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additivemanufacturing.media August 2016 Vol. 5 No. 3 I N A S S O C I AT I O N W I T H A property of Gardner Business Media Discover & Learn 4 Great Ways to Discover and Consume Additive Manufacturing Technology! Choose your favorites... AM Coverage Topics: • AM Processes • 3D Printing • Product Development • Metals AM • Prototyping • CAD/CAM • Plastics AM • Automation • Systems & Software • Composites AM • Education & Training • Inspection & Measurement the Magazine Additive Manufacturing the Website the E-newsletter the Digital Edition SUBSCRIBE TODAY! additivemanufacturing.media/subscribe A PROPERTY OF: CONTENTS 22 FEATURES 22 Contract Shop Invests in Hybrid Manufacturing for Survival and Growth An Ontario manufacturer sees hybrid manufacturing as a means for survival. By Stephanie Hendrixson 52 Inspect the Part As It Grows Technology that monitors thermal radiation to map the internal consistency of a metal part as it is being made may point to a new paradigm for inspection. August 2016 52 Vol. 5 No. 3 68 IN EVERY ISSUE Something to Add 6 News 8 Technology Review 66 Ad Index 67 Check This Out 68 Tech Trends 15 Industry Spotlight 16 Smartforce 17 MFG Advocate 18 Calendar 20 By Peter Zelinski 56 Conformal Cooling Is a Mold Enhancement A moldmaker collaborates with other manufacturers to advance conformal cooling and other AM applications. By Christina Fuges 58 Testing the Reusability of Titanium Powder The results of an experiment suggest the potential for recycling metal powder for additive manufacturing. By Peter Zelinski 60 IMTS 2016 Product Preview Preview some of the AM technologies to be exhibited at the International Manufacturing Technology Show. 26 Additive Manufacturing Conference Guide 10 Taking Shape • 3D Printing Resolution: High or Low? • Beyond Recruitment: Agile Workforce Planning for Additive Manufacturing • 3D Printing Autoclavable Composite Molds • EOS Opens New Location in Texas • Continuing to Champion AM 2 AUGUST 2016 Additive Manufacturing ABOUT THE COVER: Additive manufacturing will be a significant part of this year’s International Manufacturing Technology Show. On the cover, the letters “IMTS” are being built on a large-format industrial 3D printer by 3D Platform. Read more about this 3D printer on page 62. Photography by Creative Technology Corp. "We challenge our customers to redefine possible." – Dr. Thorsten Schmidt CEO, DMG MORI USA Visit o ur booth at IMT S to win a trip t o Germ any!* BOOTH S-8900 Visit DMG MORI at IMTS. DMG MORI is coming to the nation’s largest manufacturing show. Join our experts at IMTS in Chicago to explore the Path of Productivity, and learn how technology can solve your challenges before they exist. BOOTH HIGHLIGHTS U.S. PREMIERES DMG MORI EXPERT SPEAKERS + 26 machines on display + Customized automation solutions + Exclusive Technology Cycles for increased productivity + New Direct Sales and Service structure + Sprint 32|8 automatic lathe + ULTRASONIC 20 linear + Additive Manufacturing Conference, McCormick Place New Approaches to Additive Manufacturing Dr. Greg Hyatt Tuesday, September 13th + IMTS Conference, McCormick Place Art of Hybrid Manufacturing Mike Panzarella Wednesday, September 14th See your future in action. Learn more and schedule an appointment at imts.dmgmori.com. DMGMORI @dmgmoriusa *Exclusions apply. Visit imts.dmgmori.com for trip details. additivemanufacturing.media Publisher Travis Egan [email protected] Editor-in-Chief Peter Zelinski [email protected] Senior Editor Christina Fuges [email protected] Associate Editor Stephanie Hendrixson [email protected] Contributing Writer Jeff Sloan [email protected] Managing Editor Kate Hand [email protected] Art Director Aimee Reilly [email protected] Advertising Manager Bill Caldwell [email protected] Marketing Manager Dave Necessary [email protected] 6915 Valley Avenue, Cincinnati OH 45244-3029 Phone 513-527-8800 Fax 513-527-8801 gardnerweb.com additivemanufacturing.media Digital Community Richard G. Kline, CBC / Chairman and CEO Melissa Kline Skavlem / COO Richard G. Kline, Jr. / President Travis Egan / Group Publisher Stay Connected—to the Additive Manufacturing industry’s leading resource for the latest trends, technology and best practices. Tom Beard / Senior V.P., Content Steve Kline, Jr. / Director of Market Intelligence Ernest C. Brubaker / Treasurer William Caldwell / Advertising Manager Jason Fisher / Director of Information Services Kate Hand / Director of Editorial Operations Twitter Facebook Jeff Norgord / Creative Director Rhonda Weaver / Creative Department Manager Dave Necessary / Director of Marketing and Events Follow us @AdditiveMfgMedia Like Additive Manufacturing Media at Facebook.com The Additive Manufacturing E-Newsletter EXTRA SEARCH AM AM Magazine AM Conference AM Award Suppliers Subscribe About HYBRID MANUFACTURING New Hybrid Unites Additive Manufacturing and Grinding August 1, 2015 A machine performing surface and profile grinding, along with milling and laser metal deposition, is believed to be the world’s first hybrid grinder. Hope to See You in Knoxville! July 13, 2015 — Peter Zelinski Come to our Additive Manufacturing Conference, October 20-21, co-hosted by Oak Ridge National Laboratory. The sole focus of the conference is industrial parts and tooling. PROTOTYPES Video: New Customizable Consumer Car to Be Made Through Additive Manufacturing The sponsor of the upcoming Additive Manufacturing Conference in Knoxville, Tennessee, has revealed the electric car that it will produce in this city. July 9, 2015 — Peter Zelinski August 17, 2015 JOB SHOP CONSIDERATIONS Print & Assemble—the Future of of AM? AM E-newsletter Additive Manufacturing Conference Speaker: Bruce Colter The Better Way to Work AM Website While this technology for home 3D printers sm may be functio functioning ing on na small scale, the pick-and-place concept could ou uld d hold potential for larger industrial applications. July 7, 2015 — Stephanie Hendrixson The Linear Mold business development manager will be one of the speakers at the October 20-21 conference, focusing on industrial applications of additive manufacturing. INTERNATIONAL ADDITIVE MANUFACTURING AWARD MOLDMAKING August 10, 2015 Incorporating 3D Printing Additive Manufacturing Conference Speaker: Robert Mudge The RPM Innovations president will be one of the speakers at the October 20-21 conference in Knoxville, Tennessee, focusing on industrial applications of additive manufacturing. Gardner Business Media Also Publishes Modern Machine Shop MoldMaking Technology Plastics Technology Products Finishing Automotive Design & Production Production Machining CompositesWorld Techspex Technologies that give moldmakers the ability to test out a couple different designs before investing in the final tool. June 30, 2015 — Christina M. Fuges Search Smarter. PRODUCTION PARTS—PLASTIC Learn about 3D Printing of Large Parts at Amerimold 2015 At next week’s Amerimold show, Dr. Chad Duty will give complementary showfloor presentations on “Big Area Additive Manufacturing (BAAM).” Visit us at: additivemanufacturing.media Subscribe today at: additivemanufacturing.media/newsletter Additive Manufacturing is a registered trademark of Gardner Business Media, Inc. Subscription Inquiries: For questions or issues related A P R O P E R T Y O F: to your subscription, please call 513-527-8800 or email [email protected]. Can’t CUT IT? ADD IT with AMBIT™ additive manufacturing bits Depositing Stainless 316 + Aluminum Bronze Finish machining Booth N-63 Upgrade your new or used CNC machine with patented AMBIT™ tool-changeable metal deposition heads by Hybrid Manufacturing Technologies. Add metal. Add value. AMBIT™ heads allow CNC machines to add metal features, clad hard facing, make repairs and machine parts, all in a single setup. Heads are optimized to deposit non-reactive* powders and are compatible** with most vertical CNC machines. www.hybridmanutech.com Something to Add The Unseen Work Unleashing AM Many small advances allow a technology to realize its promise. In AM, here is where the advances are adding up. An up-and-coming technology can remain up-and-coming for a while before it breaks out to find its place. There are numerous examples of this. Computers are one. The promise of computers was understood long before these devices became commonplace. Something similar could be said of the internet. And in manufacturing, robots, electrical discharge machining and composites all arguably fit the same model. In each instance, the role of the technology and the case for adopting it were known, but adoption lagged this understanding. Until it didn’t. For all these technologies, the moment came when the technology simply mushroomed, seeming to spread suddenly into far more widespread use than it had previously seen. Once the surge happened, we quickly grew accustomed to the use of that technology, forgetting what the challenges were that once had held us back from it. Part of the reason we forget is because those challenges were plentiful. And, significantly, many of those challenges were small. For a technology to be adopted, it has to be not just powerful in what it can do, but also dependable and easy. And many, many impediments stand in the way of getting to the necessary levels of dependability and ease. Those obstacles include big hurdles, Once the surge happens, and also include nagwe quickly grow accustomed ging difficulties that to the use of the technology, make the technology forgetting what the challengseem too unfriendly to embrace. When a es were that once held us technology at last arback from it. rives, this happens not only because the price falls and the performance expands, but also because the moment finally comes when a critical mass of those nagging difficulties has been addressed and overcome. With additive manufacturing, this is the stage we’re advancing through. Vanquishing challenges large and small is the work being done today. Many large challenges have been met, but that still leaves work to do. The small problems are being beaten through victories we do not necessarily see, because 6 AUGUST 2016 Additive Manufacturing they each involve a tweak, technique or change in perspective that by itself may not seem remarkable. What manufacturers at large will see instead from this work is the cumulative effect of all these victories summing together. As I say, the work is happening today. The victories are occurring in various areas in which people are advancing AM. In particular, I see three such areas—three largely unseen spheres in which the small but important successes are being attained. When AM for production becomes commonplace, it will partly be because of efforts being made today in these three realms: 1. Software. The attention given to AM today often focuses on the process of building the part, the elaborate forms that can be made, and the useful properties of the material created this way. Against all this, the software for deploying AM gets far less attention. However, the strides software developers are making might ultimately turn AM into the most intuitive and easy-toapply industrial part-making technology we have ever seen. 2. Secret projects. When I ask manufacturers about their involvement in AM, I get the same answer repeatedly. I hear some variation on, “We’re more involved than we can tell you—we can’t talk about the experimentation we’re doing with AM.” In time, all of this secret work will come to light, and so will the knowledge gained in these projects. 3. Students. This sphere promises to be the most significant of all. Among school-age children today, consider how common it has become for them to experience 3D printing or use a 3D printer. Some of the small but important challenges I’ve been discussing here are obstacles of culture or mindset, but we are on the verge of welcoming an age group that has no such disposition against AM. Indeed, these young people will assume that manufacturing is additive. How far will AM go once this group exerts its influence? Peter Zelinski / EDITOR-IN-CHIEF [email protected] AEROSPACE CONFERENCE 2016 TRAMCONFERENCE.COM TRENDS IN ADVANCED MACHINING, MANUFACTURING & MATERIALS SPONSORED BY: REGISTER NOW! TRAM is dedicated to transferring advanced manufacturing techniques to business leaders, managers and engineers in the aerospace industry. This is your chance to see the very latest technologies from the best and brightest that aviation has to offer. GLOBAL PRESENTERS SEPTEMBER 14-15, 2016 CHICAGO, ILLINOIS, USA AT NEWS Edited by Stephanie Hendrixson / Associate Editor Report Indicates U.S. Military Cautiously Optimistic on AM for Repair Parts News outlet Aviation Week reports that additive manufacturing is on track to become a significant tool in U.S. military maintenance and repair applications, though it may take years for this to become reality. Military leaders at the Aviation Week ORNL, Cincinnati Inc. Sign Patent License Agreement The Department of Energy’s Oak Ridge National Laboratory (ORNL) and Cincinnati Incorporated have signed a nonexclusive licensing agreement on ORNL patents related to large-scale additive manufacturing. Under the agreement, Cincinnati Inc. may make, use or sell the lab’s patented developments of enhanced additive manufacturing with a reciprocating platen that enables the manufacture of parts much larger and with higher quality than current standards. e-ci.com Local Motors Expands Partnership with Siemens PLM for Large-Scale AM Repair parts for aircraft are one potential military application for additive manufacturing. Image courtesy of Boeing 8 AUGUST 2016 Additive Manufacturing MRO Americas conference were cautiously optimistic about AM’s future role for military maintenance, repair and operations (MRO) applications. Additive’s ability to repair components or print replacement parts has the potential to decrease costs and reduce lead time. Before this can happen however, millitary officials will need to work through a number of challenges, including concerns about the material science behind AM, cybersecurity, training requirements, logistics and intellectual property rights. Progress is already being made on certain new and replacement parts for military aircraft and other equipment, including flight-critical parts. Visit gbm.media/usmilitary to read the complete story. Siemens PLM Software and Local Motors have formed a new partnership for the development and large-scale additive manufacturing of cars. The partnership combines Siemens’ product lifecycle management (PLM) software with Local Motors’ leadership in 3D-printed vehicles, a process it calls direct digital manufacturing (DDM). Local Motors plans to enhance productivity in its Local Motors (LM) Labs program by leveraging Siemens’ capacity for creating “digital twins” that are said to accurately represent form, function and performance of a product and its production system. The highfidelity twins enable engineers to test the functionality of products and processes in the virtual world AM / News to predict and optimize performance in the physical world. For its part, Siemens expects to enhance its digital enterprise software suite to support advances in additive manufacturing and 3D printing. into one additive manufacturing and logistics solution will make 3D printing accessible to more potential users, enabling them to realize the convenience and cost-savings this technology offers, UPS says. localmotors.com / ups.com plm.automation.siemens.com Senvol and Granta Partner on AM Database Senvol and Granta Design have announced that the Senvol Database, a database of industrial additive manufacturing materials and machines, will be available within Granta MI and CES materials selector software. This development will enable users to more easily find AM data and identify the best materials and machines for their projects. Within both Granta products, the Senvol Database becomes part of an integrated library of materials data covering metals, composites, plastics, ceramics and more. grantadesign.com / senvol.com UPS, Fast Radius Launch OnDemand 3D Printing Network UPS has launched a distributed on-demand manufacturing network that links its global logistics network with 3D printers at The UPS Store in more than 60 locations around the United States as well as Fast Radius’ On Demand Production Platform and 3D printing factory in Louisville, Kentucky. Customers visit the Fast Radius website (formerly CloudDDM) to place their 3D printing orders, which are directed to the optimal manufacturing or UPS Store location based on speed, geography and the product quality the customer requires. The integration Concept Laser Signs Cooperation Agreement with Aerospace Manufacturer Concept Laser has signed a cooperation agreement to serve as premium supplier of the machinery and plant equipment for Premium Aerotec, a subsidiary of Airbus. Premium Aerotech is beginning series production of 3D-printed metal parts for the Airbus Group at a new facility in Varel, Germany, specifically built for the additive manufacturing of titanium parts. According to Peter Sander (Airbus, Head of Emerging Technologies & Concepts), Airbus is planning to print one ton of metal powder a month in 2018. In addition to serving as supplier, Concept Laser will also assist in the further industrialization of the laser melting process for aviation applications, development of the plant and process technology, and qualification of new powder alloys. concept-laser.de Wohlers Report Indicates AM Industry Surpassed $5.1 Billion In its 2016 report, additive manufacturing consulting firm Wohlers Associates indicates that the compound annual growth rate (CAGR) for the AM industry, including all AM products and services worldwide, grew 25.9 percent to $5.165 billion in 2015. The CAGR for the previous three years was 33.8 percent. Over the past 27 years, the industry CAGR is 26.2 percent. Wohlers Associates also reports that, despite challenges, growth continued in many segments of the industry, particularly in metal AM and the desktop 3D printer segments. In 2015, 62 manufacturers sold industrial-grade AM systems (valued at more than $5,000), compared to 49 in 2014, and twice as many as the 31 companies that sold industrial systems in 2011. The 2016 report marks the 21st consecutive year of its availability. The document includes input from 51 industrial system manufacturers, 98 service providers, 15 third-party material producers, and manufacturers of low-cost desktop 3D printers as well as contributions from industry experts. wohlersassociates.com Norsk Titanium, Bosch Rexroth Partner for Plasma Deposition Automation and Control Bosch Rexroth is partnering with AG Norsk Titanium AS to provide customized drive and control solutions for Norsk’s Rapid Plasma Deposition (RPD) machines. Bosch Rexroth’s customized solution for Norsk Titanium’s RPD motion control involves 10 servo axes configured to control the titanium part build platform, feeding and handling of titanium wire entering the machine, the real-time control of multiple plasma arc torches, and other features. boschrexroth-us.com / norsktitanium.com LEARN MORE Keep up with the latest news by following @AddMfgMedia on Twitter: twitter.com/addmfgmedia additivemanufacturing.media 9 TAKING SHAPE 3D Printing Resolution: High or Low? By Stephanie Hendrixson Image courtesy Creat3D. Beyond Recruitment: Agile Workforce Planning for Additive Manufacturing By Stephanie Hendrixson 10 AUGUST 2016 Additive Manufacturing For 2D printers and scanners, a higher resolution (more pixels or dots per inch) translates to greater fidelity and a clearer picture. Extrusion-based 3D printers have resolution too—but in this case, resolution refers to layer height, measured in microns, with thinner layers equating to higher resolution. FDM 3D printers can range anywhere from about 10 to 300 microns in layer height, also called the Z height. Print quality can vary widely even on the same printer when the resolution is changed. Take a look at the photo below. 3D printer supplier Creat3D printed each of these three couplings on the same printer, in the same material and with the same settings. The only difference is that the parts were made with different resolutions, at 20-, 60- and 180-micron layer height. It might be expected that the smallest layer height (and therefore highest resolution) resulted in the best-looking part—in this case, Part C. However, the 20-micron-layer part is actually Part A, the one that looks messiest. (Conversely, Part C had the lowest resolution, at a 180-micron layer height.) According to Jon Brydges, Creat3D director, this is the result of heat transfer: With such a small Z height, the heat from the nozzle as it applies a layer is enough to distort the layer below, resulting in a lower-quality surface finish. Other factors such as build speed and material also play a role in the quality of a print. The lesson here is not that one resolution choice is better than another; it’s to choose the best resolution that still accomplishes the goal of the part. Part A’s surface finish could be cleaned up, but if a low-resolution print such as Part C would have been good enough for the application, that finishing time could have been better spent elsewhere. There are plenty of reasons to choose a higher resolution, but for items such as workholding fixtures or assembly tools, a low-resolution print may work just fine. The “skills gap” is an industry-wide problem, but poses a particular challenge to companies seeking to build an additive manufacturing workforce. The problem is magnified in the AM space, with manufacturers who want to attract and retain AM specialists facing fierce competition for a relatively small pool of talent. Coupled with this issue is the need for AM specialists to keep up with constantly evolving AM technologies, materials and best practices. In such an environment, the skills gap is about more than bringing in new recruits. It’s also about retaining existing workers, keeping them up-to-date with the skills they need to do their jobs, and capturing institutional knowledge gained over time. In additive manufacturing especially, manufacturers must make an effort to retain existing employees and provide ongoing training to keep pace. According to a paper published by the Deloitte University Press, companies that hope to build and maintain an additive manufacturing workforce need to adopt an agile workforce planning strategy over the long term. Such a holistic approach must be AM / Taking Shape iterative and collaborative, with continued communication between human resources staff and the managers, engineers and others familiar with the organization’s AM challenges and workforce needs. Tactics that can be employed in such a strategy include: • Strategic outreach to vocational schools and universities offering relevant AM training, to attract students; • Leveraging AM’s collaborative and creative aspects to appeal to students and professionals, especially millennials; • Targeted training to grow the skills of existing employees; and • “Re-recruiting” staff by empowering them to bring ideas, creativity and curiosity into their work. Visit gbm.media/agile to access the full report. 3D Printing Autoclavable Composite Molds By Jeff Sloan The Oak Ridge National Laboratory (ORNL) built nine of these carbon fiber composite molds using the Big Area Additive Manufacturing (BAAM) machine. Each one measures about 1 by 0.8 meter and is autoclave capable. The polymer additive manufacturing research team at the Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) reports that it has successfully fabricated autoclave-capable carbon fiber composite molds, manufactured using large-scale 3D printing/additive manufacturing. Oak Ridge National Laboratory, in collaboration with numerous industry partners and materials suppliers such as TechmerES and BASF, developed these molds from two high-temperature thermoplastic materials with varying carbon fiber loads, which have been tested and proven in the autoclave process. The first material combination features polyphenylene sulfide (PPS) reinforced with high loading of carbon fiber supplied by Techmer. The second material combination features a polyphenylsulfone (PPSU) supplied by BASF, compounded by Techmer and with lower carbon fiber loading. Researchers at ORNL processed the materials on a Big Area Additive Manufacturing (BAAM) machine developed in collaboration with Cincinnati Inc. They fabricated nine concave-shaped molds in total, each measuring about 1 by 0.8 meter (see photo to the left). Each tool was either machined and uncoated or coated and not machined, in order to assess vacuum-holding capability of the molds. Subsequently, the autoclaved molds trialed at Boeing’s St. Louis facility withstood two cycles at temperatures of 250°F and 30 psi and a second cycle of 350°F and 90 psi for 2 to 3 hours per cycle. This included a prescribed heat up, a two-hour hold and a prescribed cool down. Dr. Ahmed Hassen, postdoctoral researcher at ORNL, and Dr. Vlastamil Kunc, polymer materials team lead at ORNL, say that the autoclave trials provided promising results, with only 0.002 to 0.004 inch maximum deformation after two cycles. How many autoclave cycles these 3D-printed tools might tolerate remains to be determined in future testing. The benefits of autoclave-capable, 3D-printed molds are obvious in terms of time, material and process cost savings opportunities. “Companies can save a lot of time by printing molds in-house. They can have their own printers. They no longer need to wait for months to get their parts made,” says Hassen. “It is the understanding of many facets of additive manufacturing and material science which allowed the team to successfully demonstrate how this technology can benefit American tool and die efforts, as well as increase U.S. global manufacturing competitiveness,” says Kunc. It is expected that autoclave-capable materials for largescale 3D printing will be commercially available this year. additivemanufacturing.media 11 TAKING SHAPE EOS Opens New Location in Texas By Stephanie Hendrixson Glynn Fletcher, president of EOS NA, cuts the ribbon in front of the new Pflugerville facility during a grand opening event held in May. Continuing to Champion AM By Christina Fuges 12 AUGUST 2016 Additive Manufacturing EOS is witnessing a shift in the market for additive manufacturing. The manufacturer of direct metal laser sintering (DMLS) and selective laser sintering (SLS) equipment as well as materials has seen North America surpass Central Europe in sales revenue growth over the past few years. The company has now found itself at a tipping point, where it is no longer practical to serve all of its clients and installed machines by flying personnel across the continent and shipping parts and materials long distances. “The resources that are necessary to support our customers should be distributed throughout the United States, in the places that are closest to our customers,” says Glynn Fletcher, president of EOS in North America. This is the impetus behind the company’s newest facility, which opened in Pflugerville, Texas, earlier this year. The new 45,000-square-foot building boasts office space, working showrooms for both plastics and metal AM machines, and capacity for the company’s R&D and venture projects. The new tech center replaces and expands on a previous Round Rock service hub, the employees of which have been relocated to Pflugerville. EOS will continue to operate its materials mixing facility in Temple, Texas. This technical center will help EOS better serve its customers in the southern United States, but the Pflugerville location is only one part of the plan. EOS’s final objective is better coverage of the entire North American continent. “We’re well-established and local to our customers in the Midwest with our facility in Novi, Michigan. This [new location] gives us a strong presence in the South,” says Fletcher. “Next will be Northern California, and if everything goes according to plan, shortly after that we’ll have a facility in New England, probably close to Boston.” The plan is a commitment to the growing North American market, says Dr. Adrian Keppler, executive vice president of EOS GmbH, but it is also indicative of something more. Increasing sales in North America for EOS equipment point to growth for AM in general. The conversation in manufacturing has shifted away from “Can AM do this?” to more pragmatic considerations, like cost, quality and best practices. “Many customers ask for support—and it’s not only technical solutions,” noted Dr. Keppler. “It’s also support in terms of consultancy, in terms of helping them develop their internal processes.” The company’s vision is ultimately to bring AM into existing manufacturing environments, says Keppler. “We have to grow in terms of headcounts, in terms of capabilities, in terms of locations, and this is our strategy for the future.” Faustson Tool, a five-axis machining specialist with laser melting capacity, its doing its part to help increase the competitiveness of Colorado manufacturers in the aerospace and other manufacturing industries. The company received the Manufacturer’s Edge Manufacturing Innovation Award earlier this year for “demonstrating outstanding leadership in building a practical research center in Colorado to provide testing, AM / Taking Shape performance analysis and materials knowledge for metal 3D-printed parts, especially as those parts apply to aerospace and advanced manufacturing.” Heidi Hostetter, vice president, explains, “This 3D Metal Additive Center will be a member-supported research center focused on understanding the characteristics and performance of 3D-printed metal alloys used in advanced manufacturing industries.” The relationships Faustson has built over time with industry, academia and the Manufacturer’s Edge (a NIST Manufacturing Extension Partnership center) helped lead to grants that enabled this center. The Office of Economic Development and International Trade contributed $2.5 million of grant funds, while the founding members matched that with more than $5 million in funds. They also contributed personnel and equipment resources to create the center at the Colorado School of Mines. “The first six months of activity will focus on building specified test parts at Lockheed Martin and Faustson Tool, analyzing the characteristics of those parts at a microscopic level at the Colorado School of Mines, and studying the impact of the various manufacturing processes and conditions used to create the parts,” says Hostetter. Similar activity will continue indefinitely, she says, beyond the time frame of the grant, as the center will ultimately become self-sustaining. At the six-month mark, Manufacturer’s Edge and the Colorado School of Mines will roll out initial membership details for companies wishing to participate in further research efforts and results. At that time the center will expand its scope to include new alloys and manufacturing methods, driven by the needs of Colorado manufacturers. Helping companies increase through-put, save money, and improve quality for more than 65 years. Serving the additive manufacturing community with dry-blast and wet-blast cabinet solutions in standard equipment, many options, or engineered automated systems tailored to your application. Put the power of a ZERO Blast Cabinet to work in your production line – they are seriously industrial, come standard in various sizes, and are supported by experienced authorized distributors to guide your selection and work with you to achieve your production-enhancing goals. www.clemcoindustries.com additivemanufacturing.media ________________________________________________ TECH TRENDS CATEGORY: T Trends in Additive Development Enabled (If Not Driven) by Materials By Tim Shinbara, VP – Manufacturing Technology, AMT—The Association For Manufacturing Technology Unless you are a material scientist or otherwise love sometimes unwieldy matrixed details you may find tracking material developments a bit too far removed from the everyday. The context of “everyday” is talking on a more practical level such as keeping the hot away from the cold; ensuring strong things can play nicely with weaker things; and ultimately ensuring that a functionally-shaped material provides usefulness. That something useful was developed is where theory becomes practice and is akin to technology development being demonstrated in application. This middle ground is exactly where public-private partnerships like America Makes adds its value to the AM/3DP stakeholder market. One of the key critical technical elements within that membership’s roadmap (see Figure 1) has been within the area of materials development. The materials space is beginning to accelerate both in inherent advancements and in application offerings. There are companies that have begun to combine material properties such as high strength along with increased toughness. By achieving such balance of properties using aluminum alloys one is able to also achieve a lower overall weight, which is extremely useful to industries such as transportation (see Figure 2). Other sectors are also driving demand for more functional materials. Those sectors seem to be targeting robotic integration, including drones. The ability to produce structural components, assemblies and products that also incorporate functionalities such as electrical connects or vias, embedded routing and communication connectivity to things like avionics, payload and such is potentially invaluable. Not to mention the ability to incorporate intelligent health monitoring for increasing optimal usage and holistically planning for things like sustainability. What seems to be central in all this integrated functionality is the material. Fig. 1: The Material focus area of the America Makes Roadmap is aimed at building the body of knowledge for benchmark additive manufacturing property-characterization data and eliminating variability in “as-built” material properties. This includes creating a paradigm shift away from controlling process parameters and “as-built” microstructures to instead  controlling the underlying physics of the additive manufacturing process at the microscale to achieve consistent, reproducible  microstructures and hence, “as-designed” properties.  Fig. 2: The Light Rider is an electric “motorcycle” produced by AMWorks, built using the company’s proprietary Scalmalloy material. Photo credit: AMWorks. Continued on page 20 mtadditive.com 15 INDUSTRY SP OTLIGHT By Bonnie Gurney Director – Exhibitions Strategy & Communications, AMT—The Association For Manufacturing Technology Eight years ago, The International Manufacturing Technology Show (IMTS) featured additive manufacturing in the AMT’s Emerging Technology Center as a cutting-edge technology. It was then added to the Fabricating and Laser Pavilion. For IMTS 2016, the technology has earned a stand-alone spotlight: the Additive Manufacturing Pavilion, located just off the Grand Concourse at the entrance to the North Hall. For an inside look at the state of the technology, I recently spoke with one of its early champions. David Burns co-founded and is past president and COO of ExOne, a provider of 3D printing machines, products and related services. After taking the company public, he now makes his experience available to other industrial companies as founder and principal of Global Business Advisory Services LLC. Bonnie: How far has additive manufacturing progressed? David: Additive manufacturing is a reality for the industrial marketplace. It’s not fully mature, but the technology has progressed far enough that if you’re ignoring 3D printing at IMTS 2016, you’re making a big mistake. Use the Exhibitor Search and MyShowPlanner tools at IMTS.com to set appointments with additive manufacturing exhibitors. 16 AUGUST 2016 Additive Manufacturing IMTS 2016 Additive Manufacturing Pavilion Showcases Technologies, Products Ready for Prime Time Bonnie: To your point about ignoring this important technology, that’s why IMTS located the Additive Manufacturing Pavilion right off the Grand Concourse at the entrance to the North Building. There’s a whole spectrum of 3D products on display inside the pavilion. Which ones intrigue you the most? David: New metallurgies and machines are always interesting, but designing for 3D printing requires a completely different approach, as does integrating the power of 3D printing into your industrial manufacturing operation. Bonnie: Switching from a subtractive to an additive process isn’t just a simple technology swap, is it? David: No. That’s why you need to talk with the experts inside the Additive Manufacturing Pavilion. If you just try to emulate an existing design, you need to expand your thinking to fully harness the power of 3D printing. Savings and productivity improvements are going to come from ways you have yet to imagine. For example, ExOne worked on a redesign that reduced part weight from 7 to 2 pounds and offered better mechanical properties. However, the part walls resembled an organic structure—a design you wouldn’t even think of, much less attempt, with a cutting tool. Bonnie: That brings up a good point about hybrid machines. David: Yes. Look for them on the main floor. While the AM Pavilion is dedicated to companies who focus solely on that process, several of the leading machine tool providers will demonstrate “hybrid machines.” These machines integrate 3D printing and traditional machine tool capabilities. Bonnie: What’s the best way to assess the readiness of 3D printing for your specific operation? David: Set appointments, and bring a copy of your print to the show. Within the Additive Manufacturing Pavilion, you’ll find companies that offer a full suite of 3D products, and they’re good at explaining the benefits. Exhibitors include providers of material, 3D printers and associated equipment such as sintering furnaces, design and production software, scanners that capture points to create a parametric design, 3D printing service centers, and essentially every component necessary for a manufacturing cell. SMARTFORCE CATEGORY: E Education On Guard: Virginia Tech Manufacturing Group Establishing Security Response Plan Cyber-physical security is a topic that has gained plenty of attention as manufacturers move toward digitized operations. While building a competitive edge that comes with leveraging the use of plant data, manufacturers also must remain evervigilant for cyberattacks. Researchers are hard at work on the front lines of this continuous battle. Dr. Jaime A. Camelio leads the Virginia Tech CyberPhysical Systems Security Manufacturing Group, which is looking to safeguard the physical environment of the manufacturing process. Along with its industry partners including the MTConnect Institute, AMT, Western Michigan University, the Commonwealth Center for Advanced Manufacturing, and other related government agencies, the group makes in-depth analyses of vulnerabilities, improvements and collaborations. “Every day, we rely on complex, safety-critical mechanical systems, like next-generation composite aircraft, artificial heart valves, automated Every day, we rely on complex, drug dispensary safety-critical mechanical equipment, highspeed rail systems systems, such as nextgeneration composite aircraft, and gas turbines,” Camelio says. “These artificial heart valves, systems use physautomated drug dispensary ical parts that are equipment, high-speed rail precisely engineered systems and gas turbines. for balance, strength, Malicious attacks on weight and safety. Malicious attacks on manufacturing these items the manufacturing could create significant process can modify safety issues. these precisely engineered components to change mechanical tolerances, causing problems ranging from excess shearing forces to increased humidity and creating significant safety or monetary issues.” To make a manufacturing enterprise both prepared for and responsive to unwanted cyber-physical events, the group has three main focus areas: • Vulnerability assessment of the manufacturing enterprise, • Improving in-process monitoring in manufacturing systems, and • Augmenting current quality control tools in manufacturing to detect unwanted changes in part or production. As a young engineer at GE Aviation, Tomilayo Komolafe quickly discovered security vulnerabilities in the additive manufacturing process that was being used to make airplane parts. This discovery inspired him to pursue his Ph.D. under Camelio to help lead the fight against industrial cyberattacks. Concentrating on quality control, Komolafe is developing a monitoring system to detect deviations in each part as it is produced, and discern if the discrepancies are due to machine wear, variations inherent in manufacturing or a potential attack. This monitoring system is based on piezoelectric transducers, which effectively measure changes in a part’s stiffness, damping or mass and converts these changes to easily measurable electrical signals. The parts created through additive manufacturing are often vulnerable to cyberattacks through alterations to the part’s original design intent, creating a weaker product. A specific threat might be a change to the design and manufacture of an airplane wing component, so that the part no longer functions properly under certain loads in real-world usage. The Virginia Tech Cyber-Physical Systems Security Manufacturing Group is launching a vulnerability database, located at cpssmfg.com, to allow industry stakeholders to upload and search information about potential “backdoor” vulnerabilities. Suppliers can find out if their machines need to be better engineered; operators can share weaknesses; researchers can bring about solutions; and all can help prepare for and respond to cyber-physical attacks. As manufacturing explores this new digital frontier, the immense opportunities created are just as often met with challenges of equal or greater scale. Collaboration on resources and ideas from industry, academia and government is going to be essential to realizing manufacturing’s potential while also safeguarding it from harm. Dr. Jaime A. Camelio Rolls-Royce Commonwealth Professor for Advanced Manufacturing, Virginia Polytechnic Institute and State University, Blacksburg, Virginia mtadditive.com 17 MFG ADVOCATE CATEGORY: I Industry Insight Penny Brown Director – AMT Marketing & Communications, AMT—The Association For Manufacturing Technology We got some exciting news recently with the announcement of the MTConnect Student Challenge’s Idea Creation winner. Alexander Lee, a student at Central Piedmont Community College in Charlotte, North Carolina, took home first place (and $5,000) with his idea to use a Raspberry Pi single-board computer as an MTConnect adapter on a legacy CNC controller (in this case, a Sinumerek 840D) to record machine cycle data. The Raspberry Pi collects the data, MTConnect and the Python programming language process the data, and finally an open-source Python-based application is used to visualize the data. As Lee notes in his submission, the Raspberry Pi has found widespread use in education and home automation projects, but it has very little presence in industrial applications. However, it is inexpensive—just $35—and it has unique capabilities that could make it useful on the shop floor. This was exactly what the MTConnect Student Challenge was designed to do. The idea was to present real-world manufacturing challenges to students, who could utilize their creativity and technical know-how to design solutions. Lee’s submission is cost-friendly and can be easily adopted even by smaller manufacturers with limited means. I think what I like most about this story, though, is that Lee beat out submissions that came from Clemson, Virginia Innovation Happens at the Community Level Tech, UC-Berkeley and Michigan. If you’ve ever thought that community college is a lower-tier education, I hope this helps to turn around your perception. Here are a few facts about community colleges: 1. Tuition and fees at public 4-year colleges were nearly three times that of community colleges in the 20142015 school year, according to the American Association of Community Colleges. Additionally, students attending public community colleges are less likely to take out loans, according to the College Board. 2. Research from the Aspen Institute says that community colleges are more flexible than other educational institutions in adjusting their curriculum, class schedules and even class locations to meet the needs of local employers and the workforce. 3. The Century Foundation found that between 1999 and 2009, funding for community colleges increased just one dollar per student. Meanwhile, per-student funding at private research universities jumped almost $14,000. Community colleges do a lot to bring education to underserved populations, including low-income students, minorities, nontraditional students and veterans. But they still suffer a stigma of “not good enough,” and their lack of resources echoes this. If we want to create a skilled workforce and create upward economic mobility, shouldn’t we put attention toward the institutions that will help us get there? Are you a proud community college graduate? I want to hear from you! Email me at [email protected]. To read more on AMT Advocacy, visit www.amtonline.org/Advocacy/ 18 AUGUST 2016 Additive Manufacturing 2016 Global Forecasting & Marketing Conference Hosted by AMT | The Association For Manufacturing Technology OCTOBER 19-21, 2016 • MIAMI, FLORIDA Get the industry’s best overview of market conditions, trends and forecasts, and learn how to use that data to drive your business in the coming year. At GFMC 2016, you will leave equipped with the tools you need to distinguish yourself from the competition and lead the way in today’s dynamic market. AMTONLINE.ORG/GFMC CALENDAR IMTS 2016—International Manufacturing Technology Show September 12-17, 2016 McCormick Place - Chicago, Illinois IMTS.com 2016 Global Forecasting & Marketing Conference October 19-21, 2016 Trump National Doral Miami - Miami, Florida AMTOnline.org/GFMC For a complete list of conferences and events, visit www.amtonline.org/calendar/ Development Enabled (If Not Driven) by Materials If you are a consumer of AM/3DP end-use products, then it may be interesting to watch the maturity of materials (and processes for that matter) by indirectly watching how such advancements are being demonstrated or validated. Regardless of the industry or particular functionality being demonstrated it would remain a useful market analysis tool for better business decisions by identifying things like: Is the environment similar to your (or your customer’s) operational environment? Are there similar material properties required in your market space or are there similar paths to certification/qualification in your industry? In talking with David Burns (Global Business Advisory Services LLC) we both have realized the maturing nature of materials and processes within the industrial and commercial sectors. Mr. Burns recently attended RAPID 2016 and shared his insights. Our conversation yielded a few “ah-ha” moments. In talking with David, we realized that many more displays of advanced materials along with processing prowess have begun showing up more and more at industry shows such as SME’s RAPID. Not only has HP made a huge splash in the industry with Multi Jet Fusion as a new technology solution, they have also highlighted the need for accelerated materials development. HP is participating in that space by providing an open forum, their Multi Jet Fusion Open Platform, for a network of material suppliers to more quickly match materials to applications as well as to develop next generation materials. A continued trend in AM/3DP materials has been found 20 AUGUST 2016 Additive Manufacturing Continued from page 15 in the further adoption and advancement of metal material systems. Recently, XJET has brought its NanoParticle Jetting technology to the United States. According to the company, metal “ink” jetting “produces an ultra-thin layer of droplets containing metal nanoparticles or support nanoparticles. These are deposited onto the system build tray, producing metal parts with the ease and versatility of inkjet printing without compromising throughput.” EnvisionTec also recently unveiled their new Selective Lamination Composite Object Manufacturing (SLCOM) process which is claimed to be the first industrial composite 3D printer. The SLCOM process can process a wide range of custom-made thermoplastic reinforced unidirectional or multidirectional woven fibers tailored to the customer performance needs. There are many advantages to reinforced woven fibers. Potentially many operational environments could be served with such composite solutions depending on what resins are incorporated to reinforce those fibers. It is important to identify and track such nuances in the material development world as it seems the connection of those dots tends to lead to better business decisions in an ever-increasing competitive market. AMT continues to engage the industry, especially in the advancements of processes that seem certainly driven by materials! For more information about additive technologies, contact Tim Shinbara at [email protected] or 703-827-5243. ________________________________________________ FEATURE / Hybrid Manufacturing By Stephanie Hendrixson Contract Shop Invests in Hybrid Manufacturing for Survival and Growth An Ontario manufacturer sees hybrid manufacturing as a means for survival. Marv Fiebig, president of PTooling, spoke at length about his company’s strategy in bringing hybrid manufacturing technology in-house during an April event co-hosted by Canada Makes and the WindsorEssex Economic Development Corporation. 22 AUGUST 2016 Additive Manufacturing AM / Contract Shop Invests PTooling’s DMG MORI Lasertec 65 3D is the first to be purchased in North America. It is still the only service model on the continent not part of a captive operation. PTooling may not be the place you’d expect to find the first installation of a cutting-edge hybrid manufacturing system. The contract manufacturer in Amherstburg, Ontario, is a small family-owned company that has served Canada’s oilfield industry since 1999, relying on equipment such as its CNC turning centers and vertical machining center. But today the company is the owner of the first DMG MORI Lasertec 3D 65 hybrid milling and laser deposition machine to have been purchased in North America. As to why PTooling decided to make this leap into hybrid manufacturing, the company’s president, Marv Fiebig, says: “Survival.” Invest to Survive Leveraging advanced manufacturing technology is a strategy that has helped PTooling get through difficult times in the past. When the market went south in 2008, Fiebig realized that his company would have to differentiate itself from the other “mom and pop” shops also serving the oilfield industry in order to stay in business. The solution then was to modify the supply chain and invest in new, advanced equipment. The shop purchased a coordinate measuring machine and ramped up its quality department. These changes helped PTooling survive the downturn by setting it apart from its competitors. With Canada’s oilfield industry again in a slump since mid2014, PTooling’s purchase of the Lasertec hybrid is the next step in its evolution, as a means to diversify its operations and bring benefits to existing customers. Additive manufacturing had seemed like a move in the right direction for some time, but the company was waiting for the right metal AM machine to come along. According to Fiebig, powder-bed machines didn’t have build envelopes large enough for the company’s needs. Other systems were rejected because of restrictions on the types and numbers of materials that could be used. The Lasertec 65 3D won out for several reasons. Fiebig likes the fact that it is a hybrid machining center—not just a dedicated AM system. This allows PTooling to mill parts aggressively, like it would in any other machining center; in fact, the machine is sometimes used as a spare mill if its AM capabilities are not required. And when the additive head is used on a hybrid project, parts can be easily milled as they are built, even after each layer if necessary. additivemanufacturing.media 23 FEATURE / Hybrid Manufacturing DMG MORI’s Lasertec 65 3D combines five-axis machining capabilities with a laser deposition head for additive manufacturing. Metal powder is fed directly to the laser beam, limiting the amount of material needed. The Lasertec’s dual material hoppers were part of its appeal for PTooling, as the powder-fed system is more economical for large parts and enables faster, safer change-overs than powder-bed machines. The hybrid can switch between materials in about a minute, or even mix them in the same part. 24 AUGUST 2016 Additive Manufacturing AM / Contract Shop Invests Test parts such as these help show some of the possibilities of hybrid manufacturing. The thin and square pieces on the square build plate were laser-deposited and then machined to a smooth finish. Meanwhile, the notch in the part on the round plate was machined after each layer, demonstrating how subtractive work could be limited only to those areas where it is necessary. In addition, the Lasertec’s laser deposition strategy is better suited to PTooling’s needs than a powder-bed system, says Fiebig. The machine’s powder-fed head not only makes a larger work envelope possible, which is necessary to accommodate larger parts such as oilfield components, but the material deposition also enables building up a part essentially from nothing, rather than starting with a large volume of powder. The result is lower startup cost and less waste. Furthermore, the Lasertec’s dual material hoppers make it possible to switch between materials in about one minute, versus the time it would take to safely clean out a powder bed machine and restock it. The dual hoppers even enable the use of two different materials within the same part, including blending the materials together. New Possibilities Now that the machine has been running for several months, the employees at PTooling are excited about what it can do. Early customer applications have included a mold core and cavity that were laser deposited from the bottom up with conformal cooling channels designed to encourage turbulence in the cooling fluid (for better heat transfer), and an oilfield drill with a lasercladded exterior layer meant to increase its durability. On the whole, PTooling is finding that customers are eager to work with the company and see if their parts are suitable for this kind of hybrid manufacturing. In fact, Fiebig says that for the first time ever, new customers are calling him (instead of the other way around) now that the word is out about the machine. It’s been helping the company gain traction with big-name oilfield companies, as well as diversify into new industries such as aerospace. PTooling is also in a position to teach fellow manufacturers about hybrid technology. According to Fiebig, additive is challenged right now because people like the end result—a mold that cools faster, a component that’s lighter—but aren’t necessarily willing to sign off on a purchase order for a machine. There’s fear, he says. And that fear is somewhat justified. He readily admits that bringing an additive or hybrid machine on board is an expensive proposition, and the tasks necessary to define and refine the process take time. “But we’re doing it, and we’re not regretting it,” he says. That fearless attitude has helped position PTooling at what Fiebig calls the “bleeding edge” of its industry. His advice to other manufacturers: “If you’re contemplating this type of machinery, you’re not going to make a mistake in pursuing it. If you’re contemplating a project that would use this type of technology, don’t be afraid of it.” additivemanufacturing.media 25 GUIDE / Additive Manufacturing Conference CO-LOCATED WITH SEPTEMBER 13-14, 2016 CHICAGO, IL Connecting Additive Manufacturing + Production Electron Beam Additive Manufacturing. Photo courtesy of Sciaky. The Additive Manufacturing Conference is dedicated to exploring the ways that additive technologies can be implemented in an industrial setting. The two-day technical conference will include 20 expert speakers from global OEMs, leading additive manufacturing service bureaus, machinery suppliers, cutting-edge research outfits and product developers. In addition to technical insights on additive manufacturing technologies past and present, speakers will discuss the future impact and potential applications of 3D printing and additive manufacturing. This is the only event that focuses solely on the industrial applications of additive technologies, and IMTS is the perfect venue to demonstrate the connection between emerging technology and the shop floor. Explore the processes, equipment and materials used for making production parts and tooling. The conference is designed to demonstrate the benefits and obstacles to implementing or expanding the use of additive processing in production facilities. AdditiveConference.com PRESENTED BY 26 AUGUST 2016 Additive Manufacturing EVENT SCHEDULE AM / Learn Additive Tuesday, September 13 7:00 am REGISTRATION OPENS 10:15 am-10:30 am BREAK 7:30 am - 8:00 am BREAKFAST 10:30 am-11:00 am Integration of Additive Manufacturing with Traditional Machining Benjamin Fisk | Methods 3D Inc. 8:00 am-8:45 am OPENING KEYNOTE How Additive Manufacturing is Driving the Future of Making Things Amar Hanspal | Autodesk 8:45 am - 9:15 am Integrating 3D Printing and Traditional Manufacturing to the Benefit of Both Mike Misener | Baker Aerospace Tooling & Machining 9:15 am - 9:45 am New Approaches to Additive Manufacturing Dr. Greg Hyatt | DMG MORI 9:45 am - 10:15 am A Comparison of Inert and Open Atmosphere Laser Metal Deposition Systems Jim Cann | Optomec 11:00 am-11:30 am Automated Design of Functional Support Structures for Direct Metal Laser Sintering Joel Neidig | ITAMCO 11:30 am-12:00 noon Challenges and Best Practices in Implementing a Production Unit for Industrial Additive Manufacturing Güngör Kara | EOS GmbH Electro Optical Systems 12:00 pm-1:30 pm LUNCH 2016 IAMA Award Winner Presentation Concept Laser 1:30 pm-2:00 pm Which DLA Legacy Parts Are Additive Manufacturing Candidates? Thomas K. Parks | LMI 2:00 pm-2:30 pm How 3D Printing is REALLY Changing Machining David DeJong and Darryl Short | Karma Machining and Manufacturing 2:30 pm-3:00 pm BREAK 3:00 pm-3:30 pm AM Training: Beyond the Machine Paul Bates | Additive Manufacturing Competency Center, UL 3:30 pm - 4:00 pm Designing for Direct Metal Laser Sintering and Selective Laser Sintering Greg Thompson | Proto Labs 4:00 pm - 4:30 pm High Performance Alloy Parts via Binder Jetting Rick Lucas | The ExOne Company 4:30 pm - 5:00 pm Hollow Metal AM Inserts and Liquid Spot Cooling for Injection Molding Scott Kraemer | PTI Engineered Plastics 5:00 pm-7:00 pm GRAND RECEPTION SPONSORED BY EOS Wednesday, September 14 7:30 am BREAKFAST 8:00 am-8:30 am Additive Manufacturing Deployment Strategies Austin Schmidt | Caterpillar 8:30 am-9:00 am Designing for Additive Manufacturing at the Intersection of Materials, Machine and Process Raphael Stargrove | Autodesk 9:00 am-9:30 am Evaluation of 3D Printed Composite Molds Zeke Sudbury | Cincinnati Inc. 10:30 am-11:00 am Using Biomimicry to Enhance Direct Metal Tooling for Injection Molds Keith Schneider | Harbec Inc. 9:30 am-10:00 am BREAK 11:00 am-11:30 am Industrializing Additive Manufacturing Marc Saunders | Renishaw Inc. 10:00 am-10:30 am Integration Matters: Additive and One Process Manufacturing Evan Syverson/Tom Hipp | Sodick 11:30 am ADJOURN To view full abstracts and register, please visit AdditiveConference.com CO-LOCATED WITH This year, the Additive Manufacturing Conference is co-located located with the International Manufacturing Technology Show (IMTS) at McCormick Place in Chicago, Illinois. IMTS is one of the largest industrial trade shows in the world, featuring more than 2,000 exhibiting companies and over 100,00 registrants. Access ss to the IMTS exhibit hall is included with your Additive Manufacturing Conferencee registration. For hotel and transportation information, visit imts.com/travel. additivemanufacturing.media 27 GUIDE / Additive Manufacturing Conference Learn more about AMC 2016 exhibitors at amc16.mapyourshow.com Who’s Exhibiting: Exhibitor Name Booth 3D Material Technologies .................................................................2 3D Platform ..................................................................................... 9A Authentise......................................................................................... 17 Baker Aerospace Tooling & Machining, Inc. ................................. 11 C & A Tool Engineering, Inc. .............................................................5 Concept Laser, Inc...........................................................................10 EOS .......................................................................................................1 ExOne ................................................................................................. 6 Fabrisonic, LLC ..................................................................................7 Hurco Companies Inc ..................................................................... 20 Linear AMS .........................................................................................9 Exhibitor Name Booth Methods Machine Tools ................................................................... 4 Met-L-Flo ........................................................................................... 15 Mitsui Seiki........................................................................................ 18 Optomec............................................................................................. 3 Renishaw........................................................................................... 19 Sandvik Osprey Ltd. ................................................................... TBD Sigma Labs ...................................................................................... 13 SLM.................................................................................................... 12 Strangpresse ....................................................................................14 Techsolve ........................................................................................... 8 UL, LLC.............................................................................................. 16 (list as of 7/7/2016) Special Discount for Additive Manufacturing Magazine Readers Register for the Additive Manufacturing Conference to experience state-of-the-art uses of additive technologies for making functional components and end use production parts. It will cover processes, applications and materials, and give you practical knowledge on how to implement them in your facility. Register Now and Save! CODE: AM20 CO-LOCATED WITH BEFORE AUGUST 12 AFTER AUGUST 12 REGULAR REGISTRATION $650 $725 WITH AM20 DISCOUNT $520 $580 The Additive Manufacturing Conference will take place September 13-14, 2016 alongside IMTS, in Chicago, IL. Learn more at additiveconference.com. 28 AUGUST 2016 Additive Manufacturing REGISTER NOW! Connecting Additive Manufacturing + Production Register now to attend the only conference focused on additive manufacturing for industrial applications like tooling and end-use part production! The third annual Additive Manufacturing Conference takes place with the largest machining and manufacturing event in the United States, IMTS 2016! Topics Include: Lightweighting, Robotic Additive Manufacturing, Combining Additive and Subtractive Manufacturing, Software, Automation SEPTEMBER 13-14, 2016 McCormick Place (West Hall) Chicago, IL, USA AdditiveConference.com CO-LOCATED WITH PRESENTED BY SUPPLIER SHOWCASE 3D Platform 6402 E. Rockton Road Roscoe, IL 61073 U.S.A. 3D Platform is a leading manufacturer of industrial-strength, large-format 3D printers. 3DP’s second-generation flagship 3D printer, the 3DP Workbench, is an additive manufacturing workbench that offers a large build area of 1 × 1 × 0.5 meters. Based in Roscoe, Illinois, 3D Platform is committed to utilizing their expertise in mechatronics and linear motion to design and construct the best-in-class large-format 3D printers while maintaining affordable flexibility with open market software and control solutions. Phone: 779-771-0000 www.3dplatform.com PRODUCTS / SERVICES About 3DP Workbench The 3DP Workbench has a large build area of 1 × 1 × 0.5 meters and is built on industrial mechatronics designed to deliver precision down to 70-micron layer resolution. SurePrint Servo Technology Cut print time in half with SurePrint servo motors, which generate 85 percent greater torque for faster acceleration and deceleration, and improved print accuracy and quality. Folding Gantry Designed for flexibility and accessibility, the 3DP Workbench’s two-part configuration fits through a single-width door, making it possible to easily relocate. Expanded Print Capabilities The ergonomic height and open print bed enable full access for advanced techniques such as core modeling, adding inserts of metal, electronics and other materials. Industrial Workbench The printer features a solid hardwood work area and 12 built-in storage drawers and cabinets for additive manufacturing tools and materials. 30 AUGUST 2016 Additive Manufacturing Large-Format. Industrial Strength. Additive Manufacturing Workbench. CUT PRINT TIME IN HALF! Expanded Print Capabilities • Reduced print time • Enhanced print quality • Insert non-printed objects into a print • Examples: hardware, steel, electronics, and more! Folding Gantry • Fits through a standard door • Conveniently locate where you want— office, factory, etc. Industrial Workbench • Solid hardwood work area • Industrial built-in storage drawers and cabinets for useful additive manufacturing tools and materials NEW • Big: FFF printer with 1m x 1m x 0.5m build area • Economical: Capitalize on the open market advantage, low purchase price, and operating costs. Up to 90% savings using open market materials and software. • Accurate: NEW SurePrint™ Servo Technology delivers superior print quality. Closed-loop SurePrint™ Servo motors provide positional feedback every 1.25 microns, enabling fast and reliable printing. • Robust: Industrial strength mechatronics, SIMO® Series actuators and Constant Force Technology anti-backlash lead screws nuts| LAS provide rugged, industrial framework. JANUARY 6 -and 9, 2016 VEGAS, NEVADA www.3DPlatform.com SANDS EXPO BOOTH 73134 SUPPLIER SHOWCASE Concept Laser Inc. 1000 Texan Trail, Ste. 150 Grapevine, TX 76051-3780 U.S.A. Concept Laser is the global leader in the design and manufacture of powder bed-based laser metal additive manufacturing systems. We pioneered the earliest fully-dense metal manufacturing processes in the 1990s and we’ve been delivering conformal-cooled tooling inserts since 2001. In 2003 we installed our first commercial system and we now have over 550 systems worldwide. Our global client base includes customers in the aerospace, commercial and military aviation, national laboratories, defense, automotive, medical, dental, and jewelry segments. Phone: 817-328-6500 Email: [email protected] www.conceptlaserinc.com PRODUCTS / SERVICES X Line 2000R M2 Cusing Mlab Cusing R The X Line 2000R is the largest powder-bed metal additive system in the world, with a build volume of 31.5" × 16" × 20"—nearly twice that of the nearest competitor. The X line 2000R has dual 1-kW lasers, with a build rate approaching 120 cm3/hr. The M2 Cusing has two laser options (200- or 400-W, single or dual) and offers a closed-loop material-handling system to ensure that the operator’s contact with reactive powders and soot is reduced to the absolute minimum. This, along with the patented filterchange mechanism with waterflood passivation, position the M2 Cusing to be unrivaled in terms of safety. The Mlab Cusing R is capable of building in both reactive and nonreactive materials, and produces fully-dense parts with a surface finish that is unmatched in laser systems. With a smaller build volume of 3.5" × 3.5" × 3", this machine is ideal for high-value materials as it allows the user to work with smaller powder batches. 32 AUGUST 2016 Additive Manufacturing .the art of LaserCUSING® Concept Laser was stronger than other metal additive manufacturing technology available, offered flexible parameters, and fit into our current process seamlessly. HeIdI HoStetteR VP, Faustson tool Improve Your Bottom Line By Building Metal Parts With Rapid Speed Concept Laser is the global leader in the design and manufacture of powderbed-based laser metal additive manufacturing systems. With over 15 years of design production experience, Concept Laser has the right solution for your laser metal manufacturing needs. Concept Laser Inc (USA) [email protected] t: + 1 (817) 328-6500 www.conceptlaserinc.com Concept Laser GmbH [email protected] t. +49 (0) 9571 1679-0 www.concept-laser.de SUPPLIER SHOWCASE EOS is a global leader in industrial 3D printing specializing in both metal and plastic materials enabling a world in which traditional manufacturing limitations no longer constrain the design process. EOS of North America Inc. 28970 Cabot Dr. #700 Novi, MI 48377-2978 U.S.A. Phone: 248-306-0143 Fax: 248-306-0298 www.eos.info PRODUCTS / SERVICES FORMIGA P 110 EOS M 100 EOS M 400 The Formiga P 110 is a compact system that offers a cost-efficient and highly productive entry into the world of additive manufacturing. Entry level model for The size and modular design of the EOS M 100 make it ideal as an entrylevel model for fast and efficient production of complex metal parts via additive manufacturing. In terms of process and component quality, it corresponds to the EOS M 290, the leading system on the market for Direct Metal Laser Sintering (DMLS). With a building volume of 400 × 400 × 400 mm, the EOS M 400 allows the production of highquality, large metal parts on an industrial scale—directly from CAD data and with no need for tools. 34 AUGUST 2016 Additive Manufacturing Get More Introducing Your New Wingman EOSTATE MeltPool Monitoring System delivers more quality assurance with immediate measurement and analysis of direct metal laser sintering (DMLS®) production. Every Spot, Every Layer and Every Part. Learn more at www.eos.info SUPPLIER SHOWCASE ExOne provides 3D printing machines, 3D-printed products and related services to customers in multiple segments. The ExOne process, which utilizes Binder Jetting technology, gives traditional manufacturers an opportunity to reduce costs, lower the risk of trial and error and create opportunities for design innovation. ExOne Company 127 Industry Blvd. North Huntingdon, PA 15642 U.S.A. Phone: 877-773-9663 Fax: 724-864-9663 We collaborate with our customers through the entire development and production process so they are able to materialize new concepts—designs, prototypes and production parts—precisely when needed. Production scale is irrelevant and lot quantities of one are just as efficient as lot quantities of one thousand. ExOne offers both the 3D printing services and the equipment to enable rapid point-of-use manufacturing. We support the use of traditional industrial strength materials ranging from metals to silica sand and ceramic medias, all used in revolutionary ways. www.exone.com PRODUCTS / SERVICES Transmission Turbine ExOne Exerial 3D Printer Industrial series production of complex sand cores and molds is now possible using the Exerial 3D printer with two job boxes and a printing volume of 130.5 ft3 (3,696 L). Multiple Exerial printers can be linked together, forming a networked assembly system. This high degree of automation makes the printer ideal for mass production. 36 AUGUST 2016 Additive Manufacturing Brake Assembly 3D printed in ceramic media in the ExOne M-Flex 3D printing system. 3D printed in 420 stainless steel/ bronze in the ExOne M-Print 3D printing system. Industrial-Grade 3D Printing with Binder Jetting Technology ExOne® Systems & Services offer durable 3D printed metal parts with limitless complexity for prototype and series production volumes. No tooling required • True design freedom • Broad material applications Booth N-75 877 773 9663 • ExOne.com SUPPLIER SHOWCASE Fabrisonic LLC 1250 Arthur E. Adams Dr. Columbus, OH 43221 U.S.A. Phone: 614-688-5223 Email: [email protected] www.fabrisonic.com Fabrisonic LLC is an innovative manufacturing technology company that provides 3D metal printing services in a wide range of metals through low-temperature that is well below the melting point which is an Ultrasonic Additive Manufacturing (UAM) technology. UAM is a unique 3D printing process that harnesses sound waves to merge layers of metal foil in a process without melting. The process involves building up solid metal objects by ultrasonically welding a succession of metal tapes into a three-dimensional shape, with periodic machining operations to create the detailed features. Building in the solid-state enables Fabrisonic to join dissimilar metals and embed thermally sensitive materials such as electronics. The 3D metal printing process is used by industries such as aerospace, medical devices, military and manufacturing to create complex components that have distinctive features and attributes not possible with traditional manufacturing techniques. Fabrisonic’s line of SonicLayer machines print from 15 to 30 cubic inches per hour which allows for much larger build volumes up to 72 × 72 × 36 inches. Fabrisonic has multiple machines in house to provide manufacturing services and development for customers. PRODUCTS / SERVICES SonicLayerTM 4000 SonicLayerTM 7200 The SonicLayerTM 4000 is Fabrisonic’s midsize UAM machine with a build volume of 42 × 24 × 24 inches. The 4000 starts out as a three-axis vertical machining center to which Fabrisonic integrates their patented solid-state metal print head. The hybrid CNC approach allows both internal and external geometry to have a fully CNC’d surface finish. The solid-state ultrasonic welding process allows the 3D printing of dissimilar metals while embedding electronics. The welding head is treated as just another tool in the toolchanger and can be automatically swapped out for any standard CNC tool. Options include a laser for micromachining and high-speed spindles for milling fine details. The SonicLayerTM 7200 is Fabrisonic’s largest UAM machine with a build volume of 72 × 72 × 36 inches. The 7200 starts out as a three-axis vertical machining center to which Fabrisonic integrates their patented solid-state metal print head. The hybrid CNC approach allows both internal and external geometry to have fully CNC’d surface finish. The solid-state ultrasonic welding process allows the 3D printing of dissimilar metals while embedding electronics. The 7200 has an added capability of five-axis welding allowing for printing metal on a curved base. The 7200 can also be fitted with an auxiliary rotating axis that allows welding on the outer diameter of a cylinder or conical geometry. 38 AUGUST 2016 Additive Manufacturing SOUND 3D PRINTING FABRISONIC Solid-State Additive Manufacturing Combining Dissimilar Metals Embedding Sensors & Electronics Complex Internal Geometry Our Technology Ultrasonic Additive Manufacturing (UAM) is a revolutionary 3D printing technology that uses sound to merge layers of metal foil at very low temperature (~200° F). The process produces true metallurgical bonds with full density and works with a variety of materials. The Fabrisonic system utilizes a hybrid additive & subtractive approach to provide CNC finish and accuracy. This patented technology: • Allows welding metals without changing their metallurgical properties • Enables multiple metals 3D printed into one part (Al, Cu, Ti, etc.) • Allows embedding electronics in solid metal without damage or overheating • Allows for complex internal geometries with CNC quality surface finish Call or contact us today to see how Fabrisonic makes the impossible a reality: Hybrid CNC 6’x6’ Capacity fabrisonic.com [email protected] 614.688.5197 SUPPLIER SHOWCASE One Technology Way PO Box 68180 Indianapolis, IN 46268-0180 U.S.A. Phone: 317-293-5309 Toll-free: 800-634-2416 Fax: 317-328-2812 www.hurco.com Hurco has been leading the industry in CNC machine tool technology since 1968 with more than 60 patents. We understand the importance of agility, adaptability and profitability when it comes to running a business. That’s why we design and manufacture rigid and reliable CNC machine tools with the most flexible control in the industry by providing both NC and conversational programming in addition to our signature NC/Conversational Merge programming. Our co-founder Gerald Roch invented conversational programming, which removes the obstacle of complicated G-code programming and puts the power back in the hands of the machinist. However, even shops who use NC and rely on CAD/CAM software have found increased productivity by leveraging the versatility of the Hurco control. These shops use NC for the complex parts, but use conversational for one-offs, simple 2D work, and/or fixturing. Hurco has more than 65 models of CNC machines equipped with control technologies that make our customers more productive and more profitable. Nobody gets you from print to part faster than Hurco. PRODUCTS / SERVICES VMX42SWi The Hurco VMX42SWi is a five-axis machine that utilizes a swivel head for the B-axis that has travels of ±90 degrees, and a rotary table for the A-axis. The VMX42SWi has X/Y/Z travels of 42" × 24" × 24", a 12,000-rpm dual-wound Yaskawa spindle motor, 1,378-ipm rapid traverse rates (X and Y axes), larger linear rails that are wedge locked and mounted to a machined shoulder to increase rigidity, and a 40-station swing-arm automatic toolchanger (ATC). The unique advantage of Hurco CNC machines is the flexibility of the control because it provides multiple ways to program the part: CAD/CAM and Industry Standard NC, conversational programming, or NC/ Conversational Merge. Additionally, only Hurco CNC machines are equipped with UltiMotion, a sophisticated motion control system Hurco invented that reduces cycle time by up to 30 percent or more depending upon the complexity of the part. 40 AUGUST 2016 Additive Manufacturing SUPPLIER SHOWCASE Linear Mold & Engineering 12926 Stark Road Livonia, MI 48150 U.S.A. Phone: 734-422-6060 Fax: 734-422-4118 Linear AMS, a leading provider of Additive Manufacturing (AM) Solutions, leverages 3D metal printing expertise, CAD-based advanced technologies, and traditional manufacturing to produce metal prototypes, pre-production, production parts, tooling/injection molds, and conformal cooling inserts. Linear accelerates the curve in AM adoption and the practical application of advanced manufacturing in the supply chain through Linear AMS Technology Transfer Programs—Training, Staffing, Consulting, Microfactories and R&D Pods. We go beyond making “cool parts” and deliver real products that work in applications for aircraft, space & defense, oil & gas, energy, industrial components, automotive, medical/dental, and consumer packaged goods. www.linearmold.com PRODUCTS / SERVICES Conformal Cooling Inserts Direct Metal Laser Melting (DMLM) Parts As an early adopter of DMLM technology, Linear developed a niche of building conformal cooling inserts complementing its mold manufacturing. Conformal cooling in injection molds was developed to create cooling channels that conform to the shape of the molded part to get cooling close to critical areas that otherwise would be difficult to cool conventionally. Conformal cooling offers a more uniform way to cool the parts, thus reducing cycle time and improving both productivity and quality. Studies have shown that using conformal cooling methods reduce cycle times between 15 and 45 percent. Conformal cooling is the solution for complex mold geometry, deformed parts and varying wall thicknesses. At Linear we see ourselves as an additive manufacturing (AM) solutions provider for our customers. AM processes deliver the potential to create complex geometries that were previously impossible using conventional methods. Using the DMLM process, Linear produces high-quality functional prototypes and end-use production parts for aerospace, defense, energy, medical, automotive and other applications. In this process, an array of metal alloys is used such as: stainless steels, aluminum, titanium, Inconel, cobalt chrome, maraging steel and Hastalloy-X. By using this technology, design capabilities are endless. 42 SEPTEMBER 2016 Additive Manufacturing SUPPLIER SHOWCASE Methods Machine Tools Inc. 56 Sterling Street Clinton, MA 01510 U.S.A. Phone: 978-733-1353 Fax: 978-733-1357 www.methodsmachine.com Methods 3D has partnered with 3D Systems creating an additive manufacturing team unsurpassed in industry. We have established seven technology labs across the country equipped with state-of-the-art 3D printers and staffed with a dedicated team of industry experienced, highly-skilled professionals. The company is fully integrated with and leverages the extensive machining and manufacturing experience of Methods Machine Tools to further enhance our ability to provide our customers with a total manufacturing solution. Our focus is to empower our customers with the additive manufacturing technology from 3D Systems coupled with exceptional service and applications support from Methods 3D. The solutions we provide will enable our customers to enter new markets, expand their manufacturing capabilities, and revolutionize manufacturing with 3D printing. PRODUCTS / SERVICES ProX DMP 320 Developed from the outcome of nearly half-a-million prints, the ProX DMP 320 offers fast build turnaround times in demanding 24/7 production environments. It is designed for productivity with quick-swap build modules and fast powder recycling. Low O2 during builds (25 ppm) enables exceptionally strong parts of high chemical purity. Efficient consumables management and shared ancillary equipment lower the total cost of ownership. Thousands of hours of parameter optimization ensure predictable and repeatable print quality. The ProX DMP 320’s robust, streamlined print process means you can print virtually any geometry and avoid trial-and-error steps. 44 AUGUST 2016 Additive Manufacturing FEATURING THE LATEST TECHNOLOGIES IN ADDITIVE MANUFACTURING AT IMTS 2016 Additive Manufacturing integrated with State-of-the-Art Machine Tools Automation Solutions and BOOTH S-9119 www.methodsmachine.com TECHNICAL CENTERS FROM COAST TO COAST Charlotte Chicago Detroit Los Angeles Phoenix San Francisco 704.587.0507 847.783.6800 248.624.8601 714.521.2507 602.437.2220 510.636.1430 CORPORATE OFFICE TECHNICAL CENTER AND SHOWROOM 65 Union Avenue, Sudbury, MA 01776 978.443.5388 | [email protected] M ACHINE T OOLS ■ T URNKEY S OLUTIONS ■ A UTOMATION C ELLS ■ P ARTS AND S ERVICE ■ T OOLING SUPPLIER SHOWCASE Mitsui Seiki USA Inc. 563 Commerce St. Franklin Lakes, NJ 07417 U.S.A. Phone: 201-337-1300 Email: [email protected] www.mitsuiseiki.com Mitsui Seiki USA Inc. is a wholly owned subsidiary of Mitsui Seiki Kogyo Co. Ltd. The parent company was the first to create ultra-precise machine tools in Japan in the 1930s. Its current product line is comprised of CNC horizontal and vertical spindle machining centers with up to 5+ axes, CNC jig boring and jig grinding machines, and CNC thread grinding machines. Over the last decade the optimal machining of hard metals has been a concentrated R&D effort. As such, Mitsui Seiki has the most current and thorough machining knowledge pertaining to the various titanium grades and other hard metals. The company is also on the leading edge in developing new technology that encompass both subtractive and additive machining functions in one platform. The new Hybrid Machine will be a cornerstone of Mitsui Seiki’s IMTS 2016 exhibit. The company will also demonstrate technology dedicated to blade production and will relay information about GE’s Blue Arc—a breakthrough method to machine hard metals offering dramatic time savings. Mitsui Seiki is the machine tool partner in the development of this exciting new approach. Visit IMTS 2016 booth S-8519 to learn more! PRODUCTS / SERVICES New “Hybrid” Additive/Subtractive Machining System at IMTS 2016 See it in action in Booth S-8519 Mitsui Seiki USA Inc.’s new “hybrid” technology will be demonstrated in IMTS 2016 Booth S-8519. The Vertex 55X-H combines a precision-built traditional CNC vertical machining center with a spindle-adapted laser DED (Direct Energy Deposition) / powder feed nozzle. Parts can be 3D printed from nothing or material can be added to existing parts. The nozzle loads into the toolchanger like any tool and is changed automatically via the CNC program, a milling/drilling tool replaces it and aspects of the workpiece can be machined conventionally—including internal features. The process is under full adaptive control as the part is being made. The main benefit that Mitsui Seiki offers as compared to other hybrid systems on the market is that this machine maintains common center line integrity between nozzle and tool as users change between the additive nozzle and the subtractive tool and offers a sub-15-micron volumetric accuracy within the work envelope. 46 AUGUST 2016 Additive Manufacturing AdditiveHybrid we have A New “Hybrid” Approach to Machining Mitsui Seiki is officially introducing its new “Hybrid” machine at IMTS 2016 in Booth S-8519. It’s brand new technology that applies both advanced additive and subtractive methodologies – in a viable, practical solution. Demos will be held each day and Robb Hudson will be educating show visitors about this during the IMTS Conference. Scan the QR code below for more details. Robb Hudson, Technology & Business Development Manager Booth S-8519 Please scan the code to be directed to a digital copy of our 2016 IMTS handout including all things Mitsui Seiki. Check for the latest events, times, and more. 563 Commerce Street Franklin Lakes, NJ 07417 Tel: (201) 337-1300 Fax: (201) 337-3680 www. mitsuiseiki.com MITSUI SEIKI SUPPLIER SHOWCASE Renishaw Inc. 5277 Trillium Blvd. Hoffman Estates, IL 60192 U.S.A. Phone: 847-286-9953 Fax: 847-286-9974 www.renishaw.com Fully designed and engineered in-house to be used for serialized production, the RenAM 500M builds complex metal components directly from CAD using metal powder fusion technology. Highlights of the system include a Renishaw designed and engineered optical system with dynamic focusing; automated powder sieving and recirculation; 500-W ytterbium fiber laser; and patented high-capacity dual filter system. The system is designed to significantly reduce operator touch time through efficient materials handling via the onboard sieving and powder recirculation system. Process emissions are safely handled via the patented dual SafeChange filter, automatically sensing and redirecting recirculation gas to maintain optimal performance and chamber cleanliness. Ideal for industrial production applications, RenAM 500M has a higher level of automation. Powder sieving and recirculation are all carried out within the compact system automatically, reducing the need for manual handling and exposure to materials. This provides increased safety and sustained quality of the metal powders. PRODUCTS / SERVICES RenAM 500M Industrial Metal Additive Manufacturing System Renishaw is a global company with core skills in measurement, motion control, additive manufacturing and precision machining. We develop innovative products that significantly advance our customers’ operational performance—from improving manufacturing efficiencies to raising product quality. Our products are used for applications as diverse as machine tool automation, coordinate measurement, additive manufacturing, gaging, machine calibration, position feedback and shape memory alloys. In all of these areas we aim to be a long-term partner, offering superior products that meet our customers’ needs both today and into the future, backed up by responsive, expert technical and commercial support. 48 AUGUST 2016 Additive Manufacturing Redefin Redefi ne your design Explore the potential of additive manufacturing Renishaw’s additive manufacturing systems use powder bed fusion technology to produce fully dense complex metal parts direct from 3D CAD. Also known as 3D printing, this technology is not constrained by traditional manufacturing design rules. Create complex geometries such as conformal cooling channels for tooling inserts, reduce component weight by only placing material where it is needed, and consolidate multiple parts in one assembly. Additive manufacturing is also complementary to conventional machining technologies, and directly contributes to reduced lead times, tooling costs and material waste. • No requirement for tooling. • Increased design freedom - complex geometries and hidden features. • Rapid design iterations right up to manufacture. For more information visit www.renishaw.com/additive Renishaw Inc. Hoffman Estates, IL www.renishaw.com SUPPLIER SHOWCASE SLM Solutions NA Inc. 28350 Cabot Dr., Ste. 100 Novi, MI 48377 U.S.A. Phone: 248-243-5400 Email: [email protected] www.slm-solutions.us SLM Solutions is a leading provider of metal-based additive manufacturing systems that optimize fast and cost-efficient part production. With multi-laser options, bi-directional recoating, an open system architecture for materials and parameters, and the safest operation with closed-loop powder handling, Selective Laser Melting systems achieve build speeds up to 70 percent faster than the competition for complex and completely dense metal parts. These powerful and innovative machines, available in three sizes with single, dual and quad laser capabilities, support an optimal approach for faster, more flexible metal part production and prototype development across the aerospace, automotive, academia, energy and medical industries. Headquartered in Lübeck, Germany, SLM Solutions Group is a publicly traded company (TecDax) with its North American offices located in Metro-Detroit. PRODUCTS / SERVICES SLM 125HL SLM 280HL SLM 500HL The SLM 125HL offers a build envelope of 125 × 125 × 75 (125 optional) mm. Economical and suitable for R&D as well as small lot production environments, the open software architecture and system parameters allow modifications according to the project’s specific needs. A compact, entry level machine, the SLM 125 is equipped with a 400-W laser for maximum processing capabilities. Ideal for medium- to highvolume metal part production and prototypes, the SLM 280HL provides a 280 × 280 × 350-mm build envelope. The integrated SLM Build Processor and open architecture offers the freedom of controlling system parameters to optimize and meet strict production needs. Multiple laser configurations allow twin 400-W lasers with overlap or maximized power with dual 400-W and 1,000-W fiber lasers. The flagship additive manufacturing system for high volume metal part production, the SLM 500HL increases speed, ensures operator safety and lowers operational costs. Offering up to four 400-W lasers with three overlap areas in the 500 × 280 × 365-mm build envelope, speeds are further increased with patented bidirectional layer recoating and closed-loop powder transport, eliminating time-consuming manual fills and powder handling. 50 AUGUST 2016 Additive Manufacturing The Most Productive Additive Metal Manufacturing Systems More Laser Power, Larger Build Envelope, Faster Build Speeds All systems in the SLM Solutions product line feature a common development and laser platform with transferrable parameters for high quality metal parts from the lab to production. Offering build volumes up to 22% larger and build time efficiencies up to 70% faster than the competition, SLM Solutions can enhance your capabilities with selective laser melting! Free White Paper: 7 Must Ask Questions Before Buying a Metal 3D Printer Download at http://goo.gl/csYtyp SLM Solutions is a leading provider of metal-based additive manufacturing systems and technology that support fast and flexible metal part production for the aerospace, automotive, energy and medical industries. SLM systems define the gold standard for best-in-class operator safety and greater recoating speed. SLM Solutions NA, Inc. www.slm-solutions.us I [email protected] 28350 Cabot Drive, Suite 100 I Novi, MI 48377, USA I 248-243-5400 Visit us at IMTS Booth N-71 FEATURE / Metal Additive Manufacturing By Peter Zelinski Inspect the Part As It Grows This year’s IAMA was awarded for a technology that monitors thermal radiation to map the internal consistency of a metal part as it is being made. The technology might point the way to an entirely new paradigm for inspection. Additive manufacturing does not consist of just growing a part’s geometry, as intricate as that geometry might be. Instead, AM also consists of growing that part’s material—its solid form—at the same time that this geometry is made. In fact, what makes additive manufacturing so different from other approaches to production is not the adding instead of subtracting, but instead the laying down of material within the same process that also makes the shape. This is a significant departure from the traditional practice of creating metal and shaping metal within two different processes in two different facilities. Such a departure will affect the way we validate production parts made through AM, and it will affect the means and the standards we use to certify those parts as acceptable. One company that has thought a lot about this is additive manufacturing machine supplier Concept Laser. This year, the company won the International Additive Manufacturing Award (IAMA) not for its technology in making parts, but for its related technology in inspecting those parts as they are made. “QM Meltpool 3D” is the company’s brand name for a system that uses the thermal radiation from the melting of the metal to generate a detailed image set of the internal formation of the part. The output this system generates is comparable to a computed tomography (CT) scan of the part, even though CT measures a finished part while the Concept Laser system captures data as the part is taking shape. Recently, I had the chance to speak with Concept Laser’s U.S. president and CEO John Murray about the promise of this technology. The technology is safe, he says. This is one of the points he takes care to stress, and it’s an important one. Monitoring an additive build as it is underway sometimes involves adding sensing devices to the build chamber, but the approach Concept Laser has found does not require this. As a result, the company’s monitoring system has won certification to ATEX, The spot in the midst of the bright flash is a melt pool about 200 microns wide. The spot is darker than the surrounding corona because energy is being consumed by the melting. Here is a QM Meltpool 3D map of one build layer of a mold insert for eyeglass lenses. The measured emission within the circle reveals an area of thicker powder that did not fuse consistently with the rest of the part. This may or may not be a concern. For example, the problem area might affect only a cooling channel, not the actual mold geometry. Seeing the precise location of the effect allows the user to make that determination. 52 AUGUST 2016 Additive Manufacturing AM / Inspect the Part As It Grows A schematic of Concept Laser’s system. Components include (1) laser input, (2) galvanometer scanner, (3) melt pool and powder bed, (4) wavelength-selective mirror, (5) beamsplitter, (6) high-speed camera and (7) photodiode. the European directive related to explosive atmospheres, which restricts the use of electromagnetic devices inside the sealed chamber. Thanks to a semi-permeable mirror, QM Meltpool 3D’s sensing is entirely outside the chamber. Thermal radiation passes through the mirror, while radiation at the wavelength of a laser does not. That means the laser can get out of the line of sight of the system’s thermal sensing, bouncing its beam off the mirror to melt the metal while a photodiode and a high-speed camera look through the mirror to observe the result. What that photodiode and camera are monitoring is the heat exposure of each area of the part touched by the laser. They capture this stream of data in small area increments (pixels). The heat exposure indicates of the thoroughness of the metal’s melting, and this in turn indicates the homogeneity of the additively manufactured part. The resulting correlation from heat exposure to material consistency is so strong that comparisons with CT scans of the finished part have shown that this effect accurately predicts even tiny defects within an otherwise solid metal form. What is the International Additive Manufacturing Award? The International Additive Manufacturing Award (IAMA) was created to recognize advances in the technology and application of additive manufacturing. Three industry trade groups support the award. It is presented by AMT— The Association For Manufacturing Technology and VDW of Germany, and it is sponsored by European machine tool association CECIMO. Since its founding, the annual award has had two winners. Hybrid Manufacturing Technologies won the award in 2015 for its laser cladding system that can be integrated with CNC machine tools, and Concept Laser won this year for its technology related to melt pool monitoring. The prize, valued at $100,000, consists of $20,000 cash plus an $80,000 marketing package for promoting the winning company or technology. The award’s media partners, VDI Nachrichten of Germany and Gardner Business Media of the U.S. (publisher of this magazine) provide the latter part of the prize. This year, 14 contestants submitted detailed entries for judging. The IAMA’s 10 judges consist of members of industry, academia and the trade media, all of them close to or directly involved with additive manufacturing. (AM editor Peter Zelinski is one of these judges.) They do not consult with one another during the judging, but instead evaluate entries according to various formal criteria, with the sets of scores then tallied independently to find the winner. The award will open for entries for the 2017 IAMA later this year. Follow additivemanufacturing.media for announcements. The International Additive Manufacturing Award website is www.additive-award.com, and you can read our coverage of the award at gbm.media/iama. additivemanufacturing.media 53 FEATURE / Metal Additive Manufacturing Here are examples of discontinuities engineered into test parts that the monitoring system was able to successfully detect. Seen here are the meltpool maps showing (left) a 100-micron-diameter cylindrical opening and (right) a 200-micron-diameter open sphere. How It Works In its IAMA application, Concept Laser described the operation of the system. (I was one of the 10 judges reviewing these applications.) The drawing on the preceding page shows the major components of the system, and what follows is a paraphrase of Concept Laser’s description. Measuring the part’s formation is part of the same process that achieves that formation, and that process begins with the laser. The beam first goes to the semi-permeable mirror. The mirror reflects the laser to a galvanometer scanner that positions the beam on the bed of powder metal. The powder absorbs the energy of this beam—melting as a result of the absorption— and as it does so, its emitted thermal radiation passes back through the galvanometer to return along the path of the laser. At the semi-permeable mirror, this radiation passes through, to be twinned by a beamsplitter so it can be directed to both a high-speed camera and the photodiode. A single frame from the camera is seen in the upper image on page 48. This frame is 100 by 100 pixels, with each pixel 10 microns wide. The spot in the midst of the bright flash in this image is a melt pool about 200 microns wide. Emitted radiation is less within this spot than throughout the brighter corona around it, because energy is being consumed by the melting. The camera captures 15,000 frames like this one per 54 AUGUST 2016 Additive Manufacturing second while a control board captures position information at the same rate. QM Meltpool 3D software then paints the emission data in grayscale values (zero emission = black) at corresponding location coordinates to create complete, detailed images of the inner form of each layer of the part. These images can be studied individually, or they can be viewed in sequence to watch the part’s progression—and the progression of any anomalies—throughout the additive cycle. The images above from the additive builds of two circular parts illustrate the discontinuities this system is able to detect. (Or, rather, able to predict—because the part wasn’t yet finished when the images were taken.) In one part, a cylindrical volume as long as the radius of the part, but only 100 microns in diameter, was deliberately left open in the part’s design. In the other part, a 200-micron-diameter sphere was left open. As the two images show, both of these “defects” were accurately captured as they were being formed within the part. Comparison to CT Mr. Murray says the CT scan is the right reference to use to determine the effectiveness of meltpool monitoring as a validation tool. If CT is an acceptable non-destructive means of determining a part’s internal integrity (and many manufacturers deem that it is), then meltpool monitoring ought to be AM / Inspect the Part As It Grows Emission maps also reveal the influence of one layer’s structure upon the next layer. The layer at left includes an unmelted hole. In the very next layer, the effect of the resulting change in heat conduction can be seen. acceptable as well—provided that it reliably gives results that match computed tomography imaging. Concept Laser’s system has strengths and shortcomings relative to CT, he says. In terms of precision, CT excels, offering a resolution of 10 microns versus about 35 microns for QM Meltpool 3D. However, the effectiveness of CT is limited by the density of the material. Meltpool monitoring has no such limitation. Internal maps of dense Inconel, for example, can be generated just as easily as those of any other metal. Meanwhile, meltpool monitoring has essentially no operational cost. It runs during the additive cycle, and it requires no stand-alone machine. Concept Laser has demonstrated to its own satisfaction the reliability of its meltpool monitoring at predicting the very same internal effects that computed tomography also reveals. Something like this same comparison is what manufacturers of high-value parts will need to conduct to demonstrate for themselves the effectiveness of such a system. Those taking this step will discover a new means of understanding the part, and perhaps they’ll also discover a different way of thinking about inspection. If meltpool monitoring can indeed perform as effectively as CT, then in theory the inspection of a part can begin even before the part is finished. There are challenges to this idea, Mr. Murray says. Data storage is one. Manufacturers required to maintain records for traceability would need systems to maintain the enormous amount of data (exabytes, potentially) that ongoing production of critical parts would generate. But then again, for additive manufacturing today, traceability sometimes entails storing test coupons from each build, so merely storing data might be cheap by comparison. The larger challenge relates to acceptance, he says. The U.S. Food and Drug Administration—the certifying body for medical implants made additively—is aware of the possibility of mapping a part through the Concept Laser system. However, “FDA representatives have told me they don’t yet know what to do with data such as this,” he says. The meltpool map does not fit what is currently seen as acceptable for certifying a part. In regulated industries such as medical manufacturing, meltpool monitoring cannot work as an inspection method (at least not final inspection) until the paradigm changes to allow it. Presumably, though, that change will come—because other, comparable changes in thinking related to additive manufacturing are already taking hold. For example, it is becoming understood that realizing the full promise of AM will entail new ways of thinking about component design. Perhaps it is just as true that realizing the promise of AM will entail new ways of thinking about how to validate the part’s quality. additivemanufacturing.media 55 FEATURE / Mold Making By Christina Fuges Conformal Cooling Is a Mold Enhancement Part of what makes conformal cooling so accessible is that redesign of the mold is not needed. Baker Aerospace Tooling & Machining collaborates and educates to advance this and other applications of AM. Macomb, Michigan-based Baker Aerospace Tooling & Machining started out as a duplicating company. It’s come a long way since then. In 1998, the company was one of the first in its area to purchase a five-axis machine. Now, it has 15 five-axis machines and more than 40 CNC mills in total. Today, the company is made up of three units—Baker Aerospace Tooling & Machining is parent to Baker Machining & Mold and Baker 3D Solutions, the unit leading the company’s advance into additive manufacturing. The company’s 3D printing lab includes two EOS M290 direct metal laser sintering (DMLS) machines and five Stratasys Fortus fused deposition modeling (FDM) printers. Mike Misener, director of tooling and additive manufacturing for the company, says it was demand from customers that motivated Baker to start experimenting with metal 3D printing. The company first used metal AM on fixtures that These 3D-printed conformal-cooled inserts illustrate some of the AM expertise i Baker B k now applies. li Th The company h helps l to educate d customers on misconceptions surrounding conformal cooling, including, for example, the idea that a whole new tool must be created in order to use this. In reality, only select inserts of a tool must be altered, and only in their internal geometry. 56 AUGUST 2016 Additive Manufacturing were difficult to machine, but easy to print. It outsourced this work until the company purchased its first EOS metal printer in December 2015, followed by a second EOS machine this past February. Prior to those investments, Baker had ventured into plastic 3D printing and even that process had helped to revolutionize how it manufactured fixtures. For example, a typical production fixture that previously had been machined was so heavy that it took two people to handle it. Printing in plastic removed 75 percent of the weight while retaining the same required rigidity and tolerance, allowing this to become a one-person application. Collaborative Approach Earlier this year, Baker joined forces with Excel RP/Excel Global, a tooling sourcing company, to sponsor the SA Engineering AM / Conformal Cooling Technology Center, a collaboration facility established by injection molder SA Engineering (part of SA Automotive, a Tier 1 compression molder) for emerging injection mold trends, located in Livonia, Michigan. The purpose of the center is to work with OEMs and Tier suppliers to locally promote and advance R&D in new technologies for injection molding. The center, which held its official grand opening this summer, provides a setting where companies with expertise in services that support injection molding can co-locate to develop new technologies on 110- to 3,500-ton presses. This setting promotes accountability and collaborative development of repeatable processes for the new technologies, says Misener. Through this center Baker will offer its metal 3D printing expertise for mold-related applications including conformal cooling. Baker’s expertise in building 3D-printed mold inserts with conformal cooling has already helped to improve some processes under testing and development at the center. For example, one customer reported problems it was having with cold spots in a heated compression mold. Baker evaluated the customer’s compression molding process and recommended conformal-cooled inserts, which would allow the mold to maintain heat more evenly. Misener says the customer was skeptical at first, because there is an ongoing misconception that adding conformal cooling requires design of a whole new tool to accommodate it. “What molders don’t realize is that they can take the traditional insert size and just change the internal geometry to get the conformal cooling they need,” he says. “You can take an existing tool with an in-and-out waterline configuration and design the internal channels without having to disrupt the entire design. You are only recreating the internal areas of the insert that are already existing in the tool. You don’t have to reinvent the wheel. Conformal cooling is a mold enhancement.” Using mold flow, cooling and warp analysis, Baker showed the customer how to implement conformal cooling in its existing tools. He says another point many molders don’t know about metal 3D-printed inserts with conformal cooling is that they can be used in production—not just in prototypes—if they are designed correctly. “There are wrong ways of designing conformal-cooled inserts,” Misener says. He cites two common design mistakes: • “Choking down” the insert, or quickly reducing the size of the internal chamber, which will inhibit fluid flow. • Designing a 90-degree bend in the cooling channel, which The company is one of the supporters of the new SA Engineering Technology Center, where it collaborates with other companies to develop and test injection molding technoloies and solutons. Two of the resources of the center are seen in these photos, a 285-ton press (above) and 3,500-ton press (left), both from injection molding machine maker Engel. will also restrict flow. This is conventional thinking based on drilled holes and sharp bends. Misener says both of these design mistakes negate the benefits of conformal cooling. “It is all in how you design conformal cooling with the flow of the internal channels to ensure a constant flow,” he says. “With conformal cooling, you need a flowing system, not a sharp-corner system.” He emphasizes the need for both mold flow and water flow analysis, both tools that Baker uses in designing conformal cooling for its customers. Looking Ahead According to Misener, an emerging use of AM outside of conformal cooling is on gate inserts. He explains that there are a lot of conventional, off-the-shelf cashew gate and tunnel gate inserts that need to be customized, and making any modifications conventionally on a CNC machine can be difficult. But a metal additive process allows any type of gate design or size to be placed. “We can reach any area with DMLS,” Misener says. “We grow a custom gate insert for that tool instead of modifying a shelf item. Instead of trying to make it work the best you can, DMLS lets you make it exactly the way you want it.” additivemanufacturing.media 57 FEATURE / Metal Additive Manufacturing By Peter Zelinski Testing the Reusability of Titanium Powder Researchers ran the same batch of powder through build after build, evaluating it each time. The results support the viability of AM for ongoing production. One of the promises of additive manufacturing in metal is reduced material use. An intricate form produced additively can be grown to its final shape or very near to it, whereas the same form produced through a more conventional process might require much of the workpiece material to be machined away as chips. And yet, that promise rests on an assumption. It assumes that the powder metal in a powder-bed additive process can be recycled. If it cannot—that is, if unused powder from one build is precluded from making a part in the next build—then this compromised material is just as wasted as any chip. Therefore, the material efficiency of additive manufacturing is determined by the reusability of the metal. Just how far can an additive metal machine go with a single batch of powder? This is an important question. Each experimental build consisted of a variety of geometrically intricate parts, plus test specimens. Renishaw ran 38 such builds before there was insufficient powder remaining to continue. Most of the powder in any additive build remains unwelded to the part. Re-using this powder is key to the material efficiency of additive manufacturing. The testing therefore explored whether unwelded titanium powder is affected by being used again and again in sequential build cycles. 58 AUGUST 2016 Additive Manufacturing AM / Titanium Powder Marc Saunders and Lucy Grainger of Renishaw recently reported on an experiment addressing this question. Mr. Saunders is the director of Renishaw’s Global Solutions Centers, and Ms. Grainger is a product marketing engineer for the company. Work carried out with titanium 6Al4V alloy in a Renishaw AM250 machine using a 200-W laser tested whether repeated reuse of unused powder in build after build affected the characteristics of either the powder itself or the parts it was used to make. The short version of the findings—which are very encouraging to the prospects of AM for production—is that neither the process nor the parts were much affected by re-using material. The company’s experiment tested a scenario far more extreme than any production process is likely to be. An initial batch of powder was used and reused without the powder ever being replenished. After 38 build cycles were run, there wasn’t enough powder left to make any further parts. In production, powder wouldn’t be used this way—virgin powder would continually be blended into the mix, diluting any problems that the previously used powder might present. The Renishaw experiment deliberately aimed to unmask those problems, if they exist, by removing the dilution. In other words, this wasn’t a simulation of production; it was a simulation of the far more demanding case of a manufacturer somehow marooned with an additive machine and just a single bin of titanium powder. Technically, some powder was indeed lost. Powder re-use entails sieving to remove grains that have become fused because of their proximity to the additive weld. However, this sieving removed less than 1 percent of the material, Ms. Grainger reports. All of the rest of the material except for the remnant at the end was used to make complex forms representing production parts, plus test pieces such as tensile bars. Powder consistency, powder flowability, material chemistry and the mechanical strength of the metal were all evaluated from build to build. While none of these parameters remained constant, none of them changed enough throughout the testing for the change to be significant. For example, the slight measured increase in oxygen and nitrogen contamination across the 38 builds remained well within the margin allowed by the relevant standard, ASTM F3001-13. Powder flowability actually improved. The results of this experiment can’t be extrapolated, Mr. Saunders says. Different materials might respond to re-use in different ways. Other machines will also behave differently. He points out that the Renishaw machine seals its build chamber, evacuating moisture and contaminants before replacing the atmosphere with argon. But even so, this set of findings provides a promising and even exciting early step toward qualifying powder-bed systems and materials for use in full-scale, ongoing part production. Particle size variety changed, but not enough to significantly affect the process. Seen here (top to bottom) are views of the virgin powder, the powder after build 19 and the powder after build 38. Why do small particles seem to disappear? They probably became sintered to larger particles, producing oversized particles that were removed through sieving. additivemanufacturing.media 59 IMTS 2016 ON DISPLAY The International Manufacturing Technology Show (IMTS) 2016 takes place September 12-17 at the McCormick Place complex in Chicago, Illinois. The event, held every two years, is organized by AMT—The Association For Manufacturing Technology and is one of the largest industrial trade shows in the world. The 2016 edition will include the Additive Manufacturing Conference (see pages 26-28 for a complete guide) and, for the first time, a dedicated Additive Manufacturing Pavilion located at the entrance of the North Building. This section previews some of the AM equipment that will be on display, both in the AM Pavilion and elsewhere at the show. Machining Center for Additive, Subtractive Processes Mitsui Seiki (USA) Inc., Booth S-8519 be printed to completion and then subsequently machined. Mitsui Seiki has developed the Vertex 55X-H, a hybrid According to the company, the machine maintains common machining center that combines additive and subtractive center line integrity between the additive nozzle and sub- processes on one machine tool platform. According to the tractive tool as users switch between them. The system is company, the machine’s hybrid technology results in a pro- said to offer sub-15-micron volumetric accuracy. ductive and repeatable process that produces good surface finish results. Cycle times are reduced compared to powder-bed additive processes, and both processes can be achieved in one setup on the platform. The machine is suitable for repair operations in aerospace, power generation, and oil and gas. The hybrid machine combines a CNC VMC with a spindleadapted, laser direct-energy deposition powder-fed nozzle. Using this technology, parts can be 3D printed or material can be added to existing parts. The nozzle loads into the toolchanger and is changed automatically via CNC program prompts with an adaptive programming language. Multiple nozzles can be added for different powder flow rates or angles, and exact control The machining center features either a CAT or HSK of the deposition rate is possible using a variety of laser spindle with a speed ranging from 15,000 to 30,000 rpm. beam profiles. It offers an X-axis working range from 550 to 750 mm, A milling/drilling tool can replace the nozzle to ma- Y-axis from 600 to 800 mm and Z-axis from 400 to 750 chine aspects of the workpiece conventionally, including mm. An integrated coolant system enables either dry or internal features. Surface work can be machined before wet machining. the next layer of material is added or the workpiece can mitsuiseiki.com 60 AUGUST 2016 Additive Manufacturing IMTS 2016 / On Display 3D Printer for Building in Reactive, Non-Reactive Materials Concept Laser, Booth N-87 The Mlab Cusing R by Concept Laser is capable of building in both reactive and non-reactive materials, and produces fully-dense parts with a high-quality surface finish. The machine’s smaller build volume makes it suitable for high-value materials as it requires smaller powder batches. It also enables economic fabrication of delicate dental products and medical implants, as well as medical instruments made from titanium. The 3D printer features a glovebox module docked onto the machine for loading/unloading and safe handling of material, enabling quick change-over while minimizing the risk of contamination of powder materials. The build chamber through the glovebox in order to load or remove components. After the Direct Metal 3D Printer for Titanium, Stainless, Nickel Super Alloy end of the process, the build module is moved back into the machine and the 3D Systems, Booth N-68 and glovebox is undocked. Methods Machine Tools, Booth S-9119 module can be pulled out into the glovebox, which is then flooded with argon to inert the chamber for safe titanium processing. The operator accesses the build The machine is available in three different build Methods 3D, a subsidiary of Methods envelope versions: 50 × 50 mm, 70 × 70 mm and 90 Machine Tools Inc., showcases the × 90 mm, with an 80-mm-high build envelope. Ex- ProX DMP 320 as part of the compa- changeable drawers enable the use of different build ny’s growing line of direct metal 3D envelopes in the machine, and are printers from 3D Systems. The ma- removable for storing materials. chine is also featured in 3D Systems’ The 3D printer processes a range of materials, booth in the AM Pavilion. The machine is designed for including gold, silver alloys, high-precision, high-throughput direct bronze, cobalt-chromium metal printing, and is suitable for alloys and stainless steel. applications requiring complex, Other compatible materials chemically-pure titanium, stainless include titanium and titanium steel or nickel super alloy parts, alloys such as Rematitan CL including aerospace and medical from Dentaurum, CL41TI ELI components. The 3D printer can (Ti6Al4V) and pure titanium. handle production manufacturing, with concept-laser.de exchangeable manufacturing modules that support rapid material change or replenishment, enabling efficient Software Solutions for Design, Simulation, Additive Production powder recycling. The build volume Autodesk Inc., Booth E-3222 measures 10.82" × 10.82" × 16.53" (275 Autodesk provides a suite of modular manufacturing solutions, including CAM, × 275 × 420 mm). inspection, and additive manufacturing. The company’s Netfabb software is The printer comes in two config- designed to take additive manufacturing beyond prototyping and plastics to urations, one designed for titanium create production-grade parts at scale, while and one designed for stainless steel its Within software enables generative design and nickel super alloys. The machine optimization. These solutions create a “manu- also features centralized maintenance facturing ecosystem” intended to streamline the management, reduced argon gas design-for-manufacturing workflow, improving consumption and serial manufacturing process efficiency while reducing failure rates workflow support. and product development costs. 3dsystems.com / cam.autodesk.com methodsmachine.com additivemanufacturing.media 61 IMTS 2016 ON DISPLAY Hybrid Machine Combines Additive, Milling Large-Format Industrial 3D Printer Sodick Inc., Booth E-4802 3D Platform, Booth W-10 Sodick’s OPM250L, a hybrid machine that combines direct This issue’s cover photo shows metal laser sintering (DMLS) with high-speed milling into large IMTS letters being the same workspace, enables single-process production built on the 3DP of finished components. The One-Process Machine (OPM) Workbench printer is Sodick’s first foray into DMLS technology. It is primarily from 3D Platform, designed for use by moldmakers, with the ability to create a maker of large- conformal cooling channels within a finished mold. scale, industrial-class The OPM250L enables machining workpieces before 3D printers. The printer printing is complete, making it possible to alternate laser offers a build area of 1 × sintering and milling passes. In addition to its usefulness 1 × 0.5 m (39.3" × 39.3" in producing conformal cooling channels, this capability × 19.6"), and features mechatronics enabling layer resolu- also helps reduce the number of parts necessary to pro- tion down to 70 microns. The machine is equipped with the duce a mold. According to the company, unmanned and company’s SurePrint servomotors, along with SIMO-Se- remote machining are possible. ries linear actuators and Constant Force anti-backlash Sodick has developed Z-Asso, a dedicated CAM lead screws and nuts from PBC Linear. The control system system, for this integrated machine. Z-Asso is capa- provides for positional feedback every 1.25 microns for fast, ble of importing precise printing. CAD data, gen- Printing via fused filament fabrication (FFF) enables erating laser additive manufacturing of hard, rugged, functional polymer and machining components. The dual-extruder, all-metal print heads fea- data, optimizing ture high-volume nozzles, and extrusion temperatures can cutting along range to 295°C. The machine is compatible with 3- or 1.75- high-load areas, mm filament, printing with materials including PLA, PETG, and simulating NinjaFlex, ABS, Nylon and PVA. the process to The 3DP Workbench is mounted on a mobile work- accurately esti- station with caster wheels and built-in storage drawers mate production and cabinets. A folding gantry enables the machine to fit time. through a standard door. sodick.com 3dplatform.com Modular 3D Printing Engine Integrates with Metalworking Equipment Optomec Inc., Booth N-73 Optomec Inc. features production-grade additive manufacturing systems, including its hybrid CNC machine that combines the company’s laser-engineered net shaping (LENS) technology for 3D-printed metals with subtractive milling technology in a single machine tool. The company offers LENS technology as a modular print engine which can be integrated with other metalworking platforms such as CNC mills, lathes, robots, custom gantries or table system. This open-system approach enables users to deploy metal additive manufacturing technology to meet application-specific requirements. optomec.com 62 AUGUST 2016 Additive Manufacturing IMTS 2016 / On Display Metal Additive Manufacturing Machine for Industrial Production Renishaw Inc., Booth E-5509 Metal AM System Increases Build Speeds The Renishaw RenAM 500M additive manufacturing system builds metallic SLM Solutions NA Inc., Booth N-71 components using metal powder-bed fusion technology. The machine manufac- SLM Solutions NA features its tures parts within a 250 × 250 × 350 mm (9.84" × 9.84" × 13.77") build volume SLM 280HL metal additive manu- using a high-powered ytterbium fiber laser to fuse metallic powders together. facturing system, featuring a build In-line sieving enables powder to be recycled and re-used in a single process envelope measuring 280 × 280 × under an inert atmosphere, reducing user interaction and turnaround time. Metallic 350 mm. The machine features a powder is loaded into the machine hopper at the front of the system and sieved ul- bi-directional re-coater blade to trasonically. Any un-melted material is returned to the hopper and passes through fresh powder on the build plate in the ultrasonic sieve before being processed. Sieved powder is pneumatically both directions and reduce build transferred in a flow of high-purity argon gas into the powder delivery silo. times. Multiple laser configurations, A high-capacity twin SafeChange filter system enables builds to run for long including twin 400-W lasers or dual periods of time in a stable and controlled atmosphere. Filters capture process lasers of 400 and 1000 W, are also emissions, and the intelligent control system senses the filter’s condition and said to increase build speeds. redirects the gas circuit to a clean filter before conditions deteriorate. The machine is suitable for industrial The machine uses inert gas handling to minimize the risk of operator exposure to metal pow- production, specifically serialized pro- ders and promote material quality. duction. Each system is intended to be The company provides open system dedicated to a single material type for a architecture for materials and lights-out manufacturing environment. It parameters, enabling machines to is equipped with a 480-mm (19") durable operate in-house with standard or touchscreen, machine control software, individualized parameters. Individ- and a Windows operating system with a ual developments on the machine dedicated user interface and large icons can be transferred to other ma- to show the build setup workflow. chines, such as the larger SLM renishaw.com 500HL platform. slm-solutions.us Blast Cabinets Offer Alternative to Hand Sanding Clemco Industries Corp., Booth NC-564 Clemco Industries offers the Zero BNP Wet-blast series of blast cabinets for surface finishing, designed to be an alternative to hand sanding. The series is said to be popular among stereolithography (SLA) users for the quality and speed with which parts can be processed. Wet-blasting SLA parts removes build lines and improves surface appearance. Clemco provides manual and automated dry-blast cabinets for processing various types of metal parts. Depending on the substrate, cabinets are typically used with glass bead, aluminum oxide, steel grit or shot, and other recyclable media. clemcoindustries.com additivemanufacturing.media 63 IMTS 2016 ON DISPLAY Direct Metal Laser Sintering Services Offered Proto Labs Inc., Booth N-72 Proto Labs offers Direct Metal Laser Sintering (DMLS) as a service to its customers. The technology uses a laser system that welds atomized powder into a solid. After each layer, a blade adds a fresh layer of powder and repeats the process to form parts. The process produces full-strength, functional metal parts and is compatible with a variety of alloys, enabling prototypes made of the same material as production components. Building layer by Wireless Accessory Equips VMCs with 3D-Printing Capability layer makes it possible to create internal features and passages that could not be cast or machined. protolabs.com Hurco Companies Inc., Booth S-8319 Hurco offers its 3D Print Head, a spindle-powered wireless accessory Hybrid Combines Milling, Blown-Powder Laser Deposition for Hurco VMCs that extrudes plastic DMG MORI USA Inc., Booth S-8900 PLA filament for 3D printing directly DMG MORI’s hybrid additive manufacturing machine, the Lasertec 65 3D, uses on a CNC machine. The portable print a blown-powder deposition welding process in combination with a laser to melt head is powered and controlled by powder onto a base material. In contrast to a powder-bed process, this tech- spindle rotation and can be moved nique is said to reduce the necessary quantity of powder and build up material amongst Hurco machining centers. more quickly, while enabling subtrac- A new release of the company’s Win- tive machining in the same setup. Built Max software adds support for additive on the company’s DMU 65 MonoBlock manufacturing with the 3D Print Head. five-axis machining center, the hybrid The software enables users to devel- features an integrated, automatically op complex 3D shapes quickly and exchangeable 2.5-kW diode laser. The efficiently with conversational program- hybrid enables combined additive and ming. Users can select the WinMax 3D subtractive manufacturing in a single Print button to start the build process setup, and is suited for production of on the Hurco CNC machine once the components, repair work, and the part has been programmed. application of partial or full coatings. hurco.com dmgmori-usa.com 3D Printer Capable of Liquid Metal Printing Vader Systems LLC, Booth N-85 Vader Systems debuts its commercial liquid metal jet 3D printer, the Mk1 Experimental. According to the company, the Mk 1 will be the first machine worldwide capable of printing liquid metal. The machine uses the company’s MagnetoJet printing technology to convert solid metal wire to high-speed, precise molten metal droplets. According to Vader Systems, the technology produces fast, high-strength metal parts. The company is offering the machine to select early adopter manufacturers and labs. vadersystems.com 64 AUGUST 2016 Additive Manufacturing IMTS 2016 / On Display Metal Additive Technology Creates Large Parts DM3D Technology LLC, Booth N-66 TransFormAM by DM3D Technology is an additive manufacturing technique which combines existing metalforming technologies and the company’s Direct Metal Deposition (DMD) additive technology. The approach uses technologies such as casting, forging, extrusion and roll forming to fabricate a metal preform, and then adds metal features via DMD to transform it into a functional metal part. The technique is said to improve throughput and reduce cost; simplify the fabrication of large parts; provide better quality to the finished part; and reduce manufacturing risk. DM3D offers TransFormAM services as well as systems. dm3dtech.com Trumpf Inc., Booth N-6223 Metal 3D Printing, Manufacturing Services Offered The TruPrint 1000 metal 3D printer from Trumpf uses a laser and metallic pow- Linear AMS, Booth N-61 der to build components based on data supplied directly by a CAD program. Linear AMS provides metal 3D print- Laser metal fusion (LMF) systems create the component, layer by layer, from ing, CAD-based technologies and Metal 3D Printer Generates Parts Ranging to 100 × 100 mm metal powders with grain sizes as traditional manufacturing services to small as 20 microns. According to produce metal prototypes, pre- the company, this technology is ideal production, production parts, tooling/ for parts with complex geometry injection molds and conformal cooling such as those with internal channels inserts. Industries served include air- and hollow spaces, and for manu- craft; space and defense; oil and gas; facturing individual parts or short energy; industrial components; auto- production runs economically. motive; and medical and dental. Linear Powdered stainless steel, alumi- AMS also provides training, staffing, num or other weldable material is consulting, micro-factories and R&D held in a supply cylinder aligned with pods to apply additive manufacturing the construction chamber and over- in the supply chain through its Technol- flow receiver inside the enclosure. ogy Transfer Programs. During the build, a layer of metal linearmold.com powder is applied to a substrate plate and then a 200-W laser fuses the cross-section of the geometry to the plate. After the exposure, the plate is lowered and the next layer of powder is applied. This procedure is repeated until the part is finished. The entire process takes place inside the enclosure, blanketed by protective gas, and at an oxygen content of 0.1 percent. The metal 3D printer can generate parts ranging to 100 mm in diameter and 100 mm in height. The user interface with touchscreen control steps the operator through the individual phases of the process. All the components, including the laser, optics, process enclosure, filter unit and control cabinet, are integrated into the compact housing of the TruPrint 1000. Trumpf is displaying the TruPrint 1000 alongside its TruLaser Cell 3000 five-axis laser machine. us.trumpf.com additivemanufacturing.media 65 TECH REVIEW Commercial 3D Printer Creates High-Resolution Parts Carbon 3D’s first commercial 3D printer, the M1, leverages the company’s Continuous Liquid Interface Production (CLIP) technology to produce high-resolution parts. The 3D printer is Internet-connected and collects more than 1 million process control data points per day, the company says. This capacity makes it possible for Carbon to provide precise remote diagnostics, assist with print optimization and improve print quality over time. New features, performance enhancements and resins are always available to users, while the browser-based interface enables printer operation inside a network without software installs or compatibility issues. The machine is available through a subscription-based pricing model. As part of the M1 product unveil, Carbon is also introducing seven resins. According to the company, parts produced with these materials perform similarly to injection-molded alternatives, and are suitable for a range of applications. carbon3d.com 3D Printing System Enables Continuous Production Electron Beam Melting Systems Enhanced The HP Jet Fusion 3D printing system eration of its Arcam Q series electron beam melting (EBM) systems. With Qplus, consists of the Jet Fusion 3D 4200 the company is introducing Arcam xQam, an X-ray-based function for high- 3D printer, the HP Jet Fusion 3D Pro- precision auto-calibration and improved beam control. The systems are also cessing Station, and one or more HP equipped with the EBM Control 5.0, a software platform with more efficient and Jet Fusion 3D Build Units which move accurate beam control as well as new melt strategies. The machines are said to between the station and the printer. improve productivity as well as surface finish and precision. They are intended for The 3D printer offers a build volume measuring 406 × 305 × 406 mm Arcam AB has launched Arcam Q10plus and Arcam Q20plus, an enhanced gen- use in the medical implant and aerospace industries. arcam.com (16" × 12" × 16"). Build speed ranges to 4,500 cm3/hr. (215 in.3/hr.). Layer thickness can be 0.07 to 0.12 mm Selective Lamination 3D Printer Builds Layered Composite Parts (0.0021" to 0.005"), and print resolu- EnvisionTec has launched the SLCOM 1, an industrial composite 3D printer. tion is 1,200 dpi. Using a process called Selective Lamination Composite Object Manufacturing The HP Jet Fusion 3D Processing (SLCOM), the printer builds composite parts layer-by-layer from laminated Station automates material mixing, thermoplastic composite fabric sheets. The machine builds objects up to 24" × sieving and unloading. The station 30" × 24" and is suitable for aerospace, automotive and consumer applications. is stocked with one or more HP Jet According to the company, the SLCOM 1 can process a range of custom Fusion 3D Build Units, which are load- thermoplastic-reinforced unidirectional or multidirectional woven fibers. It ed with material and slotted into the accommodates composite matrix materials including woven glass fiber, woven printer. When printing is complete, the carbon fiber, and other woven aramid fibers reinforced with a choice of nylon 6, unit is returned to the station for pro- nylon 11, nylon 12, PEEK, PEKK, polycarbonate, and more. Composites can be cessing and a new unit can be slotted tailored for required toughness, environmental resistance, vibration damping, without stopping production. low flammability, wear resistance, and/or high strength-to-weight ratio. hp.com envisiontec.com 66 AUGUST 2016 Additive Manufacturing AD INDEX Advertising Index National International Advertiser Cincinnati (HQ) / Central 513-527-8800 Europe Edward Kania RGH International (UK) 44-1663-750242 [email protected] Page 3D Platform.............................................................................30, 31 Kent Luciano [email protected] Additive Manufacturing ......................................................Cover 2 Additive Manufacturing Conference polybag...........................29 AMT - The Association For Manufacturing Technology14, 19, 21 Bryce Ellis [email protected] Brian Wertheimer [email protected] Clemco Industries Corp. .............................................................. 13 Concept Laser........................................................................32, 33 DMG MORI USA, Inc......................................................................3 Detroit / Midwest Mike Vohland 513-338-2183 [email protected] EOS of North America Inc. ...................................................34, 35 ExOne Company.................................................................... 36, 37 Fabrisonic ...............................................................................38, 39 Gardner Business Media, Inc. .................................. Cover 2, 1, 29 Global Forecasting & Marketing Conference............................ 19 Hurco North America ............................................................ 40, 41 Hybrid Manufacturing Technologies ............................................5 IMTS 2016.................................................................................14, 21 Linear AMS.............................................................................42, 43 Methods Machine Tools, Inc................................................ 44, 45 Mitsui Seiki (USA) Inc. ..........................................................46, 47 PMTS 2017 ...........................................................................Cover 3 Renishaw Inc. .........................................................Cover 4, 48, 49 Chicago / Midwest Joe Campise 513-766-5862 [email protected] John Campos 513-766-5861 [email protected] Pittsburgh / East Coast Anthony Pavlik 917-838-8734 [email protected] Denmark John Nyberg Teknovation (Denmark) 45-4613-9000 [email protected] Taiwan May Hsiao J&M Media (Taiwan) 866-42296-5959 [email protected] China Lucy Xiao Vogel (Beijing – China) 86-10-63326090 [email protected] Japan/Korea Kent Luciano Gardner Business Media (USA) 513-527-8800 [email protected] Los Angeles / West Coast Steve Kosloff 513-766-5857 [email protected] Rick Brandt 513-766-5864 [email protected] Sintavia ............................................................................................4 SLM Solutions NA, Inc...........................................................50, 51 TRAM 2016...................................................................................... 7 Marketplace/classified ads Chris Brock 440-639-2311 / [email protected] Additive Manufacturing is published quarterly and copyright © 2016 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage pending at Cincinnati, OH and additional mailing offices. All rights reserved. POSTMASTER: Send address changes to Additive Manufacturing Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, send Form 3579. CANADA POST: Canada Returns to be sent to IMEX Global Solutions, P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement #40612608. The information presented in this edition of Additive Manufacturing is believed to be accurate. In applying recommendations, however, you should exercise care and normal precautions to prevent personal injury and damage to facilities or products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in editorial presentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct further inquiry into specific products or services. additivemanufacturing.media 67 CHECK THIS OUT By Christina Fuges SLM Achieves Weight Reduction for Robot Actuator The challenge with an integrated electronic actuator for a hydraulic quadruped robot was to meet the design requirements of an existing actuator while achieving a 50 percent weight reduction, compared to a traditionally manufactured actuator body. Selective laser melting (SLM) allowed the body seen above to be grown in titanium 6Al4V as one piece, reducing manufacturing operations and improving performance through design features such as curved flow tubes that eliminate right-angle drilling, all while realizing the weight reduction. Traditional manufacturing would have entailed combining cast and fabricated pieces through brazing and welding operations. This actuator is used on each leg of a quadruped robot developed at the Italian Institute of Technology in Genoa, initially for military applications. A similar actuator concept could also be used in applications such as aircraft, tractors and earth-moving equipment, and injection molding machines. The part was built by on a Renishaw AM250 SLM machine by Moog, at the company’s Additive Manufacturing Center in New York, which is now Linear AMS’s R&D arm for additive. Linear has made other similar AM parts, including robot shin and forearm components for Boston Dynamics (bought and later sold by Google). Moog became majority owner of the company now called Linear AMS through an acquisition late last year. Read about that purchase and Moog’s view of the future of AM at gbm.media/moog. 68 AUGUST 2016 Additive Manufacturing APRIL 25 –27, 2017 SAVE THE DATE! Greater Columbus Convention Center | Columbus, OH USA .C PM T S PRESENTED BY: CO-PRESENTED BY: OM CO-LOCATED WITH: design d i esign today… …build tomorrow Unlock the potential of additive manufacturing Renishaw’s laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD. production. It is also complementary to conventional machining technologies, and directly contributes to reduced lead times, tooling costs and material waste. From tooling inserts featuring conformal cooling, to lightweight structures for aerospace and high technology applications, laser melting gives designers more freedom, resulting in structures and shapes that would otherwise be constrained by conventional processes or the tooling requirements of volume n Shorten development time—be first to market n Reduce waste and cost—build only what you need n Increase design freedom—create complex structures and hidden features For more information visit www.renishaw.com/additive Renishaw Inc Hoffman Estates, IL www.renishaw.com