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le centre collectif de l’industrie technologique belge
The collective centre of the Belgian technology industry
Our centre
Federation for the technology industry
Collective centreof the technology industry
• Nonprofit organisation
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• Nonprofit organisation• Industry owned
“Increase the competitiveness of companies of the Agoria sectors through technological innovations”
Mission
© sirris 2011 Charleroi | www.sirris.be | [email protected] |
Our technological sectors
Aerospace Automotive Construction products
Contracting & Maintenance Electrical engineering
Industrial automation Mechatronical engineering
Information and communication technologies (ICT)
Metals & materials Metal processing Mounting & cranes
Plastics & composites Security & defence
Local presence, near the companies
LeuvenMechatronics
Technology Coaching
HasseltBrussels
GhentMaterials Engineering
HasseltMaterials EngineeringProduction Technology
CharleroiAdditive ManufacturingBio-Manufacturing Platform
BrusselsSoftware Engineering & ICTTechnology Coaching
LiègeAdditive ManufacturingMaterials Engineering
Nanomaterials
Additive Manufacturing Process
• Basic data :
Scan / 3D CAD files – STL
• Pre-treatment :
STL corrections, orientation, supports, 2D slicing
3D CAD File
3D STL File
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STL corrections, orientation, supports, 2D slicing
• Manufacturing :
Full automatic
• Post-treatment :
Cleaning, sand blasting, coating, finishing
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Σ 2D layers
Sliced File
Rapid Prototyping
• Stereolithography
• Bi-material 3D Printing
• 3D Printing of wax
• Selective Laser Sintering
• 3D Printing of polymers / plaster
Rapid Prototyping vs Additive Manufacturing
Additive Manufacturing
• Electron Beam Melting
• Selective Laser Melting
• Laser Cladding
• Hybrids of Stereolithography
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• 3D Printing of polymers / plaster
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
Functionalparts
Final parts
Visual parts
SIRRIS – World leader: Most complete machine park
• 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)
Rapid Prototyping / Tooling / Manufacturing
• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (Optoform)
Sirris ADD capacities & competencies
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• Paste polymerisation for ceramics and metals (Optoform)• 3D Printing of plaster and metal powder• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser sintering of metal powder (parts and mould inserts)• Electron Beam Melting (Arcam A2)• 3D Printing of wax (Thermojet)• Vacuum Casting of Alu, Bronze, Zamak• Laser Cladding (EasyClad) • Selective Laser melting (MTT)
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
• Evolution of medical imagery technology
=> Easy access to 3D world !
Need for custom implants !
Benefits of Additive Manufacturing @ Medical field
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Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible
Every human is different (anatomy)
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
Next generation pre-operative manufactured implants:
• Custom implant manufacture :
• CT-Scan• CAD File of the patient is produced• Engineer + Surgeon 3D implant approved• FEM analysis (when needed)• Custom manufacturing (low cost)• Surgery
The utility of Additive Manufacturing technologies
in the medical field
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• Surgery• Follow up
© sirris 2011 Charleroi | www.sirris.be | [email protected] |
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[Sirris ADD]
[Sirris ADD][Sirris ADD]
Medical Additive Manufacturing Software:
ADD capacities & competencies
• Materialise: Mimics• Materialise: 3-matic• Marcam: Autofab• Able Software Corp: 3D Doctor• Medicim: Maxilim
ProEngineer
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
• ProEngineer• New: Lenexa: Analyze• New: Brisbane: Anatomics• (…)
[Mimics & 3-matic - Materialise]
Indirect Manufacturing: Optoform process
le centre collectif de l’industrie technologique belge
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Optoform
Generalities:
• Commercially not available any more• Flexible technology (hybrid SLA):
•Development of very different materials• Possible materials:
•Soft, hard, metallic and ceramic• ISO 13485 certified @ Sirris
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Fabrication steps:
• Preparation and fabrication of the bulk material• CAO / CAD File processing• Automated process manufacturing• Cleaning and recycling of the non-used material• Debinding & Sintering process
[Sirris ADD]
Optoform
Features:
• Layer thickness: 20 - 200µm• Argon laser 400-800mWatt at 351nm and 365nm• Max. Size: 250-350-500mm• Several building plates with variable sizes well suited to small parts and expensive materials• Supports needed
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Material Requirements:
• Composition :Resin+ Fillers (20% to 70% Vol.) + Photo-initiator + Wetting agent + rheological/ thixotropic Agent
• Consistency : Firmness of a toothpaste (Bingham’s model)• Good Lifetime : the filler should not deposit sediment• No UV absorption by the filler ↔ Layer thickness• Support removal & cleaning: not always easy (isopropanol, water,…)
Materials:
• Alumina• Alumina with 8% of nano Zirconia• Hydroxyapatite• α & β Tri-calciumphosphate• Zirconia• SiC• Stainless steel• Titanium
Optoform
[Sirris ADD]
[Sirris ADD]
• Titanium
• Ceramics & metals need a post-process of debinding & sintering
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[Sirris ADD]
[Sirris ADD][Sirris ADD]
Optoform & medical field: CASE STUDIES
Ongoing statuts:
• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)• Diameter ~= 10mm• Macro-porosity ~= 0,5mm• Tests various scaffold structures for bone integration• In vivo testing (rabbits & rats)• Field: Spinal implants & Maxillofacial Surgery
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• Field: Spinal implants & Maxillofacial Surgery• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)
[Sirris ADD][Sirris ADD][Sirris ADD][Sirris ADD]
06/12/2011© Sirris | www.sirris.be | [email protected] |
Optoform & medical field: CASE STUDIES
[Sirris ADD]
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0,5mm
06/12/2011© Sirris | www.sirris.be | [email protected] |
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
[Sirris ADD]
[Sirris ADD]
Optoform & medical field: CASE STUDIES
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06/12/2011© Sirris | www.sirris.be | [email protected] |
[Sirris ADD] [Sirris ADD]
Sirris Additive Manufacturing: Contact
Carsten ENGEL
R&D Biomedical Engineer
Mail: [email protected]
19© sirris 2011 Charleroi | www.sirris.be | [email protected] |
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06/12/2011
Mail: [email protected]: +32 498 91 94 50Skype: Carsten-Engel
SIRRISRue Auguste Piccard, 20B-6041 GOSSELIES BELGIUMhttp://www.sirris.be