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SLM Solutions is leading the Evolution of Metal Based
Selective Laser Melting (SLM) Manufacturing
from Prototyping to Production
김인명 / ㈜퓨전테크놀로지(FusionTechnology Co., Ltd) Tel : 031-342-6901, www.fusiontech.co.kr
위상촤적화와 Metal 3D Printing(AM) 제조기술의 융합과 효율적 활용
Understanding of 3D Printing Technology
피라미드의 건축 (적층조형방식의 시작 ; 3D프린팅의 시초??)
3D 프린팅기술??
Additive manufacturing : layer by layer ( by quad lasers )
Additive manufacturing : layer by layer
Basic understanding of Topology Optimization
4
Lessweight shape &
Lightweight structures are
inspired by nature:
1. Minimize the weight while
maintaining the stiffness
2. Create a better bone ingrowth
for medical purposes
This forms the basis for Altair’s topology (& morphology) optimization technology
Company Intro. SLM Solutions & FusionTechnology
Lübeck, Deutschland, 53° 52´ N, 10° 42´ O, MEZ
Germany´s city of science in 2012 !
Welcome to North Europe!! SLM Solutions Group AG
1996 – 1998 Basic Research F&S Stereolithography GmbH, Trumpf GmbH and Fraunhofer Institute for Laser Technology (ILT)
1998 – 2002 Fockele & Schwarze (F&S) research leading to IP with today more than 30 own patents and applications
2002 F&S/SLM Solutions(a) partner to develop, produce and market the SLM Technology to industrial requirements
2003 Launch of first Fibre Laser technology with the MCP SLM 250
2006 Launch of SLM 100 as an entry model
2007 Launch of the 400 Watt technology
2009 Launch of the new SLM 250HL
World Wide cross license agreement with Trumpf, EOS and Fraunhofer ILT
2011 Launch of SLM 125HL and SLM 280HL with hull and core (400W & 1000W) technology and 3D laser technology
2012 Introduction of SLM 500HL and the multi laser technology
2013 ~
Launch of SLM 500HL with additional automated powder handling devices, Quad Laser Technology for high productivity applications High Powered (multi) laser(s) for AM performance, Enhancing monitoring systems for secured AM production. -. 700W and high temperature heated patform (550℃), Small Volume Reduction Platform supplied
(a) In 2002 SLM Solutions Group was known as MCP. MCP changed its name to MTT Technologies Group in 2008. MTT Technologies GmbH, Lübeck was renamed into SLM Solutions GmbH in 2010
Source: Company information
SLM Solutions Group – History of Innovations
Powder bed fusion Thermal energy selectively fuses
regions of a powder bed Key technologies:
Selective Laser Melting, EBM
Prototyping, direct part
Metals, polymers
Directed energy deposition Focused thermal energy is used
to fuse materials by melting as the material is deposited
Direct part, repair
Metals
Sheet lamination Sheets of material are bonded
to form an object
Prototyping, direct part
Metals, paper
Binder jetting Liquid bonding agent is selectively
deposited to join powder material
Prototyping, direct part, casting molds
Metals, polymers, foundry sand
Material jetting Droplets of build material are selectively deposited
Prototyping, casting patterns
Polymers, waxes
Material extrusion Material is selectively dispensed
through a nozzle or orifice Prototyping Polymers
Vat photopolymerization Liquid photopolymer in a vat is
selectively cured by light-activated polymerization
Prototyping Photopolymers
(a) Powder bed fusion technology accounting for 77 % of metal based 3D systems sold as per CODEX Partners analysis Source: ASTM International Committee F42 on Additive Manufacturing Technologies; Roland Berger, CODEX Partners
Me
tal t
ech
no
logi
es
Technology Materials Typical markets Relevance for metal
Powder bed fusion technology is most relevant for metal 3D printing
Others
77 %(a)
18
Finish part with support structure welded on the
substrate plate
Powder Bed Fusion : SLM process
Powder bed fusion technology is most relevant for metal 3D printing
Laser Power: L
Scan Velocity: v
Hatch Distance: Δy
Layer Thickness: Δz
𝑬𝒏𝒆𝒓𝒈𝒚 𝑫𝒆𝒏𝒔𝒊𝒕𝒚 𝑬 = 𝑳/(𝒗 × Δ𝒚 × Δ𝒛)
Picture Source: FhG ILT Aachen
𝒗
Δ𝑦
Δ𝑧
Only need 4 parameters for optimal process!!
Impact on: • surface quality, mech properties, cost per part, detail
resolution, weight, density, build time, hardness, fatigue strength, thermal conductivity....
Key Parameters of the SLM Process
May 09. 2014 : IPO /stock market launch for SLM Solutions Group AG.
Strategic focus on metal based 3D printing, Selective Laser Melting (SLM)
SLM Solutions stands for technologically advanced, innovative and highly
efficient integrated system solutions with focus on part quality & function
SLM Solutions Group is already operating in all key industries
Multi-laser systems 60% of orders
267 installed SLM machines word wide until June 30, 2016
40% orders from existing customer base
70 % orders in the last 12 months for industrial application !
66
102
146
265
62 33
2014 2015
Sales (€) Machine Orders Employees
Machine Orders / Sales & Employees
SLM Solutions: leading provider of metal based of SLM - Selective Laser Melting “3D printing” machines
SLM Solutions Group has exposure to attractive end markets and has longstanding
relationships with blue chip customers
The market continues the shift from rapid prototyping to industrial applications
SLM Solutions Group is well positioned to capitalise on this trend given SLM Solutions'
technology and customer base
SLM Solutions Group is already operating in key industries
Selected blue chip customers
Aerospace Automotive
Healthcare Energy
GE Energy, Emerson, Alstom, Siemens P&W
and etc.
GE Aviation, Airbus, Boeing, Sintavia, Lufthansa
Teknik, Honeywell Aerospace, Safran, NASA
and etc.
BMW, Audi, VW, Toyota, Ford, Mercedes,
Bridgestone and etc.
BEGO, 3D Medical and etc.
More than 70 universities and research institutes
(e.g. RMIT (AUS), GIAT, NRIAM (CN) NTU,
NUS (SGP), Kinki University (J))
Citim, Fruth, Linear Mold, Polyshape, Innoshape
and etc.
KNU, KNUT, GJTP, Ulsan KITECH in Korea
and more worldwide,
Aviation
SLM Solutions Group is already operating in key industries
Headquarters
SLM Solutions – Subsidiary
Distribution partners
Lübeck, Germany
Moscow
Detroit
Shanghai
Singapore
Location and global sales, application and service footprint
Metal 3D Printing Technology : 3D printed car
Metal 3D Printing Technology : 3D printed car
Back to the core: What 3D printing is!!
Source : solidThinking/Inspire from Altair Technology Korea
Back to the core: What Additive Manufacturing is!!
Source : solidThinking/Inspire from Altair Technology Korea
Topology Optimization??
What Topology Optimization is!!
• 주어진 공간내 제품에 주어질 하중등을 고려한 디자인 문제에 대해, 재료 분포를 최적화 하는 수학적인 기법/알고리즘
Source : solidThinking/Inspire from Altair Technology Korea
Work Flow: Topology Optimization
스케치 또는 도면을 불러들이기
디자인 영역을 단순화 연결되는 부분을 설정 (Fasteners, Joints,
Contacts)
물성과 하중 적용
이상적인 최적화 형상 확인 성능 평가 부드러운 형상 생성 지오메트리를 추출하여 CAD에서 개선
Source : solidThinking/Inspire from Altair Technology Korea
from Topology Optimization -> LWS -> metal 3D printing
Design Space FEA TO Cleanup CAD or 3-matic
“Printable” design Topology Optimized Design (rough)
Simulation based redesign combined with in-house experience about AM process (printability)
Traditional CAE Design
Define build orientation
LWS region
Application and cellular sizing
Final stress evaluation
Finished ‘TOPAM’ design Source : Materialise 3-matic LWS
Manufacturing from SLM Solutions’
Metal 3D Printer
For successful applications of SLM metal 3D printing technology: from DfAM(Design for Additive Manufacturing) & SLM 3D printing
Part Integration Design
Topology Optimization Design
Lattice Structure Design
Topology Optimization: Idea of maximizing AM performance!!
디자인 문제를 해결할 수 있습니다. 고성능, 경량화, 보강, 재료 및 비용 절감 다양한 산업분야의 어떠한 제품도 형상을 바꾸고 부품수를 줄일 수 있습니다.
Source : solidThinking/Inspire from Altair Technology Korea
free from manufacturing limitation, needs to catch up by design innovation!!!
Manufacturing technology w.r.t Design technology.
Time
Com
ple
xity
Eff
icie
ncy
Design
Manufacture
BC Medieval Industrial revolution
1900’s 1950’s 2000’s 최근
?
Source : solidThinking/Inspire from Altair Technology Korea
Creative Higher Performance: 3D프린팅 & 위상최적화(solidThinking/Inspire)
이상적인 콜라보레이션 : TO for DfAM & AM 4 higher performance
Source : solidThinking/Inspire from Altair Technology Korea
AM Topology Optimization
자유로운 형상
특성있는 디자인
제품개발의 가속화
+
혁신적 (설계/제조) 기술
Topology Optimization Applications for Additive manufacturing
World air traffic over 24 hours!!
Aerospace projects 10.000,‒ € per Kg
Automobile industry 10,‒ € per Kg
Aircraft design 1.000,‒ € per Kg
The amount of money industries are willing to pay to safe 1 Kg
Challenge of weight reduction potential…
1) Quelle: GE Aviation
Weight
No. Of components
Durability
-25%
-95% 5x
18 components integrated as 1
Industrial revolution: Complexity through SLM Technology
Airbus Defence & Space : Multi-bracket mounting for telemetry & telecommand antennas for Eurostar 3000 satellite.
4 main parts & 44 rivets > 1 single piece, 40% stiffer & 35% lighter; aluminum alloy
SLM 3D printing technology & Optimized design – smart structure
Application
Aircraft: Airbus A380
Upper Deck Cabin Bracket
Connecting Crew Rest with Stringers
Lot Size: 1 part per aircraft
Conventional Design Bionic Design
Source: Airbus
Machined from Solid Block
Buy-To-Fly Ratio: 13 (17kg/1,3kg)
High Set-Up & Span Times
7000 Al Alloy
Source: Laser Zentrum Nord
50% Weight Reduction
Improved Buy-To-Fly Ratio: ~1-2
Build Time for 2 Parts: 41:23h
AlSi10Mg
SLM 3D printing technology & Optimized design: Aircraft applications – Bionic Cabin Bracket
1.2 kg 0.6 kg
1 kg = $3,000 fuel savings/year CO² emission reduced
SLM 3D printing technology & Optimized design: Aircraft applications – Bionic Cabin Bracket
Unlock the lightweight
potential of AM with
concept optimization
and
organic interpretation
at LZN
SLM 3D printing technology & Optimized design – smart structure
43% Mass Reduction
Topology Optimization Applications
Topology Optimization Applications
55% Mass Reduction
45% Lighter than Original
Topology Optimization Applications
Topology optimized structures are pretty good,
and lattice structures are able to make better:
Topology Optimization Applications (Morphology)
Walking Running
Topology & Morphology Optimization Applications
Creative Higher Performance: 3D프린팅 & more 위상최적화(solidThinking/more…)
이상적인 콜라보레이션 : D4E & next AM 4 better pleasure
from innovative designing
Source : solidThinking/Inspire & Click2 series from Altair Technology Korea
AM Design4Emotion
자유로운 형상
특성있는 디자인
제품개발의 가속화
+
혁신적 (설계/제조) 기술
Creative Higher Performance: 3D프린팅 & more 위상최적화(solidThinking/more…)
이상적인 콜라보레이션 : D4E & Process 4 AM 4 better pleasure
from innovative designing
Source : solidThinking/Inspire & Click2 series from Altair Technology Korea
AM Design4Emotion
자유로운 형상
특성있는 디자인
제품개발의 가속화
+
혁신적 (설계/제조) 기술
주소 : 경기도 안양시 동안구 시민대로 361 에이스평촌타워 1동 406호
TEL : 031-342-6901 FAX : 031-342-8264
Email : [email protected], www.fusiontech.co.kr (available from June 2017)
• Building up as solution provider of 3D printing technology for industry & medical
• 2016년 사무실이전(경기도 안양), “㈜퓨전테크놀로지”로 법인명 변경
• 2015년 “㈜퓨전테크”로 법인 전환
• 2008년 “퓨전테크” 설립 • 산업계 및 의료 및 의공학분야의 S/W & 3D Printer 솔루션 공급지원 업체
• Since 1991 3D프린팅장비 공급 및 활용지원
• SLM Solutions Group AG 3D프린터(SLM) 국내 공식 대리점
• Farsoon 3D프린터(SLS) 국내 공식 대리점
• Qubea 3D프린터(SLA) 국내 공식대리점
• RAISE3D 3D프린터(FDM) 국내 공식 대리점
• Materialise NV Mimics/3-matic S/W 국내 공식 대리점
• 한국알테어 국내 공식 대리점
• 기타 3D Printer 장비 외 관계 소프트웨어 Biz.
감사합니다!!! (주)퓨전테크놀로지
Superior Productivity of SLM Technology
Additive manufacturing : layer by layer ( by quad lasers )
Additive manufacturing : layer by layer
Additive manufacturing : bigger ( by SLM500 & SLM800 )
SLM Metal 3D Printers :: Better, Faster, Bigger, Automized,….
Superior factors of increasing productivity from SLM-machines
30 mm overlap
Laser #1
Laser #2
From Build chamber & Recoating process design ; Recoating over only build chamber (no powder feed cylinder)
From Recoating system ; Bi-directional recoating Dynamic powder recoating control Quick stroke recoating movement From Scanning Strategy ;
Scanning of overlapping zone by multi-lasers (SLM280 & SLM500)
From LASER ; Multi-lasers .up to 2x lasers @ SLM280 .hull & core lasers @ SLM280 .up to 4x lasers @ SLM500 Higher power lasers .400W / 700W / 1000W
Thanks to SLM metal 3D printing technologies!!!
100%
Monolaser 400W
(a) Productivity accounted without powder deposition time
(b) Productivity depending on number of layers melted with 1000W laser (More suitable 세 build bigger section area part (Thicker part)
Source: Company information
Up to 200%
2x 400W 2 Scanner SLM 280HL
Up to 400%
4x 400W 4 Scanner SLM 500HL
1x 400W 1x 1000W 1 Scanner SLM 280HL
~150 – 300%(b)
2x 400W 2x 1000W 2 Scanner SLM 500HL
~300 – 600%(b)
Build rate(a)
Hull-Core Technology
Multiple laser
SLM Solutions Productivity: Innovations & advantages using multi-lasers technology
7000 m² production floor. Currently, world wide the biggest capacity for metal AM production!
FIT AG : Germany – 14x SLM500 for series mass production
Healthier & Better Safety of SLM Technology
Features
Explosion Protection Zone 21: occasional dust cloud; Zone 22: dust cloud not likely
Health & Safety: Explosion Protection
Features
• Dust free re-filling and sieving
• Safe powder handling
• Closed loop powder handling
Health & Safety: closed loop powder handling
Production Quality Monitoring & Controlling of SLM Technology
360° Quality
Management
Build Process
Operation
Material
Machine
Factory Acceptance Test Site Acceptance Test Preventive
Maintenance & Calibration
Powder Handling Concept Operator Qualification Working Instructions Facility Conditions
Certified Powder Quality Original Spare Parts High Quality Consumables
Process Intervention Control Build Job Documentation
LCS – Layer Control System LPM – Laser Power Monitoring MPM – Melt Pool Monitoring
SLM Solutions QM & QC: SLM 360° Quality Management Approach
Quality Control System
LCS Sensors
MCS monitoring and logging
Documentation
• The QCS includes 6 modules (caustic measurement and dynamic powder control not shown here)
• The modules are already in place, are being tested or in development. (√ : standard, √ : option)
• Display and processing is divided into internal monitoring and logging.
Status
√ √
Laser power
√
Melt pool
√
SLM Solutions: Quality Control System QCS module overview
Quality Control System: Dynamic Powder Recoating Control
5 cm3
5 0 10 20 15
• Reducing powder overdose
• Saving the powder amount to be exposed at atmosphere (minimizing oxydized)
• Cost reduction
• Conserve Mechanical Properties better
Features
More Flexibility of SLM Technology
Features
• Dia. 90 x 100 mm
• 550°C heated platform
• TiAl6V4 baseplate x 19mm thick
• Ceramic recoater
• High temperature material
processing
Flexibility: High Temperature Platform @SLM280
Flexibility: Smaller Chamber Size with same build size
no powder feed cylinders at left/right for recoating only build cylinder existing shorter preparation time to start building less inert gas consumption less possibility to leak to oxygen possible to equip gloves at the front door of the chamber to minimize operator’s direct contact to metal powder minimize the exposure of the recycling powders to atmosphere to avoid oxidization
Smaller build processing chamber size Features
• Open software for full control of
all process parameters
• Optimise scanning and exposure
parameters
• Protection of in-house know-how
Flexibility: SLM Build Processor Software
Benefits of SLM Metal 3D Printer
• Higher production performance (생산효율화) • from multi-lasers with bigger power • bigger building volume • bi-directional recoating ( maximize to save building time ) • efficient powder feeding system by controlling optimized dose of powder and more
• Automation of 3D printing process (자동화) • from powder supply and removal to support cleaning up • feasible to apply for serial production and more
• Security of product quality and healthcare (안정화) • supplying best ambient with good quality of inert gas in laminated flow • many (monitoring &) controlling system provided ( layer, laser, melting pool,…) and
more
• Others (다양화 & 유연화 등) • selectable production options ( build time / material consumption / saving laboring,…) • more flexible with HTH(High Temp. Heating) / SBVR(Small Build Volume Reduction),… • Possible to control build parameter for each individual part on the same layer & more
March 12th 2015
Business Development – Automotive/ Medical/ Aerospace
Source: web
March 12th 2015
Business Development – Automotive/ Medical/ Aerospace
Source: web
March 12th 2015
Business Development – Automotive/ Medical/ Aerospace
Source: web
주소 : 경기도 안양시 동안구 시민대로 361 에이스평촌타워 1동 406호
TEL : 031-342-6901 FAX : 031-342-8264
Email : [email protected], www.fusiontech.co.kr (available from June 2017)
• Building up as solution provider of 3D printing technology for industry & medical
• 2016년 사무실이전(경기도 안양), “㈜퓨전테크놀로지”로 법인명 변경
• 2015년 “㈜퓨전테크”로 법인 전환
• 2008년 “퓨전테크” 설립
• 산업계 및 의료 및 의공학분야의 S/W & 3D Printer 솔루션 공급지원 업체
• Since 1991 3D프린팅장비 공급 및 활용지원
• SLM Solutions Group AG 3D프린터(SLM) 국내 공식 대리점
• Farsoon 3D프린터(SLS) 국내 공식 대리점
• HP 3D프린터 국내 공식 대리점
• Qubea 3D프린터(SLA) 국내 공식대리점
• RAISE3D 3D프린터(FDM) 국내 공식 대리점
• Materialise NV Mimics/3-matic S/W 국내 공식 대리점
• 한국알테어 국내 공식 대리점
• 기타 3D Printer 장비 외 관계 소프트웨어 Biz.
감사합니다!!! (주)퓨전테크놀로지