Industrial Additive Manufacturing · 2017. 9. 25. · design and analyze plan and manufacture...

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GPDIS_2017.ppt | 1

Industrial

Additive

Manufacturing

Importance of Standardization

Unrestricted

Global Product Data Interoperability Summit | 2017




GPDIS_2017.ppt | 2

Oh how far we have come…





GPDIS_2017.ppt | 3

Design for Additive ManufacturingTraditional and new design workflows supported

From Traditional

Prototyping

MakePrepareDesign

MakeModifySimulateScan

Scan to print

MakeValidateOptimizeDesign

Optimize to print

TO…





GPDIS_2017.ppt | 4

Opportunities abound

Individualization

LIMITLESS FREEDOM:

Individual part

designone-offs

Personalized

products implants,

shoes, car parts

Scan - repairrepair of non digital parts

Business Models

LIMITLESS

OPPORTUNITY:

Inventory reductionzero inventory

On-demandproduct availability

Supply chain

optimization

Manufacturing

Efficiency

LIMITLESS AGILITY:

Part reductionproduct simplification

Low serieslot size 1

Finished productsprinted as assembled

Product

Optimization

LIMITLESS CONTROL:

Weight reductionlight-weight structures –

topology optimized

geometries

Functional

optimizationcomplexity for free

Systems instead

partsReduce number of parts

Courtesy of Materialise





GPDIS_2017.ppt | 5

Optimizing Paths for AM

Status quo

Manufacturing transformation

Pro

duct

transfo

rmation

• Scan modify print

• Lightweighting

• Assembly simplification

• Functional performance optimization

• Multi-material parts

• Digital materials

• Eliminate castings

• Eliminate injection molding

• Rapid manufacturing aids

• Checking / tool fixtures

• Composite part printing

• Low volume (lot size of one)

• Multi-material parts

• Individualization

• Replacement parts / digital inventory

• Accelerate innovation cycles

• Design anywhere. Print anywhere.

• Repair parts

• Supply chain restructuring / shrinkage

Shift from prototyping / experimentation to mainstream industrial production

Shift fr

om

conventional desig

n to e

nte

rprise D

FA

M

Advancing

Manufacturing

Impacting

Business

Advancing

Products





GPDIS_2017.ppt | 6

How do you achieve Industrialization?

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Design Simulate 3D Print

Data Management and Shop Floor Connectivity

Siemens Production Software and MES Systems

Partnerships

Smart model-driven process





GPDIS_2017.ppt | 7

Design for AM

Advancing

Products

• Generative design using

topology optimization

• Design with Convergent

Modeling TM

• Lattice structures

• Design rules for

manufacturability





GPDIS_2017.ppt | 8

Design Evaluation

Product

performance

simulation

• Validate optimized

designs

• Generate simulation

models to validate

convergent body

• Access all validation

and editing tools in one

environment





GPDIS_2017.ppt | 9

Changing the face of Manufacturing

Advancing

Manufacturing

• Drive additive

manufacturing technologies

for real production

• Integrated post-printing

machining and inspection

programming

Multi-axis FDM

Multi jet fusionPowder bed fusion

Hybrid additive





GPDIS_2017.ppt | 10

General Climate for AM Today

CAD

Product

Customer

Requirements

CAE

CAM

Customer

Requirements

Quality

AssurancePost Process FinishingAM Machine

Material

Q

Print Process

Disconnectedsoftware

Multipledata conversions

Uncontrolled workflow

Conventional thinking

Certification





GPDIS_2017.ppt | 11

Moving from Prototype to Production

DESIGN AND ANALYZE PLAN AND MANUFACTURE

CAD/CAE/CAM MACHINE CONTROL and MONITOR

• PART REQUIREMENTS

• MANUFACTURING REQUIREMENTS

• INTEGRATED PRODUCT DEVELOPMENT

• DOCUMENTATION

DESIGN

• PART FILE PREPARATION

• FEATURES & SETUP DEFINITION

DECOMPOSITION

• DEPOSITION STRATEGY

• SECONDARY OPERATIONS

ADDITIVE PLANNING

• ADDITIVE OPERATIONS

• MULTI-AXIS SLICING DIRECTLY ON MODEL

• SEQUENCING

TOOLPATH GENERATION

• MACHINE ENVIRONMENT

• COLLISION, REACHABILITY & SINGULARITY DETECTION

MACHINE SIMULATION

• CAM TO CONTROLLER

• ROBOT TO TABLE SYNCHRONIZATION

• TOOLPATH TO ROBOT PATH CREATION

POST• PLANNING AND

SCHEDULING

• PRODUCTION EXECUTION

• PRINT PART

• VALIDATE PART

• SCADA

MANUFACTURE

DATA, PROCESS AND MANUFACTURING OPERATIONS MANAGEMENT





GPDIS_2017.ppt | 12

What can happen without comprehensive control?





GPDIS_2017.ppt | 13

Holistic Approach

Cloud-based, open IoT operating system

Design

Engineering / Optimization

Finishing & Quality Operation / Execution (MOM/MES)

Machine design & simulation

Machine commiss.

Automation engineering

Print PreparationSystem

EngineeringMachine Control Data Analytics

Virt. commissioning Machine Control Data Analytics

Product Manufacturers

Machine Builders

Collaboration platform

Co-innovation ecosystemProcess Sim & VC

Throughput Optimization

Security & Quality

Simulation

Security & Quality





GPDIS_2017.ppt | 14

Digital Enterprise





GPDIS_2017.ppt | 15

AM Eco-system

• A global, digital collaboration

platform for distributed, industrial

additive manufacturing (AM) and

co-innovation solutions

• Our digital platform links together

an ecosystem of product

developers, experts,

manufacturers, 3D printing

machine OEMs, AM material

vendors and software providers

• Our digital platform provides a

secure, transparent and

automated process

from idea to finished-part delivery

Software

providers

Micro-factories

and job shops

Equipment

vendors

Engineering

community

Part buyers

Machines

Expert

service

s

Materials

co-innovating





GPDIS_2017.ppt | 16

The Digital Twin

Digital Twin of

the product

Digital Twin of

the production

Digital Twin of

the performance

Digital Twin of

the product

Digital Twin of

the production

Digital Twin of

the performance

feed back insights to continuously optimize product and production

Cloud-based, open IoT operating system





GPDIS_2017.ppt | 17

Predicting Build Issues

Distortions Defects

Build failure Local over-heating

Courtesy of Sciaky





GPDIS_2017.ppt | 18

Predictive DfAM

Meso-scale

Macro-scale

• Residual

Stresses

• Distortions

• Over-heating

• Meltpool

morphology

• Porosities

• Powder

distribution

SAMCEF Multiphysics

Micro-Scale





GPDIS_2017.ppt | 19

Case Study on Inconel 718, SLM process

Diameter from CAD : 133mm

Measured Distortion : 0.4mm

Simulated distortion :

2*0.19=0.38mm

• Distortion calculation has been performed, based on effective

values of multilayer shrinkage





GPDIS_2017.ppt | 20

The journey to Industrialized AM

CAD

Product

Customer

Requirements

CAE

CAM

Customer

Requirements

Quality

AssurancePost Process FinishingAM Machine

Material

Q

Print Process

Disconnectedsoftware

Multipledata conversions

Uncontrolled workflow

Conventional thinking

Certification





GPDIS_2017.ppt | 21

Begins with collaborative development

Customer

Requirements Manufacturing Operations ManagementCAD/CAE/CAM

Data ManagementERP

PLM

0101011

0100100

Part and

ProcessG1 X1.1 Y4.2

G1 X2.5 Y3.4

Order Parts





GPDIS_2017.ppt | 22

Extends into Machine Integration

Customer

Requirements Manufacturing Operations Management

AM Machine

CAD/CAE/CAMData Management

ERPPLM

0101011

0100100

Part and

ProcessG1 X1.1 Y4.2

G1 X2.5 Y3.4

Print Process

Order Parts

2

HandlingMaterial

1





GPDIS_2017.ppt | 23

Followed by Post Operations

Customer

Requirements

Handling

Manufacturing Operations Management

Post

ProcessAM Machine

Material

CAD/CAE/CAMData Management

ERPPLM

0101011

0100100

Part and

ProcessG1 X1.1 Y4.2

G1 X2.5 Y3.4

Print Process

Order Parts

Finishing

2 3

1





GPDIS_2017.ppt | 24

Lastly the certification process

Customer

Requirements

Quality

Assurance

Handling


Post

ProcessAM Machine

Material

CAD/CAE/CAM

Products

Data ManagementERP

PLM

0101011

0100100

Part and

ProcessG1 X1.1 Y4.2

G1 X2.5 Y3.4

Print Process

Order Parts

Finishing

Q

Q1

Q2

Q3

2 3

1





GPDIS_2017.ppt | 25

All together comprises an Industrialized Approach

Customer

Requirements

Quality

Assurance

Handling


Post

ProcessAM Machine

Material

CAD/CAE/CAM

Products

Data ManagementERP

PLM

0101011

0100100

Part and

ProcessG1 X1.1 Y4.2

G1 X2.5 Y3.4

Print Process

Order Parts

Finishing

Q

Q1

Q2

Q3

2 3

1





GPDIS_2017.ppt | 26

• A focus on standards• Nadcap - provides independent certification of manufacturing

processes for the industry

• ASTM - Subcommittee F42.05 on Materials and Processes

• 3MF

• Data Analytics for Mfg

• ISA-95 for AM

What can help us get there?





GPDIS_2017.ppt | 27

Standards Drive Design and Manufacture

• ASTM - Subcommittee

F42.05 on Materials and

Processes

• 3MF

• Data Analytics for

Manufacturing

• ISA-95 for AM

• Topology Optimization

• Simulation

Generative

Design Mixer





GPDIS_2017.ppt | 28

Design for Additive ManufacturingTraditional and new design workflows supported

From Traditional

Prototyping

MakePrepareDesign

MakeModifySimulateScan

Scan to print

MakeValidateOptimizeDesign

Optimize to print

TO…

Generative Design

MakeValidatedSystem Generated Design





GPDIS_2017.ppt | 29

Let’s not be this guy




GPDIS_2017.ppt | 30

Thomas Hoffman

Sr. Enterprise Engineer – R&D

Siemens PLM Software

[email protected]

Thank You!

Date post:	20-Sep-2020
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Industrial Additive Manufacturing · 2017. 9. 25. · design and analyze plan and manufacture...

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