AM Systems, Applications, Market & Development 2024 PDF

KTEK0012 3D Printing & Additive Manufacturing AM Systems, applications, and development Features and phenomena involved in systems, applications, market and development Antti Salminen 9.9.2024 Main categories in metal AM EN ISO/ASTM 52900:2017  Powder Bed Fusion  Directed Energy Depositio...

KTEK0012 3D Printing & Additive Manufacturing AM Systems, applications, and development Features and phenomena involved in systems, applications, market and development Antti Salminen 9.9.2024 Main categories in metal AM EN ISO/ASTM 52900:2017  Powder Bed Fusion  Directed Energy Deposition  Binder Jetting 3D printers A. A platform for basis of printing B. Tools to handle material to be added on previous layers C. A process and tools to consolidate material on top of previous layer D. A system to generate movement in X-Y-Z coordinates E. Computer control over whole printing system and process F. Framework and enclosure of the system  As an example metal printing systems Printer consists of: A. A platform for basis of printing B. Tools to handle material to be added on previous layers I. Material storage II. Material feeding C. A process and tools to consolidate material on top of previous layer I. Material consolidation process II. Material consolidation tools D. A system to generate movement in X-Y-Z coordinates I. X-Y - movement II. Z - movement III. Rotational movement IV. 3 – 6 –axis movement (e.g. robot) E. Computer control over whole printing system and process F. Framework and enclosure of the system Powder bed fusion, PBF-LB/M, PBF-EB/M Powder Bed Fusion Powder Bed Fusion Laser beam or electron beam based systems Laser beam based systems are the most used and possible the most evolved method for additively manufacturing of metal parts  The laser is typically 200-1000 W fiber laser  Multiple lasers possible All metal AM systems (+30 pcs) were PBF-LB systems in Finland in 2018. First other machines utilizing other processes (ME) came in the early 2019 Powder Bed Fusion Powder bed fusion Powder bed fusion, n—an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed. (Jauhepetisulatus)  System spreads a layer of metal powder on building platform  Laser beam melts the locations that are part of the product to build in this layer  Building platform, powder bed and part billet inside is moved downwards  New metal powder layer is spread on top of previous  Laser beam melts….. … When build job is ready, the build job is depowdered and part is taken to post processing (heat treatment and/or mechanical processes) Powder Bed Fusion Printer consists of: A. A platform for basis of printing  thick metal plate B. Tools to handle material to be added on previous layers I. Material storage  powder reservoir II. Material feeding  recoater spread the powder on previous layer C. A process and tools to consolidate material on top of previous layer I. Material consolidation process  Laser/EB melting II. Material consolidation tools  Laser and optics or EB with magnetic coils D. A system to generate movement in X-Y-Z coordinates I. X-Y – movement  Scanner with laser or magnetic coils with EB II. Z – movement  Linear axis E. Computer control over whole printing system and process F. Framework and enclosure of the system  Sturdy base and cabin to ensure proper atmosphere (inert or vacuum) and to block laser beam or x-ray in case of EB and to keep powder in. Powder Bed Fusion Powder bed fusion printer 1. Container for unused, excess powder (B) 2. Building platform (A) 3. Powder container (B) 4. Scanner (C) 5. Laser (B) 6. Building chamber (E) 7. Work piece 8. Recoater (B) 9. Laser beam (B) Image: Photonik International 2011 At least 95% of lasers are single mode cw fiber lasers, l 1030-1080 nm 9 Optical scanner Guides laser beam with two mirrors (X &Y direction) moved by galvanometric motors Laser beam is focused on workpiece with lens to ensure small enough focal point thus energy density required to melt metal Advantages of scanner:  Compact design  Low inertia  - High speed - High acceleration and deceleration of laser focal point on surface (up to 200G) - High accuracy PBF-LB printer occasionally is described with one mirror scanner, but there is no known system with such configuration. Image: modified from Römer & Bechtold, 2014 Directed energy deposition, DED-LB, DED-EB, DED-Arc Directed Energy Deposition Directed energy deposition Directed energy deposition, n—an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited. Kohdennettu sulatus/ Suorakerrostus  Building platform or preform is fixed to system  Thermal energy and additive material are fed into top of building platform or preform*  Process adds material on top of existing material layer by layer by melting it on previous build material  The workpiece is lowered or process just goes up on top of part adding more and more material  billet and as process moves material is added on top of previous structure by melting it such that also previous layer melts so much that a solid metal structure can be formed. When build job is ready, the part is taken to post processing (heat treatment and/or mechanical processes) * Preform can be part of final product, i.e. one can build on existing structures Directed Energy Deposition Printer consists of: A. A platform for basis of printing  Solid metal part B. Tools to handle material to be added on previous layers I. Material storage  powder or wire reservoir II. Material feeding  Material feeder and a nozzle to feed material to process C. A process and tools to consolidate material on top of previous layer I. Material consolidation process  Laser, EB, arc welding process melting II. Material consolidation tools  Laser and optics or EB with magnetic coils, arc welding source and torch D. A system to generate movement in X-Y-Z coordinates I. X-Y – movement  Scanner with laser or magnetic coils with EB II. Z – movement  Linear axis III. Rotational movement  rotation axis for workpiece IV. 3 – 6 –axis movement (e.g. robot)  industrial robot + linear and rotation axis or 6- axis portal system E. Computer control over whole printing system and process F. Framework and enclosure of the system  Sturdy base and cabin to ensure proper vacuum in case of EB and to block laser beam, UV-radiation of arc or x- ray of EB process and to keep powder in. Directed Energy Deposition Directed energy deposition system Typical components are:  A heat source (laser, EB, Electric arc) - In case of laser some specific optics  Feedstock feeder (powder or wire)  Mechanics for process movement often a robot  Computer control https://www.beam-machines.com/products/modulo400 Binder Jetting, BJT-MSt/M Binder Jetting Binder jetting Binder jetting, n—an additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials. Sideaineen suihkutus  System spreads material to form a powder bed  Bonding agent (glue) is sprayed in locations that form the part in particular layer, binding of print with IR-light + curing  Building platform, powder bed and part billet inside is moved downwards  New metal powder layer is spread on top of previous  Bonding……  When build job is ready, the build job is cured with thermal treatment, depowdered and formed so called “green part” is taken to debinding and sintering in heat treatment oven in which the final mechanical properties of part is reached. After printing and oven there is still mechanical post processing stages. Binder Jetting Printer consists of: A. A platform for basis of printing  metal plate B. Tools to handle material to be added on previous layers I. Material storage  powder reservoir II. Material feeding  recoater spread the powder on previous layer C. A process and tools to consolidate material on top of previous layer I. Material consolidation process  adhesive bonding + curing with IR-light (+ sintering in post processing) II. Material consolidation tools  Binder reservoir and feeding tools & IR-light D. A system to generate movement in X-Y-Z coordinates I. X-Y – movement  X-Y linear movement for binder nozzle II. Z – movement  Linear axis E. Computer control over whole printing system and process F. Framework and enclosure of the system  Sturdy base and cabin to ensure proper atmosphere and keep powder in. Binder Jetting Binder jetting system Typical components are:  Powder supply  Levelling roller  Inkjet printhead  Binder feeder  Infrared light  Build platform and powder bed Binder Jetting Binder jetting https://www.desktopmetal.com/  PBF-LB/M systems More than 30 PBF system producers exist Average base price approximately 500 000 € and building volume 20 litres Typically the number in model name is about the build platform dimensions https://www.eos.info/eos-m290  PBF-LB/M - small systems  Small systems  Building volume less than 10 litres  Average volume 1.5 litres  Average base price 200 000 €  Typically 1 x 200 W laser https://www.eos.info/eos-m-100  PBF-LB/M - medium size systems  Medium size systems  Building volume less min. 10 litres and max. 30 litres  Average volume c. 20 litres  Average base price c. 400 000 €  Typically 1-2 pcs of 200-700 W laser(s) https://www.renishaw.com/en/am-400--35456  PBF-LB/M – Large systems  Large systems  Building volume more than 30 litres  Average volume c.70 litres  Average base price c. 1 000 000 €  Typically 1-4 pcs of 400-1000 W laser(s) https://slm-solutions.com/en/products/machines/slmr800/ Applications  Ways to apply 3D printing Education/Research 12 % Cosmetic models 10 % Functional prototypes 24 % Fixtures/accessories 7% Plastic models/molds 7% Metallic tools 3% End products 34 % Other 3% Wohlers Report 2022 Use of AM in filtering  Pressure difference between inlet flow and outlet flow determines the amount of energy needed for pumping.  Turbulence in flow causes increase to resistance of filter i.e. filtering efficiency decreases  Amount of inlet flow has to be increased i.e. energy needed for pumping is increased. Perforated plate Mesh filter 26 Source: Neil Burns (Croft Additive Manufacturing) PBF-LB/M Use of AM in filtering  Idea enabled by AM:  If the fluid channels and holes in the filter could be aligned with fluid flow, turbulence would decrease  pressure drop would decrease  less energy needed for pumping.  This structure is possible to manufacture only with AM.  Material: SS316L 27 Source: Neil Burns (Croft Additive Manufacturing) DED-LB(P) EHLA processed break discs According to Euro7 norm the nanoparticle emission requires new coating materials to break discs Cast iron body and wear protection layer two Metal Matrix Composites (MMC) with a matrix of 316L + silicon carbide (SiC) or titanium carbide (TiC). EHLA process is variation of laser powder DED with higher speed and lower layer thickness Process can be used nowadays also for additive manufacturing https://www.laserline.com/en-int/ DED-Arc(MIG) Propeller  Volume: 8500 cm3  Materials: 1.4370 & CuAl8  Weight: 67 kg  Machine: 3DMP  Build time: 30 h  One propeller  1 400 cm3  11 kg 29 DED-Arc(MIG) Disruption of space industries Traditional Relativity Factories and tool + high price of work Adaptive, scalable autonomous robot 100 000 + parts < 1 000 parts 24 kk production time 2 kk production time, 6 kk iterations 48 kk iterations Simple value chain Complicated value chain Digitally defined factory Physical complicity https://www.relativityspace.com/stargate System development PBF-LB/M PBF-LB/M printer with 12 lasers There is a constant need to print faster and bigger parts. Example of the large systems is SLM Solutions NXG XII 600. Machine is equipped with twelve 1 kW lasers that can operate simultaneously, thus system is 20 times faster than single-laser SLM 280. The NXG XII 600 is designed to mass produce large parts, with its size and speed it may enable serial production applications for automotive and aviation sectors. Source: https://3dprintingindustry.com/news/slm-solutions-launches-powerful-new-12-laser-nxg-xii-600-metal-3d-printer-178966/ PBF-LB/M PBF-LB/M printer with 12 lasers SLM NXG XII 600 System has 12 lasers of 1 kW power each. Beam diameter: 160 µm Hatch distance: 400 µm Build volume: 216 l, 600x600x600 mm3 Laser beam size with double lens and so called zoom function to adjust the beam size to be suitable for application. Build-up rates to 1000 cm3/h and more. Source:https://manufactur3dmag.com/slm-solutions-launches-new-12-laser-slm-nxg-xii-600-3d-printer/ PBF-LB/M Closed-loop process control in AM Process monitoring, used in AM process a decade is now changing to process control. EOS showed 2022 a closed-loop control with adaptive feedback for PBF-LB/M process, Smart Fusion. Now PBF-LB/M systems are reaching the cyber-physical system level, which will be huge game changer metal part design and production e.g. by enabling support-free structures. Figure shows AM tank, done as single print, utilizing EOS Smart Fusion technology. Source: Formnext 2022 References Römer, G.R.B.E. & Bechtold, P., Electro-optic and acousto-optic laser beam scanners. Physics Procedia 56 ( 2014 ) 29 – 39 Wohlers report 2022, 3D Printing and Additive Manufacturing - Global State of the Industry. Wohlers Associates, ASTM AMCOE SmarTech Analysis. https://www.smartechanalysis.com/market-studies/