metaal am applicaties en materiaalvalidatie

© LayerWise NV, all rights reserved 2/19/2014

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New Thinking Unmatched Performance

From pioneering high-end production to a global vision

Let Additive Manufacturing Inspire You

LayerWise 2014


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LayerWise LBM Technology Technology Development Drivers and Applications Future outlook


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Increase your added value through advantages of

Metal Additive Manufacturing

Therefore LayerWise offers its technological expertise realized by being technology developer as well as technology user

LayerWise


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2008 1989 1991 2007 2009 2010 2012

Start of AM Research

Start of METAL Research

Full Dense Metal Samples

2001

Phd P. Mercelis

Phd J. Van Vaerenbergh

SLM SLS Sintering

2014

Thin Wall 0.5MM

Thin Wall 0.3MM

Thin Wall 0.225MM

Thin Wall 0.18MM

RP

0% Manufacturing

10% Manufacturing

50% Manufacturing

80% Manufacturing

90% Manufacturing

Ti Grade 5 Ti Grade 23

Inc 718 Maraging

17-4 15-5 AlSi10Mg

Tantalum Tungsten

316L CoCr

LayerWise


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LayerWise

Service Provider for metal additive manufacturing

Main Goal:

Tools: In house development of the technology In house development of new materials In house development of post finishing techniques


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LayerWise

dental prostheses crowns and copings

standard implants customized implants medical tools medical modeling

Chemistry Pharmaceutic

Semicon High Tech

Aerospace Tooling

Food Mechatronics

Pressure & Gas Consumer

Electronics Automotive

ISO 9001 & 13485 certified


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LBM Technology AM

Polymers Metals

Powder

Bed

Tech

EBM

LBM

Powder

Deposition

Tech

Laser Cladding

Ceramics Glass …


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LBM Technology

Directly from 3D CAD Layer-wise production 3D components by successive

connection of thin 2D layers


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LBM Technology


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“Can we apply 3D metal printing for volume manufacturing of critical

components?”

Technology Developments




1) Developing New materials: • First test samples – Microstructure Analysis • Parameter Optimization

• Density • Mechanical Properties

• Composing Certified MDS



Build Style

• Laser Power • Scan Speed • Athmosphere




– Homogeneous microstructure; grain

growth across layer thickness

– Combined α/β phases

– Minimal fraction of rest porosity; may small gas inclusions

100µm 60µm

Ti6Al4V

LayerWise

Metal AM

Technology





2) Tuning Existing materials: • Constant monitoring

• Test samples during every AM job • Melt pool monitoring and control

3) Increasing part size • Without the loss of accuracy 4) Productivity enhancement • Reducing Manufacturing costs



Melt-pool fluctuations • Tracking of melt-zone characteristics

• High speed imaging and data recording

inert atmosphere air atmosphere




• Geometric influences

1 2

1 2 1




• Feedback control advantages: demonstrator




Chemical Pharma Food Pressure & gas

Mechanization Semiconductor Electronics Tooling Precision mechanics

Standard implants Customized implants

Dental prostheses Implant supported and cemented

Aviation Space

ISO 9001 and ISO 13485 certified

Materials for critical applications




Additive manufacturing Same material Same characteristics

What is the added value?

Drivers and Applications




1) Monolythic Construction




2) Flow Optimization




3) Miniaturisation




4) Add Functionality




5) Mass Reduction




10 mm

6) Others:

- First proto of a MiM-serial production

- Very small complex products



Some more Applications

Flow type Laminar Turbulent

Channel shape Cross section 3D traject

Pressure drop Variable sections restriction

Heatex Conformal Balanced

CFD analysis SLM Manufacturing



Future outlook



Future outlook

Materials : super alloys, heavy metals (18+ materials)

Cost : 2008 -> 2012 - buildrate x 4

Upscaling : max dimenions x 5 to circa 500 mm

Surface control : Ra 5 -> Ra 0.9 & Ra 0.1

Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)

Pardigm shift: DfM-> design for function



Contact details

LayerWise N.V. Kapeldreef 60 3001 Leuven Belgium tel: +32 16 29 84 20 fax: +32 16 29 83 19 www.layerwise.com [email protected]

metaal am applicaties en materiaalvalidatie

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