Laser additive manufacturing (aka 3D printing) of metallic materials

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2 Laser additive manufacturing (aka 3D printing) of metallic materials Heidi Piili Lappeenranta University of Technology Faculty of Technology Laser processing research group June 16 th 2014

3 LASER ADDITIVE MANUFACTURING ACTIVITIES AT LUT

4 LAM activities at LUT LAM (Laser Additive Manufacturing) research at LUT started on 2009 with real-time process monitoring Research LAM machine (represents EOSINT M-series machines) was received in 2011 First and so far only LAM machine at any university in Finland AM (Additive Manufacturing) teaching started on 2013 Course for M.Sc. Students in spring term AM (Additive Manufacturing) teaching for industry at LUT will start in January 2014 Ohutlevypäivät, Outotec, Messukeskus, Euromold, Lappeenranta, , Tampere, Lappeenranta, Imatra, Helsinki Hämeenlinna, Appolo Laitila

5 LAM research at LUT Process monitoring and control Application research Support technology Weldability of LAM work pieces Dimensional accuracy of LAM work pieces Mechanical properties of LAM work pieces Metallurgical properties of LAM work pieces Optimization of structures with LAM Etc. Ohutlevypäivät, Outotec, Messukeskus, Euromold, Lappeenranta, , Tampere, Lappeenranta, Imatra, Helsinki Hämeenlinna, Appolo Laitila

6 LAM research at LUT Doctoral theses: Project Engineer Tuomas Purtonen: Process monitoring Research Scientist Ville Matilainen: Production feasibility of LAM Research Scientist Anne Kalliosaari: Metallurgical properties of LAM work pieces Project manager Aki Piiroinen: High power LAM Master Theses: Jukka Järvinen: Welding of LAM parts Ohutlevypäivät, Outotec, Messukeskus, , , Euromold, Lappeenranta, , Tampere, Salo, Lappeenranta, Imatra, Helsinki Hämeenlinna, Metallin Appolo Kuopio Laitila mestarit

7 LAM projects at LUT Industrial case studies Understanding of LAM process Quality and quality control systems Optimization of weight/strength ratio of structures Metallurgical and mechanical properties New materials Euromold, Hpi, Tvä, Appolo ASa

8 BK30A0900 Additive Manufacturing PRINCIPLE OF ADDITIVE MANUFACTURING (POWDER BED FUSION )

9 Principle of powder bed fusion BK30A0900 Additive Manufacturing Phases of additive manufacturing: 1. Making of digital 3D model of work piece, for example with assist of SolidWorks; 2. Making of STL-model 3. Making of one certain layer; 4. Ready physical 3D model. Messukeskus, , , Lappeenranta, Turku, Tampere, Hpi, Tvä, Helsinki Metallin Appolo Kuopio ASa mestarit 9

10 Principle of powder bed fusion BK30A0900 Additive Manufacturing Solid computer model Model of sliced layers , , Turku, Tampere, Metallin Appolo Kuopiomestarit Heidi Piili 10

11 Principle of powder bed fusion BK30A0900 Additive Manufacturing Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

12 Principle of powder bed fusion BK30A0900 Additive Manufacturing Laser melting Powder spreading Lowering of platform Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

13 Principle of powder bed fusion BK30A0900 Additive Manufacturing Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

14 LAM application, LUT Laser BK30A0900 Additive Manufacturing 3D model LAM manufacturing Loose powder is removed Before and after finishing Finished faucet Appolo

15 BK30A0900 Additive Manufacturing INTRODUCTION OF ADDITIVE MANUFACTURING (aka 3D printing)

16 BK30A0900 Additive Manufacturing Additive manufacturing (aka 3D printing) Additive manufacturing (AM) Manufacturing of 3D shapes layer by layer Technology is very new and this is why it is typical for additive manufacturing is that there is plenty of terms to describe one certain process For example, terms to describe laser based additive manufacturing processes are: Selective Laser Sintering SLS Selective Laser Melting SLM Direct Metal Laser Sintering DMLS Laser cusing , , Turku, Tampere, asa, HPi Metallin Appolo Kuopiomestarit 16

17 BK30A0900 Additive Manufacturing Additive manufacturing (aka 3D printing) Sometimes words as laser sintering (in Finnish: lasersintraus) or rapid prototyping (in Finnish: pikavalmistus) are used to describe laser based additive manufacturing processes , , Turku, Tampere, asa, HPi Metallin Appolo Kuopiomestarit 17

18 BK30A0900 Additive Manufacturing Additive manufacturing (aka 3D printing) Laser sintering (partial melting of powder) Laser based additive manufacturing is not laser sintering! Zu et al , , Turku, Tampere, asa, HPi Metallin Appolo Kuopiomestarit 18

19 BK30A0900 Additive Manufacturing Additive manufacturing (aka 3D printing) Additive manufacturing (Full melting of powder material) Source: LUT Laser , , Turku, Tampere, asa, HPi Metallin Appolo Kuopiomestarit 19

20 CHALLENGES BK30A0900 Additive Manufacturing

21 BK30A0900 Additive Manufacturing , Turku, , Tampere, Hpi, Tvä, Metallin Appolo ASa Kuopio mestarit 21

22 BK30A0900 Additive Manufacturing BUT , Turku, , Tampere, Hpi, Tvä, Metallin Appolo ASa Kuopio mestarit 22

23 BK30A0900 Additive Manufacturing , , Turku, Tampere, Hpi, Tvä, Metallin Appolo Kuopio ASa mestarit 23

24 BK30A0900 Additive Manufacturing POINTS TO BE TAKEN INTO ACCOUNT IN DESIGN

25 BK30A0900 Additive Manufacturing Points to be taken into account in design Nothing can be built on nothing! External structures are needed when building up on nothing. Haro 2012 Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, Imatra, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

26 BK30A0900 Additive Manufacturing Points to be taken into account in design Nothing can be built on nothing! Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, Imatra, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

27 BK30A0900 Additive Manufacturing Points to be taken into account in design Support structures are needed when building on nothing! Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, Imatra, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

28 Points to be taken into account in design Support structures are needed when building on nothing! Ohutlevypäivät, Outotec, Messukeskus, , , Lappeenranta, Turku, Tampere, asa, Lappeenranta, Imatra, HPi Helsinki Hämeenlinna, Metallin Appolo Kuopio mestarit

29 CASE 1: FAUCET

30 BACKGROUND

31 Challenge within manufacturing industries Complexity and demand increases Demand to fulfill a wider range of customer requirements and customizable products is constantly increasing Time cycle shortens The product life cycle as well as the lead time for product development shortens at the same time Digital design and manufacturing Digital process eliminates old style time delays in process and as such provides response mechanism to challenges mentioned earlier Euromold, Hpi, Tvä, Appolo ASa

32 Research project To study digital vs. conventional design process from productivity point of view The digital design for manufacturing using sand casting and laser additive manufacturing (LAM) as alternative manufacturing technologies were studied and compared to each other case of electrical bathroom faucet. Euromold, Hpi, Tvä, Appolo ASa

33 EXPERIMENTAL PROCEDURE OF THIS STUDY

34 Faucet design Only two modifiable parameters Other dimensions are calculated Euromold, Hpi, Tvä, Appolo ASa

35 Challenges in design In this particular research case challenges were: Electrical components had to fit into the new faucet design Euromold, Hpi, Tvä, Appolo ASa

36 Challenges in design In this particular research case challenges were: The outlook of each model has to guide the user to put the hands into the operation zone where the sensor recognizes hands in zone so the pre aimed water jet hits the hand in correct angle. Euromold, Hpi, Tvä, Appolo ASa

37 Challenges in design In this particular research case challenges were: Possibility to have scalable product Euromold, Hpi, Tvä, Appolo ASa

38 Design for casting Joint line of the cast model Euromold, Hpi, Tvä, Appolo ASa

39 Design for LAM Design for LAM Euromold, Hpi, Tvä, Appolo ASa

40 RESULTS

41 Faucet manufactured with casting Uncoated Chromium coated Euromold, Hpi, Tvä, Appolo ASa

42 LAM fabrication Digital model LAM manufacturing Loose powder is removed Before and after finishing Finished faucet Appolo

43 Faucet manufactured with LAM Unpolished Polished Euromold, Hpi, Tvä, Appolo ASa

44 Comparison of time spent on design Relative time spent on design for sand casting and LAM The total time spent on design for LAM was 46% less than for casting Euromold, Hpi, Tvä, Appolo ASa

45 CONCLUSION

46 Conclusions Conventional manufacturing methods are often time and labor consuming In large batches, casting is cost effective but in small series production, LAM is overwhelming when manufacture costs are considered On software side, current CAD systems are effective in designing complex and configurable products In general, manufacturing techniques which requires tool design need more time than more virtual tools connected methods like LAM. Euromold, Hpi, Tvä, Appolo ASa

47 Conclusions Current engineering tools (CAD/CAM/CAE) enable virtual design and prototyping as part of the digital design and manufacturing LAM releases the full potential of digital design and manufacturing of customized products Euromold, Hpi, Tvä, Appolo ASa

48 CASE 2: PIPE JOINT

49 Typical features of LAM Typical features of the cost structure of Laser Additive Manufacturing (LAM) - Machine cost defines most of the costs. - Complexity does not increase price. - In series production, the cost remains stable. - Mass customization is cheap, only the programming costs change. Parts on Demand Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

50 Typical features of LAM - Primarily only the amount of material counts the shape has no effect - Recoating takes time -> the height of the piece has effect on costs - Building several pieces simultaneously increases profitability - It is possible and beneficial to build dissimilar pieces at the same time The Casting Company, Inc. Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

51 Calculation 1. By the weight of the piece: - Price per kilo is estimated by experience. - The effect of the piece height or building several pieces at the same time is only estimated. - Fast but rough estimation. 2. By machine time simulation: - The building time is estimated by simulating machine time with the building software. - The effect of the piece height or building several pieces at same time is taken accurately into account. - Slower but more accurate calculation. Zare S.r.l. Lappeenranta, Ohutlevypäivät, Outotec, Tampere Euromold, Lappeenranta, Imatra, Hämeenlinna, Appolo

52 Example Pipe joint: Height Widht Depth Weight 40 mm 20 mm 39 mm 30,5 g - Thin walls - Joins three different cross-sections - Organic shape - Shape easy to manufacture with LAM LUT Laser Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

53 Example - Cost of the machine is spread on 8 years and the machine is estimeated to be in use 5000 h/a - Price of the material is based on price of powder by machine manufacturer. - Energy cost is calculated via the average power of the machine. Cost Cost of machine Cost of material Cost of energy Price 17,45 / h 80 / kg 8,61 snt / kwh Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

54 Example Two scenarios: 1. Building one piece at a time 2. Building full platform at once - 40 pieces can be fitted to the platform - Cost per piece is the total cost divided by the number of pieces LUT Laser Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

55 Example One piece at a time 40 pieces at a time Total manufacturing time 8 h 49 min 67 h 42 min Per piece 8 h 49 min 1 h 42 min Energy consumption 22,5 kwh 173 kwh Per piece 22,5 kwh 4,3 kwh Material cost per piece 2,44 2,44 Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

56 Results Cost per piece at a time 40 at a time 158,23 32,35 Machine cost Material cost Energy cost 1 2 This case shows cost reduction of 80 %! Lappeenranta, Ohutlevypäivät, Outotec, Tampere Euromold, Lappeenranta, Imatra, Hämeenlinna, Appolo

57 Results Change in cost structure: Material 1,54% Energy Machine Energy 1,22% Machine 97,23% Material 1,15% 7,55% 91,30% Lappeenranta, Ohutlevypäivät, Outotec, Euromold, Tampere, Salo, Lappeenranta, Imatra, Hämeenlinna, Appolo

58 Thank you for your attention! Lappeenranta University of Technology Laser Processing Laboratory For more information: Professor Antti Salminen Research Scientist Heidi Piili Ohutlevypäivät, Outotec, Messukeskus, Euromold, Lappeenranta, , Tampere, Lappeenranta, Imatra, Helsinki Hämeenlinna, Appolo Laitila

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