Tips for Additive Manufacturing in Metal

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Q&A at the end of the presentation

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Before We Start

Moderator

Leslie Langnau Design World

Presenter

Tom Pasterik ExOne

About ExOne

• ExOne is a leading additive manufacturing

company dedicated to the industrial manufacturing

sector.

• ExOne is a global supplier of industrial 3D printing

systems and offers design and manufacturing

services of 3D printed products.

• ExOne Production Service Centers are located

throughout the United States, Germany and Japan.

• ExOne systems are able to print in a variety of

industrial materials with the largest available build

sizes.

ExOne Global Facility Locations

Products Produced

ExOne Overview

Distinctive Technology Features

• Largest build envelopes available

• Finely detailed complex shapes

• Print Speed

• Final Product Accuracy

• Industrial Grade Materials

Direct Metal Process - ExOne offers digital part materialization in several metals and metal

alloys, including:

- Additional material systems are currently in development, and

partnership opportunities are available for specific materials.

- The 3D printing process in metal includes printing, curing, depowdering,

sintering, infiltrating and annealing.

- Build Volume (WxDxH): 780 x 400 x 400 mm (30.7 x 15.75 x 15.75 in.)

- Build Speed: 6 mm/hr (.24 in/hr)

• 316 Stainless Steel Infiltrated with Bronze

• 420 Stainless Steel Infiltrated with Bronze

• Iron Infiltrated with Bronze

• Bonded Tungsten

In Direct Metal - Sand Process - ExOne offers digital part materialization in various

combinations of sand casting media and chemical binders,

depending on the desired strength and level of detail:

- Digital production of sand molds and cores eliminates the

need for hard tooling and drastically reduces lead times.

- Standard foundry industry materials are used, enabling easy

integration of the molds and cores into existing manufacturing

and foundry procedures.

- This digital process offers design freedoms not possible in

molds and cores produced using the traditional pattern

approach.

- Build Volume (WxDxH): 1800 x 1000 x 700 mm (70 x 39 x 27 in.)

• Silica Sand

• Synthetic Sand

• Other casting media

ExOne Systems

M-Lab M-Flex M-Print

S-Print

S-Max

ExOne’s Process

ExOne’s Process

ExOne’s Process

Optimizing for Manufacturing

• With simple changes such as automated transfers and print run

layout, an additive manufacturing production process can be

optimized to maximize output.

ExOne in a Factory Environment

Advantages of Additive Manufacturing

• The digital process offers design freedoms not possible in

traditional molds, cores and machining approaches

• Endless patterns and part geometry

• Functional working prototypes for real life applications

• Prototyping can turn directly into low or high volume

production runs

• Draft angles can now be eliminated

• No tool paths or tooling required

• Advanced venting schemes and integrated rigging

features are also possible

• Different parts can be built in a single print bed

• Parts can be modified on the CAD file in seconds, and

reprinted without complicated tooling changes.

Project Overview

• Advance optimization of a traditionally manufactured control arm from a domestic super car by using additive

manufacturing processes.

• Push the boundaries of 3D metal printing and design inside a real and applied production workflow with

practical outcomes.

• Examine existing and heavily optimized designs made using traditional methods and see if they can be

optimized even further using new modeling approaches.

• Develop new workflows and processes that can directly capitalize on the many benefits that 3DP offers.

• Reduce weight while still retaining the same structural properties of the what is said to be “already optimized”

traditional control arm.

The Idea

Take existing production part and provide further

optimization and modeling in pre-constrained

areas of the part for three different 3DP

workflows:

• Printed sand mold package for traditional

foundry casting

• Conservative/constrained direct metal

printing

• Unlimited direct metal printing

The Idea

Take existing production part and provide further

optimization and modeling in pre-constrained

areas of the part for three different 3DP

workflows:

• Printed sand mold package for traditional

foundry casting

• Conservative/constrained direct metal

printing

• Unlimited direct metal printing

Unlimited Variable Geometry

Finding the Best Internal Structures

Initial Reference for Cellular Structure

Base Model Control Arm

Indirect Metal Printing Process and Cast

Advanced Control Arm Is Modeled with Free Constraints

Advanced Model Passes Simulation: Export

Direct Metal Printing Process

Direct Metal Printing – Final Product

Direct Fabrication

Project Specifications

Next Steps – Advanced Designs w/ Automatic Closed Loop Simulation Feedback

Services

Questions?

Design World Leslie Langnau llangnau@wtwhmedia.com Phone: 440.234.4531 Twitter: @DW_3DPrinting

ExOne Tom Pasterik tom.pasterik@exone.com Phone: 724.765.1361 www.exone.com

Thank You

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