1. State of the Art and Future of Additive Manufacturing
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2. Contents Additive Manufacturing (AM) Thinking AM State of the art
Its Applications
Thinking AM
State of the art
What does the future hold?
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3. AM and its Applications
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4. What is AM?
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5. 3D Printing or Additive Manufacturing
Rapid Prototyping
Machines less than £5K
Additive Manufacturing
Production components
Machines more than £500K
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6. Applications Aerospace Medical Motorsport
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7. The Hype
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8. Thinking AM
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9. AM – the Key Points Design: completely different thought process
Need to design for AM
Focus on critical features: pathways/channels
Reduced weight, scrap and cost
Combine components
Mounting holes and brackets built into the part.
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10. AM – the Key Points Process:
Not self supporting – may require supports
Attached to platform and removed post-build
May require post-processing to achieve finish required
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11. Additive vs. subtractive example1 2 3 4
PDF version also available – Please contact me
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12. Final Part Mass reduced to <30% of original Smooth flowing pathways
Higher performance
Manufacture lead time halved.
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13. State of the Art
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14. Materials Titanium: Ti6Al4V, TiCP Nickel: Inconel 718, Inconel 625
Maraging steel: /M300
Stainless steel: 15-5PH & 316L
Cobalt Chrome: UNS R31538
Aluminium: AlSi10Mg & Aerospace Grade Alloys
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15. Machines – EOS M280 Key characteristics:
Build volume 250 x 250 x 300mm
400W Yb fibre laser
Spot size 100µm
Layer thickness 20-80µm
Wall thickness: 0.1mm
Accuracy: ± 0.2mm or better
Surface finish: As built 4-10µm  Post finishing µm
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16. Machines – Renishaw AM250 Key characteristics:
Build volume: 250 x 250 x 300mm
400W Yb fibre laser
Spot size 70µm
Layer thickness µm
Wall thickness: 0.1mm
Accuracy: ± 0.2mm or better
Surface finish: As built 7-15µm  Post finishing µm
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17. The Future
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18. The Future - Markets Aerospace:
GE’s New Leap Engine will have 9 AM parts
Over 1,000 individual components
Parts already flying in US military aircraft and in orbit in satellites
Other components are in test for future missions
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19. The Future - Markets F1: safety critical components already racing
Further components and materials being tested
Medical: optimised surface structures under approval by FDA
Outer surface of acetabular cups
Selective areas of hips and shoulder implants
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20. The Future - Materials New material suppliers coming on line
New materials can be sourced in weeks
3T building in pure copper
In talks with CERN
Potential materials:
Tungsten, Niobium, Molybdenum, Copper alloys
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21. Machines – EOS M400 Key characteristics:
Build volume 400 x 400 x 400mm
1kW Yb fibre laser
Spot size 90µm
Layer thickness µm
Wall thickness: 0.04mm
Accuracy: ± 0.1mm or better
Surface finish: As built 2-8µm  Post finishing µm
All in one system  Production
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22. Machines – Arcam Q20 Key characteristics: Build volume 350Ø x 400mm
3kW laser
Spot size 180µm
Layer thickness µm
Wall thickness: 0.1mm
Accuracy: ± 0.1mm
Surface finish: As built 20-30µm  Post finishing µm
All in one system  Production
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23. AM and FCC RF components Tuners / Couplers / Antenna Spacers
Complex novel WG
Multiple WG’s combined
Tuners / Couplers / Antenna
Spacers
Oxygen free materials
Mixed materials
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24. Summary New opportunities: Parts already in use for real application:
Holes & channels, lightweight optimised structures, multiple parts built as one.
Parts already in use for real application:
Safety, flight & mission critical
Materials being developed and supply improved
New machines allow for more materials
Machines no longer a limitation
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25. Confidence in the technology is growing fast – With this we will see the development of new materials and machines
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26. Questions Daniel France R&D Project Manager +44 (0)7917524544

27. Questions Daniel France R&D Project Manager +44 (0)7917524544