© 3T RPD Ltd 2015 – All Rights Reserved State of the Art and Future of Additive Manufacturing.

© 3T RPD Ltd 2015 – All Rights Reserved

State of the Art and Future of Additive Manufacturing


Contents

• Additive Manufacturing (AM)

• Its Applications

• Thinking AM

• State of the art

• What does the future hold?


AM and its Applications

What is AM?


3D Printing or Additive Manufacturing


3D Printing

•Rapid Prototyping

•Machines less than £5K

Additive Manufacturing

•Production components

•Machines more than £500K

Applications


MedicalAerospace

Motorsport

The Hype



Thinking AM

AM – the Key Points

• Design: completely different thought process

• Need to design for AM

• Focus on critical features: pathways/channels

• Reduced weight, scrap and cost

• Combine components

• Mounting holes and brackets built into the part.


AM – the Key Points

• Process:

• Not self supporting – may require supports

• Attached to platform and removed post-build

• May require post-processing to achieve finish

required


Additive vs. subtractive example


http://www.manufacturingthefuture.co.uk/design-guidelines/

PDF version also available – Please contact me

Final Part

• Mass reduced to <30% of original

• Smooth flowing pathways

• Higher performance


• Manufacture lead

time halved.


State of the Art

Materials

• Titanium: Ti6Al4V, TiCP

• Nickel: Inconel 718, Inconel 625

• Maraging steel: 1.2709/M300

• Stainless steel: 15-5PH & 316L

• Cobalt Chrome: UNS R31538

• Aluminium: AlSi10Mg & Aerospace Grade Alloys


Machines – EOS M280

• Key characteristics:

• Build volume 250 x 250 x 300mm

• 400W Yb fibre laser

• Spot size 100µm

• Layer thickness 20-80µm

• Wall thickness: 0.1mm

• Accuracy: ± 0.2mm or better

• Surface finish: As built 4-10µm Post finishing 0.04-0.5µm© 3T RPD Ltd 2015 – All Rights Reserved

Machines – Renishaw AM250


• Build volume: 250 x 250 x 300mm

• 400W Yb fibre laser

• Spot size 70µm




• Surface finish: As built 7-15µm Post finishing 0.04-0.5µm© 3T RPD Ltd 2015 – All Rights Reserved


The Future

The Future - Markets

• Aerospace:

• GE’s New Leap Engine will have 9 AM parts

• Over 1,000 individual components

• Parts already flying in US military aircraft and

in orbit in satellites

• Other components are in test for future missions


The Future - Markets

• F1: safety critical components already racing

• Further components and materials being tested

• Medical: optimised surface structures under

approval by FDA

• Outer surface of acetabular cups

• Selective areas of hips and shoulder implants


The Future - Materials

• New material suppliers coming on line

• New materials can be sourced in weeks

• 3T building in pure copper

• In talks with CERN

• Potential materials:

• Tungsten, Niobium, Molybdenum, Copper alloys© 3T RPD Ltd 2015 – All Rights Reserved


• Build volume 400 x 400 x 400mm

• 1kW Yb fibre laser

• Spot size 90µm




• Surface finish: As built 2-8µm Post finishing 0.04-0.5µm

• All in one system Production

Machines – EOS M400



• Build volume 350Ø x 400mm

• 3kW laser

• Spot size 180µm



• Accuracy: ± 0.1mm

• Surface finish: As built 20-30µm Post finishing 0.04-0.5µm

• All in one system Production

Machines – Arcam Q20


AM and FCC

• RF components• Complex novel WG• Multiple WG’s combined

• Tuners / Couplers / Antenna

• Spacers

• Oxygen free materials

• Mixed materials


Summary

• New opportunities:

• Holes & channels, lightweight optimised structures, multiple parts built as one.

• Parts already in use for real application:

• Safety, flight & mission critical

• Materials being developed and supply improved

• New machines allow for more materials

• Machines no longer a limitation



Confidence in the technology is growing fast – With this we will see the development of

new materials and machines

Daniel France

R&D Project Manager

+44 (0)7917524544

[email protected]

Questions

Daniel France

R&D Project Manager

+44 (0)7917524544

[email protected]

Questions

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© 3T RPD Ltd 2015 – All Rights Reserved State of the Art and Future of Additive Manufacturing.

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