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
LASER ADDITIVE MANUFACTURING ACTIVITIES AT LUT
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, 28.11.2013, 16.6.2014 Tampere, Lappeenranta, Imatra, 26.11.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo Laitila 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 22.3.2013
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, 28.11.2013, 16.6.2014 Tampere, Lappeenranta, Imatra, 26.11.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo Laitila 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 22.3.2013
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, 21.11.2013, 20.11.2013, Euromold, Lappeenranta, 28.11.2013, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 26.11.2014 13.11.2013 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, Metallin 4.12.2013 24.10.2012 Appolo Kuopio Laitila 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 7
BK30A0900 Additive Manufacturing PRINCIPLE OF ADDITIVE MANUFACTURING (POWDER BED FUSION )
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, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, Hpi, 26.11.2013 Tvä, 7.1.2014 Helsinki 24.10.2013 Metallin Appolo Kuopio ASa 17.10.2013 3.6.2013 4.9.2013 mestarit 9
Principle of powder bed fusion BK30A0900 Additive Manufacturing Solid computer model Model of sliced layers 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, 26.11.2013 7.1.2014 24.10.2013 Metallin Appolo Kuopiomestarit Heidi Piili 10
Principle of powder bed fusion BK30A0900 Additive Manufacturing Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 26.11.2013 HPi 7.1.2014 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 11
Principle of powder bed fusion BK30A0900 Additive Manufacturing Laser melting Powder spreading Lowering of platform Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 26.11.2013 HPi 7.1.2014 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 12
Principle of powder bed fusion BK30A0900 Additive Manufacturing Photonik International 2011 Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 26.11.2013 HPi 7.1.2014 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 13
LAM application, LUT Laser BK30A0900 Additive Manufacturing 3D model LAM manufacturing Loose powder is removed Before and after finishing Finished faucet 16.6.2014 7.1.2014 Appolo
BK30A0900 Additive Manufacturing INTRODUCTION OF ADDITIVE MANUFACTURING (aka 3D printing)
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 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, asa, 26.11.2013 HPi 7.1.2014 24.10.2013 Metallin Appolo 24.10.2012 Kuopiomestarit 16
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. 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, asa, 26.11.2013 HPi 7.1.2014 24.10.2013 Metallin Appolo 24.10.2012 Kuopiomestarit 17
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. 2005 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, asa, 26.11.2013 HPi 7.1.2014 24.10.2013 Metallin Appolo 24.10.2012 Kuopiomestarit 18
BK30A0900 Additive Manufacturing Additive manufacturing (aka 3D printing) Additive manufacturing (Full melting of powder material) Source: LUT Laser 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, asa, 26.11.2013 HPi 7.1.2014 24.10.2013 Metallin Appolo 24.10.2012 Kuopiomestarit 19
CHALLENGES BK30A0900 Additive Manufacturing
BK30A0900 Additive Manufacturing 21.11.2013, Turku, 16.6.2014 20.11.2013, Tampere, Hpi, 6.11.2013 Tvä, 7.1.2014 24.10.2013 Metallin Appolo ASa Kuopio 3.6.2013 mestarit 21
BK30A0900 Additive Manufacturing BUT 21.11.2013, Turku, 16.6.2014 20.11.2013, Tampere, Hpi, 6.11.2013 Tvä, 7.1.2014 24.10.2013 Metallin Appolo ASa Kuopio 3.6.2013 mestarit 22
BK30A0900 Additive Manufacturing 21.11.2013, 20.11.2013, Turku, 16.6.2014 Tampere, Hpi, 6.11.2013 Tvä, 7.1.2014 24.10.2013 Metallin Appolo Kuopio ASa 3.6.2013 mestarit 23
BK30A0900 Additive Manufacturing POINTS TO BE TAKEN INTO ACCOUNT IN DESIGN
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, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 6.11.2013 Imatra, HPi 7.1.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 25
BK30A0900 Additive Manufacturing Points to be taken into account in design Nothing can be built on nothing! Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 6.11.2013 Imatra, HPi 7.1.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 26
BK30A0900 Additive Manufacturing Points to be taken into account in design Support structures are needed when building on nothing! Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 6.11.2013 Imatra, HPi 7.1.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 27
Points to be taken into account in design Support structures are needed when building on nothing! Ohutlevypäivät, Outotec, Messukeskus, 21.11.2013, 20.11.2013, Lappeenranta, Turku, 16.6.2014 Tampere, asa, Lappeenranta, 6.11.2013 Imatra, HPi 7.1.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, Metallin 24.10.2012 Appolo Kuopio 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 mestarit 22.3.2013 28
CASE 1: FAUCET
BACKGROUND
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 31
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 32
EXPERIMENTAL PROCEDURE OF THIS STUDY
Faucet design Only two modifiable parameters Other dimensions are calculated Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 34
Challenges in design In this particular research case challenges were: Electrical components had to fit into the new faucet design Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 35
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 36
Challenges in design In this particular research case challenges were: Possibility to have scalable product Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 37
Design for casting Joint line of the cast model Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 38
Design for LAM Design for LAM Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 39
RESULTS
Faucet manufactured with casting Uncoated Chromium coated Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 41
LAM fabrication Digital model LAM manufacturing Loose powder is removed Before and after finishing Finished faucet 16.6.2014 Appolo
Faucet manufactured with LAM Unpolished Polished Euromold, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 43
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 44
CONCLUSION
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 46
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, 16.6.2014 Hpi, Tvä, 4.12.2013 Appolo ASa 3.6.2013 47
CASE 2: PIPE JOINT
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
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 16.6.2014 Euromold, Lappeenranta, Imatra, 30.4.2013 Hämeenlinna, 24.10.2012 Appolo 17.5.2013 4.12.2013 24.4.2013 20.5.2013 22.3.2013 51
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
Results Cost per piece 180 160 140 120 100 80 60 40 20 0 1 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 16.6.2014 Euromold, Lappeenranta, Imatra, 30.4.2013 Hämeenlinna, 24.10.2012 Appolo 17.5.2013 4.12.2013 24.4.2013 20.5.2013 22.3.2013 56
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, 16.6.2014 Tampere, Salo, Lappeenranta, Imatra, 13.11.2013 30.4.2013 24.10.2013 Hämeenlinna, 4.12.2013 24.10.2012 Appolo 17.5.2013 24.4.2013 20.5.2013 22.3.2013
Thank you for your attention! Lappeenranta University of Technology Laser Processing Laboratory For more information: www.lut.fi/laser Professor Antti Salminen antti.salminen@lut.fi Research Scientist Heidi Piili heidi.piili@lut.fi Ohutlevypäivät, Outotec, Messukeskus, Euromold, Lappeenranta, 28.11.2013, 16.6.2014 Tampere, Lappeenranta, Imatra, 26.11.2014 30.4.2013 Helsinki 24.10.2013 Hämeenlinna, 4.12.2013 Appolo Laitila 17.5.2013 17.10.2013 3.9.2013 24.4.2013 4.9.2013 22.3.2013 58
www.lut.fi/laser 59