Haruo NARUKE
Nanotechnology & Materials UnitTechnology Strategy Center (TSC)
New Energy and Industrial Technology Development Organization (NEDO)
New Manufacturing Technology— Metal Additive Manufacturing —
Innovate UK-NEDO Meeting5 July 2016
TSC Nanotechnology & Material Unit
Introduction
‘Nanotechnology & Materials Unit’ is formulating strategies in the field of R&D of nanotechnology and materials used for industrial applications.Our strategy field also include new manufacturing technology contributable to material productions.
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1. Innovative development method for advanced functional materials
2. Application of spontaneous process for material production
• Remarkable acceleration of development of functional materials with the aid of mesoscale simulations and mathematical science.
• Industrial application of self-assembly and self–organization.
• Material production through low cost and energy saving processes.
3. Today’s topic: Metal additive manufacturing (AM)
(under investigation)
• Japan’s position in the world.• National R&D projects.
TSC Nanotechnology & Material Unit
Market : Additive Manufacturing (AM) for all materials
The market of products by AM and related service are rapidly increased from 2011.Predicted total effects to economy in 2020 is 218 billion USD (￡ 157500 million).Sales of AM system from Japan is only 3.0 %.
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Fig. Global market of AM products and services
Material
Printing service for personal use
Printing of parts
Printing of spare parts
Trial & devel-opment process
Production process
Software
AM equipment
(for industry)
Cost reduction
Equipment & related items
Product
10 billion USD
101 billion USD107 billion USD
11
65
31
16
85
Fig. Predicted effects of AM to economy in 2020
3D printer(for general consumers)Year
Products
Service
Bill
ion
US
D
5
4
3
2
1
0
Wohlers Report 2016
Total : 218 billion USD (￡ 157500 million)
“Report of new manufacturing study group” METI 2014
(1998-2015)
Fig. Cumulated total sales of AM sold from each geographic region. Wohlers Report 2016
TSC Nanotechnology & Material Unit
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Metal Additive Manufacturing (Metal AM)
Methods Materials Major machine makers
Sheet Lamination paper, polymer, metal Mcor Technologies (IE)Fabrisonic (US)
Vat Photo-polymerization photo-curing resin, ceramic
3D systems (US)Sheemet (JP)
Material Extrusion thermoplastic resin Stratasys (US), 3D systems (US), XYZ Printing (TW)
Material Jetting photo-curing resin, wax
Stratasys (US), 3D systems (US),
Binder Jetting resin, metal, sand, ceramic
3D systems (US), ExOne (US), Voxel jet (DE)
Powder Bed Fusion metal, resin, ceramic Arcam (SE), 3D Systems (US), EOS (DE), SLM Solutions (DE), Concept Laser (DE), Realizer (DE), Renishaw (UK), Aspect (JP), Matsuura (JP)
Directed Energy Deposition metal Optomec (US), TRUMPF (DE),DMG-Mori (JP), Yamazaki-Mazak (JP)
We are focusing on metal AM system because of large impact on wide application fields, such as aerospace, medical, robot, automotive, etc.‘Powder bed fusion’ is the most common process used by leading vendors.
YearFig. Number of sales of metal AM system.
Wohlers Report 2016
Uni
t
800
600
400
200
0
TSC Nanotechnology & Material Unit
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Patent applications – equipment and materials –
Metal
Ceramics
Wax
Others
Thermo-plastics
resin
Light-curing resin
JP US EU CN KR OthersApplicant Nationality
Share 23%
AM materials
Material extrusion
JP US EU CN KR OthersApplicant Nationality
Binderjetting
Directed energy deposition
Materialjetting
Powder bedfusion
Sheetlamination
Vat photo-polymerization
Share 23%
AM equipment (for all materials)
Fig. Patent applications (2000-2011)
Period : 2000-2011
TSC Nanotechnology & Material Unit
Patent applications – top 10 applicants –
Period : 2000-2011
Rank Applicants Totalnumber
1 Panasonic (JP) 45
2 GE (US) 13
3 ALSTOM (SWS) 11
3 STRATASYS (US) 11
3 EX ONE (US) 11
3 EVONIK DEGYSSA (DE)
11
7 BOEING (US) 10
8 KONINK PHILIPS ELECTRONICS (ND)
9
8 UNIV QUEENSLAND(AU)
9
8 MITSHUBISHI ELECTRIC (JP)
9
8 IHI (JP) 9
8 UNIV HUAZHONG SCI & TECH. (CN)
9
Rank Applicants Totalnumber
1 HONEYWELL INT (US)
10
2 MITSUBISHI ELECTRIC (JP)
9
2 IHI (JP) 9
4 NORSK TITANIUM COMPONENTS (NR)
7
4 POM GROUP (US) 7
6 STARCK H C (US) 6
7 AIST (JP) 5
7 MATERIALS & ELECTROCHEMICAL (US)
5
7 SIJ Technology (JP) 5
10 GE (US) 4
10 INESS TECH. (KR) 4
10 INSSTEK (KR) 4
Rank Applicants Totalnumber
1 EOS ELECTROOPTICAL SYSTEMS (DE)
240
2 Panasonic (JP) 161
3 EVONIK DEGUSSA (DE)
127
4 3D SYSTEMS (US) 74
5 ARCAM (SWN) 61
6 MATSUURA Machinery (JP)
35
7 CL SCHUTZRECHSVERWA LTUNGS (DE)
29
8 VOXELJETTECHNOLOGY (DE)
28
9 CONCEPT LASER (DE)
21
10 BEGO MEDICAL (DE) 20
Powder bed fusion Directed energy deposition Metal for AM
JP
6
TSC Nanotechnology & Material Unit
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AM System manufacturers in Japan
Company Material Shaping method
Matsuura Machinery ─ Powder bed fusion＋Mechanical milling
Sodick ─ Powder bed fusion (Laser)＋Mechanical milling
ASPECT ─ Powder bed fusion (Laser)
DMG-MORI ─ Laser Metal Deposition＋Mechanical Milling
Yamazaki-Mazak ─ Laser Metal Deposition＋Mechanical Milling
MUTOH Industries Metal wires for general welding are available
Arc welding
FUJITSU ISOTEC Stainless, Aluminum, Inconel (NiCralloy), other Ni- and Cu-alloys
Metal fusion (Arc discharge)
RICOH ─ Binder jetting (with sintering) (Under development)
Sodick Matsuura Machinery Yamazaki-Mazak MUTOH Industries
TSC Nanotechnology & Material Unit
National R&D projects for metal AM in Japan
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Project name Funding organization
Period Budget Development Points
Advanced Laser and Processing Technology for Next-generation Materials Project
METI* 2010～2014
8 Million USD/year
・CFRP cutting technology・Large area surface annealing ・Laser AM using metal powder
Development and Practical Application of 3D Shaping Technology for Energy Saving Production
METI* 2016～2018
26 Million USD(2016-2018)
Development points・AM processing technology・Production technology of metal powder・Demonstration of testing machine
Manufacturing Innovation Through Development of Next-Generation 3D Printers(TRAFAM)
METI*NEDO
2013～2019
60 Million USD(2013-2016)
Development points・High-spec 3D metal AM system・Metal powder for AM process・Post-process, parts, etc.….
Cross-ministerial Strategic Innovation Promotion Program(SIP)
(consisting of 11 regions)
Cabinet Office
2014～ 1.5 Billion USD(2014-2016)
The followings are themes related to metal AM.Laser metal build-up process for aircraft engine Laser metal deposition process for titanium alloysstructure controlled TiAl turbine bladeBuild and demonstrate the R&D center for 3D anisotropy customized design and AM
*METI: Ministry of Economy, Trade and Industry
TSC Nanotechnology & Material Unit
TRAFAM Project − Summary −
Development of 3D manufacturing technology and high-functional metal powders suitable for high-value additive manufactures.
①Next-generation industrial 3D printing technology
Project name Funding organization
Period Budget(million USD)
Manufacturing Innovation Through Development of Next-Generation 3D Printers
METI→ NEDO
(2017)
2013-2019
60 million USD(￡ 43 million)(2013-2016 total)
Industrial AM systemProcessing (Laser)
Sand-mold
Sand-mold 3D printer
Hopper
Liquid unit
Transfar unit
Z-axis table
Mold sand recoater
Fabrication area
Liquid controller
②Ultra-precision 3D sand-mold manufacturing system
Development Targets
Product
Product
Objectives
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TSC Nanotechnology & Material Unit
② Ultra Precision Three-Dimensional Sand-mold Manufacturing System
PL Dr. Okane(AIST)Laser Beam System
PL Prof. Kyogoku(Kinki Univ.)
System DevelopersKinki Univ., AIST,
Matsuura machinery, Toshiba machinery,
Toshiba, MHI, CMET, Furukawa electric Binder & Molding
sand DeveloperGun-Ei chemical
・Waseda Univ.・Hyogo Pref. Inst.
Tech.・Hokkaido
Research Org.
System DevelopersTohoku Univ., AIST, Tada electric, JOEL,
CMET
E-Beam SystemPL Prof. Chiba(Tohoku Univ.)
User CompaniesIHI, KHI, MHI, Metal technology Co., Koiwai, Toshiba, Komatsu, Sumitomo precision, Panasonic, Panasonic eco-systems, Honda R&D, Nakashima medical, Yazaki
User CompaniesIHI, Koiwai, Nissan,
Komatsu, Komatsu castex, Kimura foundry,
Material DevelopersDaido special steel, Sanyo special steel,
Fukuda metal foil & powder
① Next-Generation 3D Printers PROJECTPL Prof. Kyogoku（Kinki Univ.）
System DevelopersAIST, JOEL, CMET
Matsuura machinery, Tada electric
Collaboration
Collaborate development of software,material handling
Collaboration
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TSC Nanotechnology & Material Unit
PerformanceSystem
Max. work size(mm3)
Speed(cc/h)
Precision±(µm)
Price(USD)
E-Beam (powder bed) 1000×1000×600 500 50 < 0.5 Million
E-Beam (powder bed) 300×300×600 500 20 < 0.5 Million
Laser (powder bed) 1000×1000×600 500 20 < 0.5 Million
Laser (deposition) 1000×1000×300 500 20 < 0.5 Million
Performance System
Max. work size(mm3)
Speed(cc/h)
Precision±(µm)
E-Beam (powder bed) 500×500×600 214 78
Laser-Beam (powder bed) 600×600×400 69 30
Laser (deposition) 500×500×400 250? 24
Current performance (2016)
Target performance (2018)
Commercialization (2019)
Start (2014)①Next-generation industrial 3D printing technology
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TSC Nanotechnology & Material Unit
Sales of metal AM system show rapid growth.
Japan possesses patent shares 23 % for both equipment (powder bed fusion) and material (metals).
Japanese companies started to commercialize equipment.
TRAFAM project aims to commercialize high-performance equipment by 2019.
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Conclusions
Trends of metal AM in Japan
TSC Nanotechnology & Material Unit
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Discussion points
Major technical issues of equipment, metal powder, and processing.
There are several methods for shaping. Which method will becomepopular in future?
In Japan, some of the user companies feel that metal AM is unavailablefor mass production due to high cost of metal powders and low shapingspeed. We would like to know Innovate UK's view or roadmap of massproduction.
If set of material data and process condition will put in, anyone canmake the same products by AM technology. It would be difficult toprotect production technology. How do you think about to preventtechnology leakage?
