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10/06/2019 1 Increasing productivity without compromising quality in Additive Manufacturing Marc Saunders
10/06/2019
1
Increasing
productivity without
compromising quality
in Additive
Manufacturing
Marc Saunders
10/06/2019
2
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
About Renishaw
10/06/2019
Slide 3
World leading metrology & engineering company
Metrology Research Healthcare Additive
• FTSE 250 public company, UK headquarters
• Independent
• Strategic focus on breakthrough innovation
Metal AM machine builder and user
10/06/2019
Slide 4
AM machine production
AM medical implants
10/06/2019
5
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
A new AM world is emerging
10/06/2019
Slide 6
• 20 – 35% CAGR forecasted
• Equipment sales set to triple
over next 5 years
• Strong growth in services
also predicted
• Industrial AM applications
are the main growth driver
• Metal AM is showing the
fastest growth
10/06/2019
Slide 7
What’s driving industrial AM growth?
We can create parts that were not practical
or economical to make before
• Produce complex geometries to
improve part performance
• Consolidate multiple parts to
improve reliability and reduce
inventory
• Light weight – only build material
where it is needed
• Create fully customised components
• Parts can be manufactured directly
without tooling
• Enables rapid design iterations
10/06/2019
Slide 8
High-value manufacturing
• Heat exchangers & thermal management
• Fluid transfer
• Structural parts where weight is critical
• Difficult-to-process, expensive materials
• Where extensive quality assurance is acceptable
• Customised or low / medium volumes
Mature applications
• Aerospace and turbo-machinery
• Healthcare
• Tooling
Applications where additive is more mature
10/06/2019
Slide 9
How AM will grow – lower part costs
Volume
Unit cost
AM
marketHigh unit costs have
confined AM to low
volume, specialist
applications
Conventional
manufacturing
Additive
manufacturing
Reducing AM part costs
will open up new market
opportunities
AM
market
expands
10/06/2019
Slide 10
How AM will grow – lower part costs
Volume
Unit cost
Conventional
manufacturing
Additive
manufacturing
10/06/2019
Slide 11
Part cost-v-mass – subtractive manufacturing
Processing
costs dominate
Mass
Unit cost
Material costs
dominate
Minimum
mass
Minimum
cost
Subtractive
manufacturing
• Low-weight products are
expensive
• Material is too expensive to
remove
• Exotic alloys used to
minimize weight
• If we minimize processing
costs, material costs rise
• Minimum cost achieved by
balancing material and
processing costs
10/06/2019
Slide 12
Typical market segmentation
Motorsport
Mass
Unit cost
Minimum
cost
Subtractive
manufacturing
Space
Aerospace
Automotive
Industrial
(static)Industrial
(mobile)
Minimum
mass
• Products often used in multiple
market sectors
• Same basic function,
performance, reliability
• Different value assigned to
weight and space claim
• Motorsport, space,
aerospace will pay more for
lighter products
• Automotive and industrial
sectors are more driven by
cost
10/06/2019
Slide 13
In AM, a lighter part is a cheaper part
Mass
Unit cost
Minimum
cost
Subtractive
manufacturing
Additive
manufacturing
Minimum
mass
• In AM, we have a virtuous circle:
Lower part
mass
Lower part
cost=Productive AM
• The position and gradient of the
AM part cost-v-mass curve
depends on several factors:
• Material cost
• AM productivity
• Post-processing
10/06/2019
Slide 14
Design for AM enables market disruption
Mass
Minimum
cost
Subtractive
manufacturing
Unit cost
Minimum
mass
An innovative AM product
design could serve the
whole market
• One product instead of many
• Simplified product
configuration & sales process
• Reduced inventories
• Streamlined servicing
DISRUPTION!
Productive AM
Single product suitable
for all market sectors
AM is a business strategy
10/06/2019
Slide 15
• AM’s real impact is on competitive positioning:
✓ Product performance and efficiency
✓ Lower product costs
✓ Value-added services (e.g. personalisation)
✓ Responsiveness to changing demands
✓ New product development lead times
✓ Alternative production and distribution logistics
10/06/2019
16
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
Productive laser powder bed fusion
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Slide 17
Higher productivity = lower part cost
10/06/2019
Slide 18
Faster laser powder bed fusion
• 4 x 500W lasers, each can address the whole build plate
• Efficient use of all lasers for any geometry – typically reducing build times by a factor of 3 to 4
• c. 50% increase in machine cost for 200 – 300% increase in productivity
• Machine component of part costs typically halved
More lasers = more variables to control
10/06/2019
Slide 19
Multi-laser coordination challenges
• Laser-to-laser consistency – power & focus,
across the bed
• Laser cross-referencing – relative position
& stability
• Laser task assignment – load balancing
• Multi-laser interaction – relative position
w.r.t. gas flow
Innovative optical system
10/06/2019
Slide 20
AM galvanometer mounting
• Compact mounting block for
8 motorized guiding mirrors
• All 4 laser beams enter build
chamber close together
• Each laser can address the
whole build plate – full
overlap
• AM mounting block includes
complex internal cooling
channels for optimum thermal
stability
RenAM 500Q
quad laser
overlap
Quad laser galvo
mounting
Flexible use of multiple lasers
10/06/2019
Slide 21
Adaptable laser assignment
• Each laser can address the whole build plate
• Flexible assignment of lasers to each task
• Build with 1, 2, 3 or 4 lasers
• Select number of lasers to suit budget and
required build rate
Laser
assignment
More lasers = more throughput
10/06/2019
Slide 22
4 x 500W lasers
3 x 500W lasers
2 x 500W lasers
1 x 500W lasers
Upgra
de a
fter
insta
llatio
n
Dynamic focusing
10/06/2019
Slide 23
Laser
source
Dynamic
focussing
Galvo
mirror
F-theta
optic
✓ Programmable focus
✓ Adjust for thermal drift
✓ Fewer optical surfaces
x Fixed focus
x No adjustment
x More optical surfaces
Programmable focus
• Active focusing upstream of the
steering optics
• Programmable focus control –
can be different for each laser
• No F-theta lens – reduced
thermal lensing
• Enables compact galvo mounting
• Multiple lasers pass through
single window
Laser
source
Galvo
mirror
Precise, stable laser cross-referencing
10/06/2019
Slide 24
Process plane
High precision z-axis
• Optical encoder with a
1nm resolution for high
accuracy positional
sensing
Kinematic recoater
• Kinematic recoater
ensures a precise and
repeatable working
plane
Narrow beam
spacing reduces
laser alignment
sensitivity to process
plane variation
10/06/2019
25
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
Multi-sensor
High-frequency data across a
range of wavelengths
• Infrared thermal sensor
• Near-IR plasma sensor
• Laser input energy
Synchronised with actual galvo
mirror positions to enable 3D
modelling and visualisation
10/06/2019
26
Real-time process monitoring
Analysis software
• Collect and view process data
live as the build progresses
• View and compare data from
previous builds
• Software tools to change
thresholds and reveal
anomalous data
• Guide post process quality
assurance techniques
• Keep records by capturing
traceable process data
10/06/2019
27
Process monitoring data visualisation & analysis
Understand - gain insight into process performance
Record - compare and store traceable process data
Improve - check quality during the build to optimise output
10/06/2019
28
Process monitoring benefits
10/06/2019
29
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
Effective gas flow
10/06/2019
Slide 30
• Inert Argon gas flow carries process emissions
away from melting zone
• Consistent conditions in all locations
• Effective handling of ‘dirty’ materials such as
maraging steel – reduced cleaning
Laminar flow of 2
m/sec across bed
High speed flow at
outlet effectively
removes emissions
High volume / low velocity gas
flow from chamber ceiling
suppresses recirculation
Single laser window
makes space for
ceiling perforations
Tensile testingStress-strain curve
• The more ductile the material, the more easily it can withstand tensile stress
• Good ductility = good fatigue strength which is important for loading stress, shows lack of defects in the build
• Correct chemical composition and good ductility allows users the freedom to use heat treatment to tailor
mechanical properties as required.
10/06/2019
Slide 31
High and consistent material properties
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Slide 32
Nickel super-alloy IN718
60 µm layer
Ti6Al4V Grade 5
60 µm layer
• Consistent melting conditions
• Lack of defects results in high ductility and fatigue performance
10/06/2019
33
But what if we provoke poor melting conditions?
10/06/2019
Slide 34
Multi-laser interaction mechanisms
Melting of a downwind laser can be affected by…
1. De-focusing by airborne condensate – leads to reduced intensity
2. Occlusion by airborne spatter – prevents energy reaching the bed
3. Incorporation of spatter in the component – large particles shield powder from laser energy
All mechanisms can result in lack-of-fusion porosity
De-focusing by airborne condensate Obscuration by airborne spatter Spatter incorporation
Ductility & tensile strength variation with downwind distance
-40
-35
-30
-25
-20
-15
-10
-5
0
5
-200 -150 -100 -50 0
% L
os
s o
f d
ucti
lity
of
do
wn
win
d s
am
ple
Downwind distance (mm)
Downwind sample ductility vs. upwind
IN625-60um_AB IN718-30um_HT
Ti64-30um_HT Maraging Steel-50um_AB
-250
-200
-150
-100
-50
0
50
-200 -150 -100 -50 0
Lo
ss
of
UT
S o
f d
ow
nw
ind
sa
mp
le (
MP
a)
Downwind distance (mm)
Downwind sample UTS vs. upwind
IN625-30um_AB IN718-30um_HT
Ti64-30um_HT Maraging Steel-50um_AB
Impact of downwind
melting increases
with distance
Fracture surfaces
• Classic ‘cup and cone’
ductile fracture
• No ‘lack of fusion’ defects
visible even at high
magnification
• Premature fracture
• ‘Lack of fusion’ defects
leading to localized
brittle failure
UPWIND DOWNWIND
Melt pool analysis
• InfiniAM Spectral real-time melt pool monitoring
http://www.renishaw.com/en/infiniam-spectral--42310
• Downwind sample exhibits more variation in visible /
near-IR spectrum – evidence of hot spots due to
spatter passing through the laser beam
• Downwind sample exhibits lower average IR signal –
evidence of de-focusing and obscuration of the laser
beam
Downwind Upwind
Photo-diode 1
Visible / near IR
Photo-diode 2
Infra-red
Multi-laser build strategies – multiple parts
1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4
Gas flow
Laser 1
Laser 2
Laser 3
Laser 4
Build in columns from left to right
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
Gas flow
Laser 1 Laser 2 Laser 3 Laser 4
Build in rows from back to front
Avoids downwind melting Downwind melting
10/06/2019
39
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software and support
Agenda
Minimising material costs by maximising powder re-use
10/06/2019
Slide 40
• Rapid inert atmosphere generation using vacuum
& Argon purge
• Sealed machine enables 0 ppm oxygen during
build
• Integral powder handling keeps powder under
inert atmosphere at all times
Powder is never exposed to oxygen or moisture
throughout the cycle
Ti6Al4V re-use on RenAM 500Q
10/06/2019
Slide 41
• Series of builds, topping up
with new powder after each
• Oxygen and Nitrogen
remain with specification
limits
• Hydrogen drops from high
initial levels as powder
‘dries out’ with repeated
use
• Further data to be
presented at AMPM0
200
400
600
800
1000
1200
1400
Inte
rstitial ele
men
t con
cen
tra
tion (
pp
m)
Oxygen, Nitrogen and Hydrogen trends in Ti6Al4V
Oxygen Nitrogen Hydrogen
10/06/2019
42
• Renishaw introduction
• A new AM world is emerging
• Advances in AM system performance
• Quad-laser optical system
• Real-time process monitoring
• Gas flow and multi-laser processing
• Powder management & re-use
• Software & support
Agenda
Software productivity tools
10/06/2019
43
Build preparation software
Orientate, support, slice
and material development tools
In-process monitoring
Identify potential defects
Compare serialized builds
Productivity Management
Machine utilization and status
Data acquisition and analysis
PLAN CONTROL MONITOR
AM process chain
10/06/2019
Slide 44
Design for AM AM build Gauging Machining Inspection
Pro
cesses
To
ols
Support for process development - AM Solutions Centres
10/06/2019
Slide 45
• Try before you buy: develop your product
and process, acquire knowledge, build
your business case
• Global network of centres providing
facilities, machines, post-processing and
engineering support
10/06/2019
46
Boosting AM productivity and quality
Progression rather than revolution
• Better design for AM with a focus on disruption
• Lower cost AM parts enabling more business cases
• Faster builds
• Cheaper materials
• Higher yields / less waste
• Advanced processing techniques delivering tailored
material properties
• Enhanced process sensing and control
• Reduced reliance on post-process inspection
Thank you
10/06/2019
Slide 47
Renishaw.com/am-guide
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