Planning of the event

15h – 16h30 SIRRIS Introduction Thierry Dormal

Jtekt Jean-Louis Dam

Safran Aero Boosters Olivier Devriendt

Höganas Olof Andersson

SIRRIS AM trends Benjamin Denayer

16h30 – 18h00 Tour and discussion with experts (10 tables)

17h30 Drink

Soon… email with the link to upload the PDF files

1

T-ADD service portfolio7/06/2016

Thierry Dormal

Program Manager T-ADD

SIRRIS

3

1990 – 2015

Rapid PrototypingRapid Tooling

Additive Manufacturing3D Printing

Direct Manufacturing

4

Prototypes Direct Part Production

0

1000

2000

3000

4000

5000

6000

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Product and services revenues from AM

Direct part production

Direct Part Production

2010: 20 %

2015: 51 %

Compiled from Wohlers Associates data

M$

Evolution of AM

• From prototype to real part production

• From time reduction to higher product performance

• From plastic to high performance alloys

• From shapes to consistent qualified parts

• From 3D Printing to an integrated production process

6

1990

• One of the first stereolithography machine in EU (3DSystems)

1994

• One of the first FDM machine in EU (Stratasys)

• EU projects based on Rapid Tooling & SLA moulds

1996

• SLS : PA Sintering (EOS)

• DMLS: the first direct metal solution (with metal binder)

2000

• Technological breakthrough: Optoform and Prometal

2008

• LBM EBM and Laser cladding – Ti Alu Steel Inconel

• Bi-materials and composite technology (Connex 500)

• Bio-ceramic applications

2015 - 2020

• New strategy towards AM transfer & AM integration

SIRRIS T-ADD - A bit of history

Rapid Prototyping

Rapid Tooling

Rapid Manufacturing

Additive Manufacturing

Sirris | 25 years of Additive Manufacturing

Most complete installed base in

EU

MetalsPolymersCeramics

More than 10 additive

technologies in house

Team of 20 independent

experts

© sirris | www.sirris.be | info@sirris.be | 7

9.06.16© sirris | www.sirris.be | info@sirris.be | 8

1. Material extrusion: the material is selectively dispensed through a nozzle or orifice.

2. Material jetting: droplets of build material are selectively deposited.

3. Binder jetting: a liquid bonding agent is selectively deposited to join powder materials.

4. Sheet lamination: sheets of material are bonded to form an object.

5. Vat photopolymerization: a liquid photopolymer in a vat is selectively cured by light-activated polymerization.

6. Powder bed fusion: thermal energy selectively fuses regions of a powder bed.

7. Directed energy deposition: focused thermal energy is used to fuse materials by melting as the material is being deposited

4 selected processes in the ASTM/ISO list

ICT &

D

esig

n

tools

ProcessLeading-edge

Applications / Components

Materials Post-Process

© sirris | www.sirris.be | info@sirris.be | 9

Sirris T-ADD projects

ProcessLeading-edge

Applications / Components

MaterialsPost-

Process

Cert

ific

ati

on

Validati

on

Com

pany

sti

mula

tion

VIS – Design for AMFEDER – Iawatha Riatas

ICT &

D

esig

n

tools

ProcessLeading-edge

Applications / Components

ESA - AM Nano satellitesESA - AGHPESA - Siam

Materials Post-Process

Any-Shape 4.0

© sirris | www.sirris.be | info@sirris.be | 10

Sirris T-ADD projects

ProcessLeading-edge

Applications / Components

MaterialsPost-

Process

FEDER – TipTopLamFEDER – IawathaExiatas

ESA Scamp Cornet TCAM

Skywin Aero+Skywin FASAMASkywin 3SASkywin INHexSkywin FasOPTSkywin AMassy

GreenoMat - RecylcladMarshall ThermAM

EraNet - Ceracell

RW Collective - QUALAMFirst - OSAMInterReg PolyValves

CORNET Opp3DBiowin Bioptos

Cert

ific

ati

on

Validati

on

Com

pany

sti

mula

tion

GT AVATARVanguardInterReg NWE VITAMIN Cwality EasyAM (GeonX)

Antenne NormePrénormatif POWDERAM

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T-ADD 2015 - industrial activity

- 500 industrial projects

- 150 companies

- > 25 new companies / year discovering AM

- Growing demand in

- Performance (materials & processes)- AM Design of new products or services based on AM- Technology transfer for specific technology and materials- Qualification (technology, materials & products)- Post-processing (surface quality, accuracy,…)- AM integration (internal needs or service providers)

AM transfer • Scan opportunities• Cases 1on1• Educate• Qualification

AM integration

• Chain automation• Chain

demonstration• Chain integration

Efforts

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2015 2016 2017 2018 2019 2020

AM Integration AM Transfert AM Demo

AM demo

• Sensibilization• Demonstration• Benchmarking

TRL 7-9

TRL 6-9

TRL 4-9

Sirris ADD : Effort evolution 2015 - 2020

TRL 4-8Digipreneurship

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• AM oriented design based on specific AM rules

• Prototypes for development and then real direct AM production

• No way to go back to conventional way of working for series production

• Lattice Structures, topology optimization and components reduction

• After 3 years: 80 % components of the helicopter are produced by AM

Flying Cam

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Test bench for anti-ice system

• Trials and validation of the anti-ice process in flight condition

• 46 parts & 112 sensors

AM benefits:

• Hollow components with

cables and sensors

• Flexible & functional

• Much faster to build

• No 2D drawings required

Safran Aero Boosters

9.06.16 15© sirris | www.sirris.be | info@sirris.be |

Safran Aero Boosters

Challenge

• Positioning in additive manufacturing

Sirris contribution

• Support for technology selection

• Technology transfer (process, powder handling)

• Understanding of pros & cons of metal AM

• Case studies with real parts

Business impact

• AM Integration in the company with a long term

development plan

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Smart drilling machine for

aerospace applications

•Technical reasons to use AM

Mechanical properties of Titanium

Designed for weight optimization

Integration of functions

Vibration reduction

• New company (integrated in BMT Aerospace)

created for one single product.

AMT Titastar

Intervertebral cages with bioceramic material

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• Material formulation : HA/TCP (Bone substitute)

• Process development: paste polymerization

• 0.1mm tolerance / Fully controlled porosity

• ISO13485 compliance

• >10.000 parts / year in 2012 2013 2014

• New company created by Kasios in Gilly for production + Cerhum

Intervertebral bone replacement (HA/TCP)

Kasios

18Date : 14-07-

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Validation of LBM with Titanium material for space parts

• Feasibility – Aerospace Qualification – Traceability

• Integration in the building process

• Set up of a certification methodology

• Topology Optimization

• 5 axis Post milling on AM parts for surface quality

and high local accuracy 153 x 144 x 50mm

Vol = 56cm³

Propriété

Thalès Alenia Space

Fabrication: Sirris

Propriété

Thalès Alenia Space

Fabrication: Sirris

Thales Alenia Space

Sirris 2016 – Service offering

Explore the potential of AM- Feasibility study, benchmarking,

- New applications and opportunities, new business models,…

Design for AM- Design rules for each AM technology,

- Weight reduction, process simulation,

- Topology optimization, lattice structures, channels,…

Optimize, implement & transfer AM Technologies for production- Enhance the use of AM technologies, materials, powder handling, post processing

- Enhance process reliability and repeatability with certification procedures

- AM integration and automation of the full chain

Reduction of repetitive projects with low added value >> transfer to Service Providers, creation of new start-up

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20Thierry Dormal Program Manager T-ADD

Thank you That’s it for now…

Any questions ?

Planning of the event

15h – 16h30

SIRRIS Introduction Thierry Dormal

Jtekt Jean-Louis Dam Managing Director Jtekt Torsen Europe

Safran Aero Boosters Olivier Devriendt Projects & Incubation, Dept Innovation

Höganas Olof Andersson Manager Biz Dev High Alloy powders

SIRRIS AM trends Benjamin Denayer Senior Biz Developer

16h30 – 18h00

Tour and discussion (10 tables)

17h30

Drink

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