prof. d.sc. m.sc. gideon n. levy [email protected]...

TTA Gideon Levy © 09/2014

Additive Manufacturing- meets Sustainable

Environment needs

Prof. D.Sc. M.Sc. Gideon N. Levy

[email protected]

Additive Manufacturing and

Electro Physical & Chemical Processes

AM the enabling space for future innovation

and progress

NSF Workshop: Environmental Implications of Additive Manufacturing

October 14-15, 2014, NSF, Arlington, VA

mailto:[email protected]


World gov. funding 5`561 Mio € Mio €

Singapore 500 Mio SGD 293 Mio € 293

China 2 Billion USD 1466 Mio € 1466

UK 60 Mio GBP 74 Mio € 74

European Union (approx.) 2 Billion EUR 2000 Mio € 2000

Russia 2 Billion USD 1466 Mio € 1466

Australia AMCRC 250 Mio AUD 171 Mio € 171

Australia AM machines 17.5 Mio AUD 12 Mio € 12

US (NAMII) 30 Mio USD 22 Mio € 22

US America Makes 9 Mio USD 7 Mio € 7

New Zeland

Taiwan

South Africa

South America

Mexico

Mio € 5'561

50

Additive Manufacturing government funding


Agenda I

1. What is Additive Manufacturing

2. What is Sustainable Manufacturing

3. Where do they meet?

4. Conclusions


5 Senses

Why do have AM a great potential? A

bstr

act

Real

Perc

ep

tio

n

Thinking

Speaking

Writing

Printing

Painting

Crafting

Art, Music

Virtual reality

Software

Film TV

Simulation Modelling

Science: Rules and

equations

Physics, Chemistry

Mathematics

Everything

we have

And more….


AM is an Enabling Multidisciplinary Technology

System / Process

Materials

Applications

Up stream/ Down stream

Polymers

Metals

Ceramics

Composite

Biologic

Application dedicated

Automation

Part and powder handling

Batch to continues

……………..

Adaptive control

Closed loop

Productivity

Repeatability

………………

Design for AM

3DP design

tool

Part finishing

Coating

Modifications

…………

Industry

Aviation

Automotive

Jewelry

Medical devices

Scaffolds

Organ printing

……..


Terminology - Process Categories I (2012)

1. Vat Photopolymerization Process

Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon

Liquid Photopolymers,

Ceramic or Metal filled photopolymers

2. Material Jetting Process

Multiple nozzles Single nozzles

Thermoplastics, Wax or Photopolymers, Metals,

Optical materials, Electronic materials

3. Binder Jetting process

a liquid bonding agent is selectively deposited

to join powder materials.

Polymer, Metal, Ceramic powders

4. Material Extrusion Process

FDM Polymers, composite

C

C

C

T

T

C Chemical

T Thermal

T Thermal post processing

T


Terminology - Process Categories II (2012)

5. Powder Bed Fusion Process

SLS, SLM, EBM

Polymers, metals & ceramics powder

6. Sheet Lamination Process

Bonding, hot melt, glue, US welding

Paper, Metal, Polymers

7. Directed Energy Deposition Process

focused thermal energy is used to fuse materials by melting as they are

being deposited

Metal, polymers, powder, wire

T

T

T

C

C Chemical

T Thermal

T Thermal post processing


Hybrid Systems in metal and polymers


Process / material matrix

For most process some bio-compatibles

are available.


https://www.additively.com/en/


Gartner Hype Cycle of Emerging Technologies, Trends for 2014


The value chain in product creation

CONCEPT MODELING

RAPID PROTOTYPING

Pre-SERIE / BRIDGING

CONFORMAL COOLING / TOOLING

ADDITIVE MANUFACTURING REVERSE ENGINEERING

The Trend


http://sitemaker.umich.edu/ykoren/education

Manufacturing paradigms


China 2013 $80 million investment in AM

An AM-built beam for use in

aviation, printed at Northwestern

Polytechnical University in China.

Courtesy of Guancha Zhe.


SME RAPID Detroit 2014


AM Micro Parts


http://www.grantadesign.com/ and 3DP materials

3DP

3DP

3DP

3DP

3DP

Food

3DP

Bio-mat

http://www.grantadesign.com/




Applications arrays divide and focus consequently on different quality issues and standards

Entertainment

Movie?


Main Application areas of AM/ 3DP

Difficulty

Value


Added Value: Translate process characterization into specific applications

Freedom of Design

Lightweight structures (hollow)

No-Tool production

Assemblies, integrated design

Anatomical personalized

Ergonometric design

Customization individualization

Conformal cooling

Gradual materials (on the way)

Medical scaffolds (on the way)

Bio Materials (on the way)


Bio inspired AM fabricated systems

4_Festo - Bionic Handling Assistant.flv


32

Conformal cooling systems and heat exchanger

A great chance is coming up in moulds!


Renishaw's additive manufacturing system to boost production capabilities at Directed Manufacturing Inc


3D Printers in 30% of Households

Experts Futures Researchers


Agenda I




4. Conclusions


Venn diagram - Path to sustainable development

"Sustainable development is an

organizing principle for human

life on a finite planet. It posits a

desirable future state for human

societies in which living

conditions and resource-use

meet human needs without

undermining the sustainability of

natural systems and the

environment, so that future

generations may also have their

needs met. Sustainable

development ties together

concern for the carrying

capacity of natural systems with

the social and economic

challenges faced by humanity”. http://en.wikipedia.org/wiki/Sustainability


Why sustainable?

"Less than 10 % of global population consume more than

80 % of global resources. With more than 7 Billion

humans on globe we in the early industrial countries carry

responsibility to chance value creation in the direction of

wealth for all global citizens”

Prof. Dr.-Ing. Günther Seliger

TU Berlin


LCA Standards

ISO: International Organization for Standardization

LCA standards are voluntary

Part of 14000 Environmental Management Series

• LCA Standards:

– 14040 Principles and Framework

– 14041 Goal and Scope Definition and Inventory Analysis

– 14042 Impact Assessment

– 14043 Interpretation

– 14020 series: Environmental Labeling


Life Cycle Assessment (ISO Standards)

According to the ISO 14040 and 14044 standards, a Life Cycle Assessment is carried

out in four distinct phases as illustrated in the figure shown to the right. The phases are

often interdependent in that the results of one phase will inform how other phases are

completed.

http://en.wikipedia.org/wiki/Life-cycle_assessment


Reducing Environmental Impact Through Product Life Cycle Assessment


Fuel consumption per 100 passenger kilometre


Most car manufacturers on track to meet 2012 CO2 targets

http://w

ww

.eea.e

uro

pa.e

u

http://www.eea.europa.eu/

http://www.eea.europa.eu/


COMPARE: Is AM a better alternative to Casting e.g.?


Agenda I




4. Conclusions


ATKINS Project: a low-carbon footprint manufacturing solution

The £2.7 Million ATKINS Project …

DirectSpare: A European Approach for Spare Parts on Demand

Birth and

youth

problems

Aging and

wear

problems

http://www.bpo.nl/nederlands.htm

http://www.hexagonstudio.com.tr/default.asp

http://www.eos.info/index.php

http://www.berenschot.com/


The impact of the DirectSpare concept

Obsolete equipment because of

unavailability of spare parts becomes

useful

Millions of unused

spare parts being

reduced to scrap...

Ordered spare parts

transported around

the globe...

Warehouses

stacked with spare

parts...


Autodesk Sustainability Workshop, November 22, 2013

Environmental Impacts of 3D Printing , By Jer Faludi

See more at:

http://sustainabilityworkshop.autodesk.com/blog/environmental-

impacts-3d-printing#sthash.tKT7DEf0.dpuf

http://sustainabilityworkshop.autodesk.com/blog/environmental-impacts-3d-printingsthash.tKT7DEf0.dpuf











Light-weight “material“ selection done by geometry

Materials designed with new additive manufacturing techniques exhibit high stiffness

and low density, occupying a previously unsettled area of the Ashby material

selection chart for Young’s modulus (stiffness) versus density. The octet truss

structure recently fabricated by Livermore researchers is a stretch-dominated lattice.


Topological Optimizations

Topological optimized design results are:

• Complex geometries

• Conventionally not produce able

• Have to be smoothed

• Highest geometrical freedom

• Agile manufacturing

• New design concepts

Chances for Layer Manufacturing:


AM made - (no supports) Heat exchanger

Heat exchanger 450x4050x500 mm


Multi Physics-CAD (MP-CAD) Tools are in due

– Light weight

– Ecological design

– Topological optimization

– Flow

– Minimal parts(Diffusor)

– Static mixer

– Aeronautics

– Heat transfer

– Local physical properties

– Digital materials

– Alloyed materials

– Medical

– Biological design

– Engineered surfaces

– Scaffolds

– Life Style


AM a green technology

AVIO AERO and Additive Manufacturing.mov


Agenda I




4. Conclusions


Construction of a CUBESAT using AdditiveManufacturing

Additive manufacturing

The sky is the limit !


Additive Manufacturing has the potential to improve the entire

Life Cycle Engineering

AM is a Green Technology

AM may replace less environmental friendly process

AM can reduce row material consumption

AM can reduce weight by freedom of design

AM can save energy in the use phase

The AM process themselves can and have to be

environmentally improved ( higher efficiency, bettery

recyclability of materials, less waste)


67 years ago…

The First Transistor was Invented,

November 17-December 23, 1947

John Bardeen William Shockley and Walter Brattain at Bell

Laboratories


30 years ago: The AM was invented

08.08.1984

Dr. Charles W. Hull; born May 12, 1939, is

the co-founder, board member, executive

vice president and chief technology officer

of 3D Systems Inc.( the biggest 3DP

OEM). He is the inventor of the

Stereolithography; he holds more than 60

U.S. patents

Dr. Chuck Hull is recognized as “the

father” of the worldwide upcoming 3D

Printing or Additive Manufacturing

technologies.


We are on the right track

prof. d.sc. m.sc. gideon n. levy [email protected]...

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