exone technology 3d sand printing
TRANSCRIPT
Asia | The Americas | Europe
Company & Technology Overview
David Stevenson
Product Manager
Asia | The Americas | Europe
Company Introduction and Global locations
ExOne 3D printing Technology (incl. short video)
Equipment Overview
Production Service Center
Industries, Applications and Customers
Case Studies
Agenda
Asia | The Americas | Europe 3
Company Introduction
and Global locations
Asia | The Americas | Europe
ExOne Digital Part Materialization
History / Ownership
ExOne founded by Lawrence Rhoades in 2005 when the finishing
technologies of Extrude Hone were sold to Kennametal, Inc. and
the remaining advanced manufacturing processes were formed
into a new company.
S. Kent Rockwell of Rockwell Venture Capital (formerly of
Rockwell International) acquired ExOne in 2008.
Over $80 million in investment in global research & development
over the last decade.
The ExOne company
Asia | The Americas | Europe
• Digital Part Materialization (Additive Manufacturing)
– Sand Printing for Patternless Production of Sand Molds & Cores
– Metal Printing for Functional Metal Parts
– Glass Printing for Glass Components
• Micromachining with Short-Pulse Laser Technology
– Short-pulse laser micromachining for small, complex holes
• Services and Equipment Provided for all Technologies
The ExOne company
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Global Facility Locations
160 employees
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3D Printing Technology
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Digital Part Materialization
Industry-Proven Technology
CAD data Digital cores
CAD data to Digital Part Materialization layer by layer
Cost saving: eliminate tooling
Improve product quality: design freedom
Short lead time: Rapid casting process
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Binder systems
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Equipment Overview
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S-Print S-15 S-Max S-Print 2012
750x380x400 mm 1500x750x700 mm 1800x1000x700 mm 800x500x400 mm
Max 10 liters/hours Max 29 liters/hours Max 108 liters/hours Max 28 liters/hours
Rapid Prototyping Small production Medium production Medium production
High flexibility
Overview
out of production
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Build size: 1800x1000x700mm
Speed: up to 108 Liters/hours
Branch: medium production batches
Features:
• Sand recycling;
• Fluidmatic central fluid supply;
• Jobmatic automatic job starter;
• Joblist feature;
• Larger printhead;
• Multisand: silica sand, aluminoxyd, zircon, synthetic sand;
Post-processing: None
S-Max (Furan)
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Build size: 800x500x400mm
Speed: up to 28 Liters/hours
Features:
• Sand recycling;
• Joblist feature;
• Larger printhead;
• Multisand: silica sand, aluminoxyd, zircon, synthetic sand;
Post processing (Phenolic and Silicate versions):
Load jobbox into oven using the roller coveyer:
Cure in Microwave oven
Cooling down of jobbox
Extraction and Cleaning of parts
S-Print (Furan – Phenol – Silicate)
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Industry – Machine Sales
Industry Machine Count
S15 S-Max S-Print Grand Total
Aerospace 6 4 1 11
Automotive 8 3 3 14
Engineering 2 1 3
Foundry 3 8 2 13
Marine 1 1
R&D 1 1 2 4
PSC 12 7 5 24
Grand Total 33 24 13 70
S15 S-Max S-Print S-Print 2012
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Commercial Use
Installations
University/Research
Installations
Machine Locations
Germany: 24 UK: 4
France: 2
Italy: 1
Japan: 10 Kazakhstan: 1
Russia: 9
USA: 14
Canada: 1
Thailand: 1
China: 1
India: 1
Switzerland: 1
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Remote Machine Assist
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Production Service Center
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Production Service Center (PSC)
PSC facilities print digital cores and molds for foundries,
manufactures and engineering companies
ExOne has PSC facilities in Germany, Japan, Russia, America
and Britian
It is planned to open up new PCS facilities in Scandinavia, Italy,
Spain & Portugal, Brazil, China and India
Cores are printed with a high resolution directly from the CAD
data files
Ideal for complex geometries where conventional methods are
difficult
Reverse Engineering of obsolete parts is also possible
CAD Core Cast
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Production Service Center (PSC)
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Production Service Center (PSC)
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Production Service Center (PSC)
Typical S-Max layout
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PSC - Digital Core Example
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PSC - References Customers
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Industries,
Applications and
Customers
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Industries - Market Capabilities
Aerospace
Energy/Oil/Gas/Pump
Automotive
Reverse Engineering
Hydraulic systems
Faucets industries
Marine
Institute
Foundries
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Gear housing
Decrease lead time by more than 10 weeks
High complexity of cores (reduced number of core)
40% cost saving
Excellent material properties
Applications - Aerospace
Magnesium castings
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Pump impeller prototype
Reduce Impeller Prototypes Costs
up to 90%
Decrease lead time by more than
4 weeks
Applications - Energy/Oil/Gas/Pump
Housing and impeller castings
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Applications - Automotive
Powertrain castings
FORD 4-cylinder engine block
Aluminium engine block with
cast-in liners
30 blocks casted in 3 months
Decrease lead time by more
than 6 weeks
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Applications - Reverse Engineering
Examples
Submarine replacement parts
Reverse Engineer Compressor
Pump Castings with 43 weeks
reduction in lead time
40% cost saving
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Customers - Installations
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Case Studies
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Case Study
Automotive Industry
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Benefit
Easier design of mold package (no tool needed)
excellent design freedom
Engineering and CAD Design
Digital Core Production at Danielson
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ExOne Technology
3D Sand Printing
Benefit
Molds and Cores with complex geometry available without tooling
cost saving due continous product design modifications
Asia | The Americas | Europe
Benefit
Faster assembly and high precision of the cores
Reduce number of cores as freedom in core design
Assembly
Digital Molds and Cores ready for Casting
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Benefits
Molds and cores are ready in hours
Industrial proven casting materials (aluminium, magnesium, cast-iron…)
Foundry
Casting with Digital Molds and Cores
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Benefits
Short lead time in product development
Complex parts feasible: Innovative product design
Cost saving with design changes (no tooling)
Case study of MCE-5 VCRi
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Case Study
Aerospace Industry
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• Put the foundry in the 21st Century
Implement digital core production technology
• Create a new economic model
Attract new market and customers
• Develop a process using digital tools
Propose innovative design with the introduction of new materials
Why Digital Core Production
at Fonderie Messier?
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• Using sand molds and cores without tooling
High cost reduction
• Reduction of casting development cycle
Reduce lead time for prototypes with digital molds and cores
Systematic usage of digital core for serial production
• Substitute old core box tooling with digital core production
Print directly from CAD data
Digital Core Production
Advantages at Fonderie Messier?
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ExOneTechnology
3D Sand Printing
Benefit
Molds and cores with complex geometry available without tooling
Economic and optimised product design modifications
Asia | The Americas | Europe
Benefit
Molds and cores are ready in hours
Faster assembly and high precision of the cores
Reduced number of cores through freedom in core design
Assembly
Digital Molds and Cores ready for Casting
Asia | The Americas | Europe
Benefits
Short lead time in product development
Complex parts feasible: innovative product design
Cost saving with design changes (no tooling)
Case study of Door hinge
Thank you for your attention [email protected]
Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.
ExOne The Americas
MID-ATLANTIC
127 Industry Boulevard
Irwin, PA 15642
USA
+1 877 773 9663
MIDWEST
2341 Alger Drive
Troy, MI 48083
USA
+1 248 740 1580
SOUTH
7409 Railhead Lane
Houston, TX 77086
USA
+1 281 931 0011
ExOne Europe
ExOne GmbH
Am Mittleren Moos 41
86167 Augsburg
Germany
+49 (0) 821 7476 0
ExOne Asia
161-5 Haneo
Odawara-shi, Kanagawa
Japan 256-0804
+81 465 44 1303
www.ExOne.com