1. New manufacturing technologies - Additive Manufacturing
Additive Manufacturing (AM)
Initially seen only for concept modelling and rapid prototyping, but now also;
Pilot series production and short series where tooling costs would be too high,
High geometrical complexity not possible with conventional manufacturing techniques.
Materials
Number of available materials is still limited, but growing;
Plastics (Polyamide, ABS, Alumide, Fiber reinforced resins,…)
Metals (Stainless Steel, Titanium, Silver, Gold, Aluminum,…)
Ceramics (Alumina-silica, Porcelain,..)
Advantages
Complexity and variety is free there are only few constraints,
Little lead time and no assembly required,
3D model sufficient, no direct need for 2D drawings,
Less waste,
Drawbacks
High production costs,
Extensive knowledge of material design and AM is required to make quality parts,
Surface finish and dimensional accuracy are lower quality than conventional manufacturing techniques,
Limited component size,
Poor mechanical properties.
3D printed CU coated diffuser for light coupling thyristor wafers (Janusz / Herve)

2. New manufacturing technologies - Overview summary.
Goal
Manufacture technique to produce complex parts without the design constraints of traditional manufacturing routes.
Timescale to possible deployment
Technology available at CERN (Polymer) and in Industry (Metallic)
Gains w.r.t. present technology
Faster production of complex components
(Almost) No Design Limits
But limited dimensional accuracy and material properties
Possible deployment scope
Outside vacuum cooling manifolds
Low-mass structural pieces
3D Scanning/Printing of discontinued commercial parts
Etc.
Present status and outlook
Workshop "Challenges on Additive Manufacturing for High Energy Physics“
3D printing developments at CERN and Industry & The new 3D printing facility at the CERN polymer lab
Entire Royal Netherlands Navy fleet undergoes 3D scanning for repairs
Section Involvement
BTP EC XX
EDS
XXX
KSC
PPE SE