiWC)
• Copper (e.g. GRCop-84)
• Beryllium (e.g. AlBeMet)
• Amorphous metals
• Niobium
• Invar
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• Freedom in Design
• Design for function
• Integrated trabecular structuresfor improved bone ingrowth
• Light-weight structures
• Excellent Material Properties
• Controlled microstructure
• Better than cast
• Compliant with applicablestandards
• Cost-Efficient Production
• High productivity
• Material recycling
EBM® - Core Benefits
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Contact
Arcam AB
Krokslätts Fabriker 27A
SE-431 37 Mölndal, Sweden
Phone: +46 31 710 32 00
Web site: www.arcam.com
E-mail: [email protected]
Thank you for your attention!
Arcam - CAD to Metal®