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Bionics Designs – Disruptive Technology in Aerospace

March 2017 I © Bionic Production GmbH

Klaus Mueller CCO

Seite 2 March 2017 I © Bionic Production GmbH

Evaluate

Enab

le

Bionic Smart Factory

Skills & Education Products & Resources

Bionic Consulting

Change Technology

Material & Equipment Development & Quality

Bionic Systems

Operations

Parts & Cost Time & Delivery

Bionic Manufacturing

Improve Optimize

Rea

lize


Customer

Follows a clear Market Strategy

Operations Technology

Bionic Smart Factory

Material & Equipment Development & Quality

Parts & Cost Time & Delivery

Skills & Education Products & Resources

Bionic Manufacturing

Bionic Systems

Bionic Consulting

Change


Bionics in Aerospace – a definition ! 1

New enabling technologies and their readiness 2

Future designs Aerospace Industry 3


bi·on·ics (bī-ŏn′ĭks)

The use of a

system or design found in nature,

such as the ability of plants to store solar energy, as a

model for designing artificial systems,

such as machines.

Source: The American Heritage® Dictionary of Student Science, Second Edition. Copyright © 2014


Introduction of Bionics – „uncountable number of proven concepts“ – learn from nature

Image source: sciencefoto.de, Nachtigall, Hill, Matheck, bambus.de

more informal: „Humans copy from nature“


OK

Done !

CHALLENGE Improve both margin and cash flow at a mature Boeing supplier.

SOLUTION Applied lean factory physics and developed a shop simulation model for hundreds of parts processed from raw material to finished sub-assemblies and kits.

RESULTS Margins improved by 20% and inventory turns by 27% in less than 6 months.

„Humans copy from nature“


Bionic Production is more than 3D-Printing Paradigm Shift to Integrated Operation

Bionic Design inspired by nature!

Image sources: sciencefoto.de, Nachtigall, Hill, Matheck, bambus.de

•  Additive Manufacturing enables to use Bionic Designs •  Use new Production Technology for industrial Solutions •  Reduce cost, time and improve quality of parts, processes and supply

chains

Integrated Bionic Production

•  Analytical Processes to Optimize Topology •  Ressource efficient products and manufacturing •  Individual and decentral customer part delivery on

demand with reduced stock

Manufacturing by growing parts


State-of-the-art applications of 3D-Printing in industry

Bird bone structure

iLAS TUHH

Bionic Design Lattice Structures

Airbus Innovation Cell & LZN

Implantcast & LZN


Adidas rewards medal winners with

3D printed shoe

Adidas offers 3D printed shoes

Adidas This ‘3D-printed Winners Shoe’ goes one step further with a 3D printed midsole that doesn’t just give it a USP. It also meant that Adidas could avoid a certain amount of stitching and glueing in the shoe, which all adds weight and detracts from the natural balance




3DAM - enabling technology and their readiness 2

Future designs in Aerospace ? 3


Medical & Dental - Healthcare

Today: §  Medical AM industry is most mature market. Main driver

is the customisation of products§  More than 150.000 hip implants were manufactured

using SLM & EBM technology. Around 50% already implanted (Full FDA approval)

§  >12.000 crowns and copings for dental usage are produced daily by SLM

§  Customised medical instruments for surgeons

Expected market development: §  5 % annual market growth till 2026

The application of metal Powder Bed Technologies in the Medical industry is mature. Annual growth rates

will stay about 5 % for the next 5 to 10 years.

Challenges: §  High demands for certification of medical

products§  Cost reduction


Large numbers of implants

-

Already in Use

Implants Examples



EDAC

Cars are printed !

Example: Divergent3D

More than 48 car designs already

printed and tested

Local Motors: 68 days



Example: Potential of laser additive manufacturing for design

Weight reduction of 80% Reduction of pressure losses of 50% Additional functionalities: sensors, cooling, …


Complexity reduction due to integrated 3DAM-design

Conventional Design Integrated AM-Design

§  reduction of individual parts from 14 to 1 §  reduction of processing steps from 18 to 5 §  reduction of manufacturing costs by 50%


THOR Project – an Aircraft flying in 6 Weeks !

•  1st Flight: Nov 2015 •  Testflights: planned 18 •  # of Parts: 60 •  Printed at LZN •  Wing: 3.5m •  Lenght: 3.7m •  Weight: 25kg •  Engines: 2 1.5kW

•  Listprice J: 20 T€


3DAM develops fast in Aerospace....

§  1st Certification Processes §  Roadmaps at GE, PW, RR, AI, BOE,

PAG, MTU... §  A new Supply Chain develops §  Automation and industrialization in

progress

§  Strong growing Built rates §  Larger Building Chambers §  NEW: Process Monitoring Systems §  New available materials (Polymers

and Metals) §  Quality Assurance Systems

$0.7b $0.6b (75%)


Challenges of Bionic Designs

§  Integrated Software Solutions §  Weak Support of Industry Standards §  Limited number of calculation models §  Lack of catalog solutions for developments §  Experience with certification processes §  3DAM still with „expensive“ Image

§  Future Challenge: Connectivity and Integration in Automation / Industry 4.0 activities

2018

Est. 2017

2019

2020


Future 3DAM Factories – Insourcing – New Supply Chain

Source: ConceptLaser



3DAM - enabling technology and their readiness 2

Future designs in Aerospace ? 3


Strong DEMAND in Aerospace - Market at TRL 8-9

→  All large OEMs in Aerospace developing Additive Manufacturing as new production model

→  Selected Industry Examples: →  GE >100.000 printed AM parts (one Part#) till 2020 →  GE invested €1.3b in ARCAM and ConceptLaser (75%)

to safeguard machine capacity -> 10.000 printers in 10yrs

→  RR, GKN and MTU established Competence/Production Centers

→  Moog bought a 20printer facility in UK, Oerlikon bought CITIM

→  Airbus and Boeing started to establish a supplier network

→  Airbus educates 700 design engineers →  ALCOA bought in 2015 RTI International –Titan Powder

producer –and transfer in Arconics Low

Mac

hine

C

apac

ity

Hig

h M

achi

ne

Cap

acity

High Low ADDITIVE MANUFACTURING „ACTIVITY“

Source: Kmue, MTU, GEAviation

Industry activity map

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Exiting Cost Saving potentials

§  Shorter and more efficient R&D times

§  Less Prototyping expense §  Significant less weight ->

optimizes operation profiles (less weight more drag / smaller wings / more range....

§  Reduced lead times (operation / MRO)

§  Reduced assetts / stocks §  Lower # of parts

•  OEMs

•  OEMs •  Airlines/

Operators/Lessors

•  OEM/Airlines

•  All


Disruptive Technologies ?

§  Additive Manufacturing is beneficiary in combination with new (BIONIC) designs -> New Aircraft/Engine needed (2025-30ff)

§  Next Generation of Engines and Aircraft will integrate bionic designs and develop the skills for future airplanes/engine

§  Additive Manufacturing will enable the industry to gain extra efficiencies to operate aircraft

§  It will not change everything – but the technology drives the industry - in combination with Industry 4.0/Big Data

§  Industrialization has started !


For questions regarding this presentation, please contact:

Klaus Mueller

THANK YOU!


AM Campus Location / HQ

BPG @ LZN Laser Zentrum Nord GmbH Am Schleusengraben 14 21029 Hamburg-Bergedorf Germany

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