Additive Manufacturing (AM) is undergoing a revolution as it moves from the model and tooling shop and onto the factory floor. A growing range of firms are deploying AM to create innovative new products that deliver increased performance in use and which could not be produced conventionally. Here we explore the drivers behind this transition and the increased demands that series production places on AM to deliver predictable, consistent parts. We look at the chains of linked processes and tools that are needed to create an integrated manufacturing process with AM at its heart, and the controls that must be employed to make AM a mainstream manufacturing process.
2. • From research lab onto the factory floor
• From prototypes & tooling to series production
• From time compression to higher product performance
• From shapes to consistent, qualified parts
• From plastics to high performance alloys
• From 3D printing to an integrated production process
Additive manufacturing
3. Industrialising AM
How is AM being used today?
The disruptive potential of AM
Integrated manufacturing process chains
Productive AM processes
4. Low volume parts
made direct from CAD
Levels of AM deployment
Rapid prototypes & tooling
Why use AM for prototype & tooling development?
• Prototypes help to de-risk system designs at low cost
• No intention to use AM to make production parts
• AM avoids tooling costs whilst the design is still in flux
• AM enables cost-effective manufacture of complex tooling
Benefit
5. Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Levels of AM deployment
Rapid prototypes & tooling
Direct part replacement
Why use AM for direct part replacement?
• Gain experience with AM in low risk applications
• Develop a supply chain for AM parts
Benefit
6. Complex parts that simplify
assembly & enhance reliability
Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Levels of AM deployment
Rapid prototypes & tooling
Direct part replacement
Part consolidation
Why combine parts using AM?
• Simpler assembly & fewer joints / bonds
Higherbenefit
7. New product designs that
1. Deliver lifetime benefits in use
2. Provide mass customisation
Complex parts that simplify
assembly & enhance reliability
Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Levels of AM deployment
Rapid prototypes & tooling
Direct part replacement
Part consolidation
DfAM
optimised
Highestbenefit
8. Industrialising AM
How is AM being used today?
The disruptive potential of AM
Integrated manufacturing process chains
Productive AM processes
9. Financial benefits of AM
Production benefits
£ Less materials
£ Lower tooling costs
£ Shorter process time
£ Shorter lead time
£ Simpler assembly
£ Automation
Lifetime benefits
£ Less weight
£ Faster product launch
£ Product reliability
£ Higher performance
£ Better adaptation
£ Product attraction
£ Reduced stocking
£ Higher responsiveness
Financial benefit
10. AM impact on product design
Disruptive AM capabilities
Design freedom
Precision & automation
Complexity
Thermal performance
Part consolidation
High performance materials
New business models
12. Level 1 – direct part replacement
Near-net-shape manufacture Localised manufacturing
Production benefits
£ Less waste
£ Lower tooling costs
£ Shorter processing
£ Shorter lead time
Lifetime benefits
£ Faster product launch
Production benefits
£ Shorter lead time
Lifetime benefits
£ Better adaptation
£ Product attraction
£ Reduced stocking
£ Higher responsiveness
Elimination of
expensive tooling
and simplification
of production
process chain
makes small scale
production viable
13. Level 2 – part consolidation
Feature-rich parts Removal of joints
Production benefits
£ Lower tooling costs
£ Shorter processing
£ Shorter lead time
£ Simpler assembly
Production benefits
£ Simpler assembly
Lifetime benefits
£ Less weight
£ Faster launch
£ Reliability
£ Performance
Mechanisms
Production benefits
£ Simpler assembly
£ Automation
Lifetime benefits
£ Faster launch
£ Attraction
14. Level 3 – DfAM optimised
Porous parts Topological optimisation
Production benefits
£ Less waste
£ Lower tooling costs
£ Simpler assembly
Lifetime benefits
£ Less weight
£ Faster product launch
£ Better adaptation
£ Increased performance
Increased surface area
15. Level 3 – DfAM optimised
Heat transfer Metal foams
Production benefits
£ Less waste
£ Lower tooling costs
£ Shorter lead time
£ Simpler assembly
Lifetime benefits
£ Product reliability
£ Better adaptation
£ Increased performance
£ Reduced stocking
£ Product attraction
£ Higher responsiveness
CustomisationBuild the B.O.M.
16. Industrialising AM
How is AM being used today?
The disruptive potential of AM
Integrated manufacturing process chains
Productive AM processes
17. • To be useful every manufacturing process needs an effective tool chain
Process chains – machining example
3D CAD
FEA
CAM
MT
controller
CAM
Inspect
SPC
(This only illustrates the software tool chain for CNC metal cutting)
18. • A tool chain can look simple until you put on information flows
Process chains – machining example
PLM
3D CAD
FEA
CAM
MT
controller
CAM
Inspect
SPC
(This only illustrates the software tool chain for CNC metal cutting)
19. • Supports multi-disciplinary teams
• Encourages design around the most appropriate
and controlled processes
• User-friendly, connected tools
• Allows information-driven decisions - use of
process capability data, etc.
A good process chain
20. Why we need chains for additive manufacturing
Additive manufacturing is not an island!
The advertising promise The reality
21. Process chains for AM
• The design and manufacture
tool chain
3D CAD
FEA /
CFD
CAM
AM
machine
CAM
Inspect
Verify &
SPCPost-
process
PLM
22. Process chains for AM
• Then there is a process chain for qualifying the machine
3D CAD
FEA /
flow sim
CAM
AM
machine
CAM
Inspect
Verify &
SPCPost-
process
Calibrate
to NMS
Machine
Qual
23. Process chains for AM
• And a chain for materials
3D CAD
FEA /
flow sim
CAM
AM
machine
CAM
Inspect
Verify &
SPCPost-
process
Metal
refining
Powder
Prep
Powder
Recycle
Calibrate
to NMS
Machine
Qual
24. Process chains for AM – the challenges
• Most current CAD packages and
measurement systems are based on the
capabilities of 3-axis linear devices
– AM’s ability to make almost any shape
challenges their relevancy
• The single biggest challenge is how to
validate and verify complex parts you are
now able to make
25. Sailboat manifold – process chain
CAM/
Machining
In-process
control
Robot handling/
gauging
Integrated
measurement
Shop floor
gaugingDfAM
Additive
manufacture
26. Sailboat manifold – process chain
CAM/
Machining
In-process
control
Robot handling/
gauging
Integrated
measurement
Shop floor
gaugingDfAM
Additive
manufacture
32. Sailboat manifold – process chain
Design for AM AM build Gauging Machining Inspection
ProcessesTools
33. Process chain for industrial AM
• CAD tools optimised for AM part design
• Integrated build file preparation and post-
process development
• Metrology as a ‘golden thread’ through
the process
• Process controls to minimise variation at
each link in the chain
34. Industrialising AM
How is AM being used today?
The disruptive potential of AM
Integrated manufacturing process chains
Productive AM processes
35. Productive machining
• 140 productive hours per week
• 24 hour unattended operation
• > 99.5% process yield
36. Process setting
Predictive controls
applied just before building
In-process control
Active controls
applied during the build process
Post-
process
monitoring
Informative controls
applied after building is complete
Process foundation
Preventative controls
applied in advance
Process control in manufacturing
The Productive Process Pyramid™
37. • Laser, optics and mechanics calibration
• Optical system health check
• Powder sampling
• Build parameter development
• Test parts – density, tensile, fatigue
Process controls for industrial AM
38. • Build file issue control
• Powder level & condition checks
• Filter condition
• Build plate & wiper alignment
• Build chamber O2 & temperature control
Process controls for industrial AM
39. • Layer inspection
• Dosing control
• Weld pool monitoring & overlap
• Filter condition & powder sieving
• Thermal mapping
• O2 concentration
Process controls for industrial AM
40. • CMM inspection
• Gauging
• CT scanning
• Test piece build integrity checking
Process controls for industrial AM
41. • From research lab onto the factory floor
• From prototypes & tooling to series production
• From time compression to higher product performance
• From shapes to consistent, qualified parts
• From plastics to high performance alloys
• From 3D printing to an integrated production process
Additive manufacturingManufacturing
It is nice to think of design and manufacture as a set of steps which have to be climbed.
One starts at the bottom without a design, proceeding up the steps as the design is formed, iterated through analysis, and through machining part programming, inspection part programming and then process control analysis.
Looking at the information flows it is obviously more complex than a simple stair case. It becomes apparent where flows of information have to be compatible at a basic level, or smooth and automatic at a sophisticated level.
The diagram also doesn’t include information flows from history, or in to the future – so for instance SPC data from previous similar parts may feed in to 3D CAD, and SPC from this design may feed into later designs if new information about capabilities was discovered.
In not so many words, read the slide…
First a very high level summary of how metal AM works.
Just like for subtractive machining there is a tool chain for getting from design to qualified part in AM.
There is also a tool chain which sits orthogonal to the design chain, but which intersects at the machine, in qualifying the dimensional performance of the machine and therefore the parts the machine is capable of producing.
There is also a tool chain which sits orthogonal to the design chain, but which intersects at the machine, in qualifying the dimensional performance of the machine and therefore the parts the machine is capable of producing.
First a very high level summary of how metal AM works.
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First a very high level summary of how metal AM works.