tecnologie additive, un’opportunità da cogliereinjector head ariane 6 – panoramica del progetto...
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Tecnologie additive, un’opportunità da cogliere
12 Aprile 2018
Davide Zurro
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This presentation may contain confidential and/or privileged information. Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
Additive Minds
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#1 Consultente nel mercato AM
3
#1 Consulente in AM
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#1 Consultente nel mercato AM
4
100 esperti in AM: squadra in tutto il mondo
100 Esperti
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#1 Consultente nel mercato AM
5
100 esperti in AM: squadra in tutto il mondo
8 training e 14 pacchetti di consulenza
Find Your Application
Develop Your Application
Ramp Up Your Production
Certify and Scale Your Production
22 Pacchetti di consulenza
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Interni settore aerospaziale
#1 Consultente nel mercato AM
6
100 esperti in AM: squadra in tutto il mondo
8 training e 14 pacchetti di consulenza
250 progetti di successo in 25 Paesi
Interni settore trasporti
250 Progetti
Settore calzatura
Applicazioni in elettronica ed automazione
Mercato di massa e beni di consumo
Componenti metallici e polimerici nel settore
auto e motor sport
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Applicazioni
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Caratteristiche di una parte innovativa in AM
Geometrie Complesse
Integrazione Funzionale
Highly innovative AM part
Customizzazione
New and complex design Leightweight
structures
Customized products
Patient specific restorations
Integrated and complex functions
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Caratteristiche di una catena produttiva di AM efficiente
Produzione Flessiblile Volume
Produzione Flessibile Location
Digital AM Manufacturing cells
Produzione Flessibile
nel tempo
„one“ to „many“
small and economic production runs
„local to global“ to „globally local“
„just in time“ to „on demand“
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I vari pacchetti AddMi includono soluzioni ottimizzate per tutti i segmenti di nuovi clienti
Trova la tua applicazione
Sviluppa la tua applicazione
Avvia la produzione
Certifica e scala la produzione
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Additive Minds Storie di successo
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Automotive – Evobus
Trova la tua applicazione
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EvoBus affronta diverse sfide nel settore dei pezzi di ricambio
Enorme portafoglio prodotti
Oltre 320,000 parti di ricambio diverse
Alti costi di gestione
I clienti si aspettano tempi rapidi (consegna, manutenz, etc.)
Durata del prodotto
Costi di stoccaggio e logistica molto alti, alto numero di fornitori
Obiettivo di Evobus
Utilizzare Additive Manufacturing per sviluppare un modello di business sostenibile nella gestione delle parti di ricambio
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1. Ridurre i costi
• Tempi di consegna minori
• Indipendenza e riduzione numero fornitori
• Costi minori di stoccaggio e logistica
2. Generare valore aggiunto
• Sfruttando l’AM per ottimizzare le applicazioni
• Aumento della durata dei bus
• Sviluppare nuovi modelli di business
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Oil & Gas- Linde
Sviluppa la tua applicazione
Source: Linde Logo: http://www.the-linde-group.com/de/news_and_media/image_library/index.html 15
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Linde si trova di fronte a diverse sfide
Ambiente ad alta competitività
Aumentare la produttività e rispettare le normative ambientali allo stesso tempo
Invito all’innovazione
Le tecnologie di produzione esistenti sono obsolete
Carenza di competenze
Carenza di knowhow in Additive Manufacturing
Obiettivo di of Linde
Costruire e testare prova nuove competenze di produzione e progettazione nella produzione additiva in pochissimo tempo
?
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Garantire un aumento significativo e sostenibile della posizione competitiva:
• Prestazioni dei componenti
• Personalizzazione
• Ridurre i costi di gestione
• Disponibilità dei ricambi su richiesta
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Re-design e produzione del bruciatore Hydropox
Function integration (15 to 1)
Redesign of burner Minimization of
support structures
complex sandwich construction
Optimized gas flow
production-friendly design
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Risultati del progetto della cooperazione tra Linde e Additive Minds
Bruciatore
• Fronte fiamma uniforme
• Bassi tempi di produzione: solo 5h per parte (18 per job)
• Design compatto ed integrato
• post processing ridotto
• Riduzione dei componenti da 15 a 1
Strategia competitiva
• Costruire un ampio know-how all'interno di Linde nel campo della produzione additiva
• Espansione delle competenze interne per diffondere la produzione additiva ad altri reparti e prodotti
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Aerospace – Ariane Group
Avvia la produzione
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Il Gruppo Ariane deve affrontare diverse sfide nello sviluppo della testa dell'iniettore
Ridurre la complessità delle parti
248 Parti singole
(> 8,000 forature)
Alte Performance
Garantire alte prestazioni
Mantenere gli alti standard qualitativi
Componente di
Classe 1
Obiettivo di Aiane Group
Produzione di una testa dell’iniettore per motori a razzo con il minor numero possibile di componenti e costi unitari inferiori
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1. Ridurre i costi
• Tempi di consegna più brevi
• Maggiore indipendenza e riduzione dei fornitori
2. Generare valore aggiunto
• Utilizzo dei vantaggi di AM per ottimizzare le applicazioni
• Aumento delle prestazioni
• Aumentare la qualità
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Testa iniettore di Ariane 6 realizzato come un progetto all-in-one (AiO)
Injector Head Ariane 6 – Panoramica del progetto
The additively manufactured baseplate of the injector head of a rocket engine with 122 injection elements is made from EOS NickelAlloy IN718.
Injector head of Ariane 6 upper stage propulsion module VINCI as an all-in-one design (AiO).
Risultati
• Semplificato: un componente invece di 248 • Economico: costi inferiori del 50% • Veloce: riduzione significativa • in tempo di produzione (riduzione dei tempi di consegna
dell'80%) • Qualità superiore e prestazioni migliori • Produzione interna
Soluzione
Additive manufacturing su EOS M 400-4 (IN 718) ed integrazione funzionale.
Sfida
Produzione di una testa iniettore per motori a razzo con il minor numero possibile di componenti e costi unitari inferiori.
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Medical – Permedica
Certifica e scala la produzione
Source: https://www.permedica.it/en/company/ 22
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Permedica si trova di fronte a diverse sfide
Garanzia della qualità
Standard rigorosi per dispositivi medici
Invito all’innovazione
Nuovo sistema coppa acetabolare con una struttura altamente porosa
Carenza di competenze
Carenza di knowhow in Additive Manufacturing
Obiettivo di Permedica
Acquisire know-how nella stampa 3D di metalli industriali all'interno dell'organizzazione
?
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• Nuovo know-how tecnologico implementato in azienda
• Convalida rapida dell'attrezzatura e dei processi
• Aumento del mercato
• Trasferimento ad altri prodotti impiantabili (protesi custom, protesi di spalla)
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Permedica & Additive Minds
• Sviluppo di un nuovo sistema coppa acetabolare con una struttura in titanio altamente porosa per promuovere la nuova formazione ossea e una veloce osteointegrazione
• Guida da Additive Minds dall'inizio alla produzione in serie
• Particolare attenzione alla qualità, all'impostazione della produzione e al processo di qualifica
Panoramica del progetto
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Thank you for your attention!
Davide Zurro
Application Development Consultant
www.additive-minds.com
EOS s.r.l. Electro Optical Systems Via Inverigo, 2 | 20151 Milano, Italia
Tel. +39 328 2363921 www.eos.info | [email protected]
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Appendix
Made by EOS GmbH based on design by Derek Hugger 26
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Medical application examples
Airduct
Challenge: Economic production of patient-specific restorations made of high-performance alloy
Solution: Manufacture of fully dense restorations w/o porosity using EOS M 100
Fast and cost-efficient manufacturing
Accuracy of units is +/- 20 microns
Restorations are durable, high-performing and consistently high quality
Challenge: Design, CAD engineering and production of orthoses that combine several functions
Solution: Construction of customized orthoses, using PA 11 with EOS P 396
Complete freedom of design for structures and material thicknesses
High-quality and precision, inde-pendent of level of craftsmanship
Each orthoses is bespoke
Challenge: Production of acetabular cups that pro-motes osseointegration
Solution: EOS DMLS using EOS Titanium Ti64. Design using WITHIN software
Fully dense sections for stability, lattice structures for better osseointegration
Both sections produced in a single production step
Sections merge seamlessly for optimum load absorption
Challenge: Simplify production of ROTOLAVIT washing rotor
Solution: Laser sintering on EOSINT P 395 with PA 2200 as series material
High functional integration
3 parts (laser sintered parts plus 1 steel ring) vs. 32 parts
Significant reduction in finish and assembly requirements
Hettich wash rotor Rotolavit Orthoses, PlusMedica OT Acetabular Cups, WITHIN Labs Bridge made from EOS CobaltChrome SP2
Dental Applications Orthopedic Devices Implants Medical Devices
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Aerospace application examples
Swirler, Morris Technologies Injector head, ArianeGroup
Challenge: Substitute a conventional primary flight control hydraulic component with an additively manufactured part – fulfilling all certification requirements for flight test
Solution: Manufacture of a lightweight 3D-printed component with fewer parts using an EOS M 290 and an efficient process chain
Challenge: Build a highly complex design (fuel injection systems, vane segments) as “one piece”
Solution: Manufacturing with DMLS using EOS technology and EOS CobaltChrome MP1
Challenge: Produce an injector head for rocket engines with as few components as possible and lower unit costs
Solution: Additive manufacturing with EOS M 400-4 and functional integration
Optimized: 35% less weight
Simplified: 10 parts eliminated
Safe: Meets all certification requirements for flight
Efficient: Identical functionality to conventional part
Optimized: Improved design, no brazed joins, increased robustness
Quick: Delivery time less than 2 weeks (vs. 6 weeks)
Economic: Significant cost reduction – typically 50% less
Simplified: 1 component vs. 248
Speedy: Significant reduction in production time
Economic: 50% lower costs
Source: Liebherr
Jet engines Injector heads Hydraulic components
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Industry application examples
Challenge: Produce a HYDROPOX® burner for flame-based glass surface treatment with as few components as possible, lower unit costs and improved functionality
Solution: Additive manufacturing enables functional integration
Challenge: Produce a bionic gripper able to reliably pick up and safely put down objects gently and flexibly
Solution: Small batch production using EOS FORMIGA P 100
Challenge: Produce a device to adjust laser mirror in Y and Z direction for EOS FORMIGA
Solution: Production with EOS plastic laser sintering technology using EOS material PA2200
Simplified: 1 part vs. 15
Efficient: Homogeneous flame front
Speedy: 5h per part (18 parts/build job), functional design optimized for serial production
Optimized: Functional integration reduces number of single parts and cuts assembly costs
Economic: Lightweight and long-lasting due to innovative manufacturing method
Efficient: Tool-free production saves time and money
Optimized: Functional integration:
Integrated cam levers to fix regulating screws
Integrated control angle markings (no stickers required)
Economic: Manufacturing on Demand possible, enabling adjustments and production of spare parts
Gripper: lightweight and complex components
Special purpose machinery: integrated functionality
HYDROPOX® burner: complex and scalable components
EOS FORMIGA P 1 Laser adjustment unit
Festo gripper Bionic Assistance System HYDROPOX® burner, Linde
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Tooling application examples
Airduct
Injection Molding
Challenge: Enable precision cooling for production of plastic parts for cell phones
Solution: Improved cooling design. Manufacture of core inserts using EOS technology
Production increased by 56,000 units/month
Rejection rate reduced from 2% to 1.4%
Annual cost savings of approx. 20,000 euros
Repairing
Challenge: Repair a partially damaged tool insert
Solution: Generation of a new reference surface; positioning of part in EOS machine. On-top construct-ion of missing parts
Reduced construction costs for a complete new insert
Reduction of lead time: partial construction instead of complete construction
Die Casting
Challenge: Build a tool insert for a die-casting application
Solution: Cooling system optimization; insert built via DMLS on EOSINT M 270 in EOS MaragingSteel MS1
Significant reduction of cycle time
Improved lifetime of inserts
Rapid Tooling
Challenge: Injection molding tooling for 50,000 electrical component parts
Solution: Redesign of inserts with conformal cooling channels; inserts built in EOS MaragingSteel MS1
Reduced lead time and costs
Increased mold productivity
Better thermal management
Salcomp tool insert and injection-molding part Innomia tool insert for die casting PEP (Pôle Europeen de Plasturgie) tool insert Ecoparts tool insert
Smarter design of conformal cooling channels: Reduced costs, cycle times and scrap rates, increased performance
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