Design for Additive Manufacturing

2. Founded 1906 by Gunnar Gregersen
 ”To support Danish industry, mainly small enterprises, by providing
technical assistance in the form of teaching, advice, testing and
technological research”
Status
 An independent, not-for-profit institution
 Approved as a technological service institute by the Danish Ministry
of Science, Technology and Innovation.

4. Performance
contracts
12%
28%
Research and
Development
activities
25%
Danish business
customers
Revenue
EUR 131,6 millions
13%
22%
International customers
Organisations and
public customers

5. Hirtshals
Gothenburg
Aarhus
Roskilde
Kolding
Taastrup
Odense
Danish Technological Institute
Teknologisk Institut AB (Sweden)
FIRMA 2000 Sp. z o. o. (Polen)
Dancert A/S
Poland
Danfysik A/S
DTI Robotics US, Inc. (USA)
Warsaw

6. Area of Operation
Idea
Basic/strategic
Research
Technological uncertainty
Is it
possible?
DTI’s area of
operation
New/emerging
Technologies
Commercial/proven
Technologies
8-15 years
Is it feasible?
3-8 years
Can it be improved?
0-2 years
Market
Is it attractive ?
Is there a need ?
Resource depletion
How are all the markets
demands fulfilled ?

7. It s just a tool ……
……not the solution !!!

10. Economy and
Environment
Education
Design
AM
Quality
control
Production
Finish

11. EPO's European Inventor Award 2012 goes to outstanding
inventors from Germany, France, Denmark and Australia
Industry: Widex (Denmark), for their invention of a computer-aided method to manufacture
individually-fitted hearing-aid devices;

12. The beauty of Rapid Manufacturing.

13. ”The RM technology has given us a bigger creative designing space, because we
are no longer limited by a particular geometric shape.
We do not produce tools, which means that the production process is reduced to
a few weeks where it before took between 4 to 6 months.
The time factor means that we can now try out our ideas, and it gives us
an enormous amount of freedom”
Leif Johannsen, Chief Officer of Acoustics and Technology

15. Qphase density for a scan velocity of 23 cm/s
100
90
Relative density (%)
80
70
21/01 test cubes
22/01 test cubes
60
50
40
0
50
100
150
Laser power (W)
200
250

17. Sustainable
Pumps and the world's electricity consumption
•
•
•
Today pumps account for no less than 10% of the world's electricity
consumption.
Two third of all pumps use up to 60% too much energy.
If every business switched to a high efficiency pump system there could be
global savings of 4% of the total electricity consumption- comparable with
the residential electricity consumption of 1 billion people

18. Parts with complex internal channels
•
Demonstrator part: crossing manifold
a manifold to let 2 hydraulic lines cross each other in limited space
Conventional manifold design
230x230x54 mm
20,15 Kg
0,95 Kg
80x80x50mm

20. F•MAT
Svingningsdæmpning
Styrkeoptimering
Funktionsmodellering
Additive
Manufacturing
Støbeteknologi
www.fmat.dk

22. The STL Legacy
CAD
STL
Sliced

23. Then What?
VTK
CAD
?
Mesh
FRep
STL
Sliced

24. Comparing mechanical properties of different
cellular structures experimentally and
theoretically
BCCz
FCCz
BCC
F2CCz
Tryl1b

25. Compression test of different cellular structures
(7x7x14) with same size and density
Cellular structures:
• Nylon PA2200
• 4 highly ordered structures and 1 unordered
• Same outer dimensions (40 x 40 x 80 mm3) and
density (19 vol%)
• Different bar thickness in different structures
(same thickness within same structure)
• 7x7x14 unit cells
• Built with two different set of machine parameters

26. Plast 250 Kg.

27. Compression tests and FE simulations:
18
Stress at Maximum (MPa)
1000
Parameters 1
Parameters 2
800
Fe simulation
600
400
200
BCC
Solid
Parameters 1
16
Parameters 2
14
Max stress in
FE simulation
(arb. units)
12
10
8
6
4
2
0
0
BCCz
F2CCz
FCCz
Solid
BCC
Tryl1b
FCCz
BCCz
F2CCz
FCCz
Solid
Tryl1b
8
F2CCz
BCCz
Tryl1b
BCC
Strain at Maximum (%)
Elastic Modulus (MPa)
1200
7
Parameters 1
6
Parameters 2
5
4
3
2
1
0
BCC
BCCz
F2CCz
FCCz
Solid
Tryl1b

28. 5703Hz
Structure

29. Skærmklip taget: 12-06-2012; 09:09

30. Graphene-based Thermoplastic
Masterbatches for Conventional &
Additive Manufacturing Processes

31. The NanoMaster Concept
•
•
•
•
•
•
•
Develop processes for large-scale rapid production of graphene, expanded graphite and
nano-graphite
Develop machinery and processing methods designed for efficient, high-throughput
production of masterbatches and compounds
Develop material systems which can be incorporated into current conventional and
additive manufacturing processes quickly, easily and safely.
Reduce the amount of polymer required to produce components by 50%, whilst still
meeting performance requirement
Open up an extensive field of applications for plastic mouldings with significantly
enhanced functionality
For the first time, make industrial-scale quantities of graphene-filled compounds and
masterbatches available to European industry
Place European companies in a position to exploit the rapidly growing US and Asian
markets

32. Graphene Functionalisation and
Development
Additive Manufacturing Process
Development
Nanocomposite Development
and Project Coordination
Additive Manufacturing Process
Development and Case Study
Expanded Graphite Development
Environment, Health and Safety
Assessments
Compounding and Dispersion
Method Development
FDM Process Development
Nanomaterial Compounding and
Formulation Development
Pilot-scale Compounding and
Injection Moulding
Conventional Moulding Process
Development and Case Study
Production
Composites Development and
Case Study
Production and Testing of
Demonstrators

33. Preliminary results
34

35. It s just a tool ……
……not the solution !!!
98% of all ideas are old

36. Thank You!
Olivier Jay, Head of Additive Manufacturing section