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Innovations in Filtration through exploitation of metal Additive Manufacturing Louise Geekie Project Director www.filters.co.uk www.additive–manufacture.co.uk.

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Presentation on theme: "Innovations in Filtration through exploitation of metal Additive Manufacturing Louise Geekie Project Director www.filters.co.uk www.additive–manufacture.co.uk."— Presentation transcript:

1 Innovations in Filtration through exploitation of metal Additive Manufacturing Louise Geekie Project Director www.filters.co.uk www.additive–manufacture.co.uk Project Manager

2 Croft Filters was founded by two brothers – Neil and Mark Burns – in Warrington in 1986 Initial focus was retailing mesh and finding practical uses for it Natural progression led to the introduction of filter production Today, Croft Filters is a leading manufacturer of customer specified filters About Croft

3 Croft as an SME: Vital Statistics Employees: 23 Turnover: £1.4 million Customer type: 40% new, 60% repeat Nature of business: No standard products No production line products Everything hand crafted

4 Industrial Filter Types Bespoke filters can be made in any shape or size. Popular styles include cones, cylinders, baskets and screens. Filters can be manufactured in wire mesh and metal perforated plate Mesh screen Vacuum filter housing & filter Removes powder particles from air Woven wire mesh sleeve Anchor bonding Removes particulates from waste water Wedge Wire screen Cylinder Filter

5 In-House Automation Slit Mesh drawn into machine 2. Tube formed3. Welded4. Cut to length5. Crimped SUCCESSFULLY COMBINED FOUR OF SIX PROCESS STEPS ON ONE MACHINE PRODUCTION COSTS LOWERED SIGNIFICANTLY SUCCESSFULLY COMBINED FOUR OF SIX PROCESS STEPS ON ONE MACHINE PRODUCTION COSTS LOWERED SIGNIFICANTLY 1. Slit Mesh 6. Flange TSB Smart Grant

6 Conventional Manufacturing Process Layers: filter and filter support Possibility for one or two mesh layers to suit filtration requirements Subtractive manufacturing method Perforated Plate: Bespoke Automation Welds Filtration portion: woven wire mesh Inside to out (above) Outside to in (below)

7 Filtration Perforated plate Filter support Mesh filter Fluid flow Pressure drop across a filter determines the amount of energy required for pumping Turbulence created by change in fluid flow direction increases resistance 13% UK industrial electrical energy is used for pumping Costing £728 million in 2007 Represents 6% of the UK’s carbon footprint The British Pump Manufacturers Association commissioned Report into pump usage in the UK (UK Pump Market Study”, by Steve Schofield (BPMA) and John Veness.2007

8 Effective Filtration: Product Development FILTER PROPERTIES Maximum open area Maximum strength Creates resistance LIMITED BY Required aperture size Operational pressure Space available

9 Prototype Development and AM FIRST PROTOTYPE: Acrylonitrile Butadiene Styrene (ABS) Fused Deposition Modelling AM technology 3 inch / 76.2 mm ‘Straightliner’ filter Technology Strategy Board Feasibility Study

10 Prototype Evaluation Decreased resistance Decreased pumping energy required Cost savings to end user Decreases carbon footprint Flow Test Rig Measures (±3%) the pressure drop of filters for water across a wide range of flow rates (100-450 l/min) Short Knowledge Transfer Partnership: Product specifications

11 Advantages of AM Design freedom Prototype production No tooling Less labour Innovation & diversification Product materials Time to production Single product, multiple components

12 Becoming an Industrial Adopter of AM We invested in an AM machine… … and created new business: Croft Additive Manufacturing Ltd

13 250 mm x 250 mm x 300 mm Stainless Steel 316L Realizer 250 Video here

14 Additive Manufacturing VARIABLES Laser Intensity & duration Powder Layer thickness & type Support structures Angle of build Design INNOVATION AREAS Filter design Filter production processes New products

15 Integrated filter support and mesh Metal AM: holes–in-line filter SS316L Scaled to height/filter diameter Design delivers decreased pressure drop, decreased resistance and decreased carbon footprint as per prototype Designed around the holes in the filter Built layer by layer AM technology delivered energy saving filter New Product

16 Aperture Size and Shape Equivalent AM filters can maintain aperture size and shape Woven wire mesh distorts aperture size and shape when moulded Improved Product

17 Integrated filter support and mesh Integration: Support & Mesh One component Mesh & Support Different aperture sizes Single aperture size Single Part Product

18 Wedge wire Tooling required Winding of wires End caps

19 AM Wedge wire Multi to Single Part

20 AM Wedge wire No tooling Lead time greatly reduced Can be easily made in other sizes, with no tooling requirements Customer customisation Multiple parts produced as single component Improved Manufacturing Process

21 A copy… CONVENTIONAL FILTER DISC Recesses in rim and mesh Difficult to clean to very high standard AM FILTER DISC No recesses Easier to clean ….no, not quite!

22 Combining conventional with AM CONVENTIONAL FILTER AM Filter Disc combined with woven wire mesh Quick release filter Easy to remove easy to replace mesh easy to clean Woven wire mesh Improved Industrial Process Perforated plate support Adhesives, Resins Hygenic processes Water Fuel dispensing

23 AM Filter Designs Solution Design Designed around holes New Product Designed for AM Variable Lattices New Product Decrease pumping energy Decreased carbon foot print Improved Filtration Long Lead time Multi-part to single part New Manufacturing Process

24 Have a product that works Don’t need new products Will it work? Will it cause down time? Expensive Don’t know what it is: metal 3D printing Lack of understanding of how it works Industry’s adoption of AM Perceived Barriers

25 AM non-filter applications Prototype Development Shoe Industry New Product & New patent Process Development Pharmaceutical & Printing Decreased downtime, novel delivery Rapid delivery Automotive Industry Complex series parts Prototype Development Scientific Research New Component

26 AM opportunities

27 Thank You www.filters.co.ukwww.additive–manufacture.co.uk Louise Geekie louise@croftam.co.uk 01925 767070 Thinking differently opens doors


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