Design for AM fundamentals Marc Saunders Director of AM - - PowerPoint PPT Presentation

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Design for AM fundamentals Marc Saunders Director of AM - - PowerPoint PPT Presentation

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Design for AM fundamentals Marc Saunders Director of AM Applications 21/12/2018 Slide 1 Agenda Why do we need design for AM? Innovative AM product design Lightweight AM parts are cheaper Ideal AM product positioning

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SLIDE 1

21/12/2018 Slide 1

Design for AM fundamentals

Marc Saunders

Director of AM Applications

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SLIDE 2

Agenda

21/12/2018 Slide 2

  • Why do we need design for AM?
  • Innovative AM product design
  • Lightweight AM parts are cheaper
  • Ideal AM product positioning
  • Buildability considerations
  • Residual stress
  • Orientation
  • Supports
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SLIDE 3

21/12/2018 Slide 3

  • From research lab onto the factory floor
  • From prototypes & tooling to series production
  • From time compression to higher performance & low costs
  • From shapes to consistent, qualified parts
  • From plastics to high performance alloys
  • From 3D printing to an integrated production process

Additive manufacturing 3D printing

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SLIDE 4

Why do we need to design for AM?

21/12/2018 Slide 4

  • The purpose of design for AM is

to produce parts that:

  • Provide higher performance

than conventional components

  • Can be built cost-effectively

in series production

  • Require minimal post-

processing

  • Get this right, and we have a

profitable AM application

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SLIDE 5

Levels of AM deployment

21/12/2018 Slide 5

Low volume parts made directly from CAD

Value creation Commitment Knowledge

Re-production parts that avoid complex manufacturing Complex parts that simplify assembly and enhance reliability New product designs that deliver lifetime benefits in use or customisation

Best AM business cases at upper levels

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SLIDE 6

Business impact of industrial AM

21/12/2018 Slide 6

Production benefits

£ Less materials £ Lower tooling costs £ Shorter process time £ Shorter lead time £ Simpler assembly £ Automation

Product benefits

£ Less weight £ Faster product launch £ Product reliability £ Higher performance £ Better adaptation £ Product attraction £ Reduced stocking £ Higher

responsiveness

Financial benefit

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SLIDE 7

Agenda

21/12/2018 Slide 7

  • Why do we need design for AM?
  • Innovative AM product design
  • Lightweight AM parts are cheaper
  • Ideal AM product positioning
  • Buildability considerations
  • Residual stress
  • Orientation
  • Supports
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SLIDE 8

Innovative product design

  • Reduced weight

Lattice test structures

built on Renishaw AM250 metal AM system at The University of Nottingham, as part of the Aluminium Lightweight Structures via Additive Manufacturing (ALSAM) project.

Topology

  • ptimised car

door hinge

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SLIDE 9

Innovative product design

  • Reduced weight
  • Reduced space claim

Compact heat exchanger (HiETA) Integrated micro-wave guide

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SLIDE 10

Innovative product design

  • Reduced weight
  • Reduced space claim
  • Increased heat transfer

Micro-turbine recuperator (HiETA)

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SLIDE 11

Innovative product design

  • Reduced weight
  • Reduced space claim
  • Increased heat transfer
  • Efficient fluid flow

3 into 1 exhaust manifold Hydraulic manifold

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SLIDE 12
  • Reduced weight
  • Reduced space claim
  • Increased heat transfer
  • Efficient fluid flow
  • Efficient joining

Innovative product design

Double-lap adhesive joints Acetabular cups with lattice exterior

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SLIDE 13

Agenda

21/12/2018 Slide 13

  • Why do we need design for AM?
  • Innovative AM product design
  • Lightweight AM parts are cheaper
  • Ideal AM product positioning
  • Buildability considerations
  • Residual stress
  • Orientation
  • Supports
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SLIDE 14

21/12/2018 Slide 14

Part cost-v-mass – subtractive manufacturing

Processing costs dominate

Mass Unit cost

Material costs dominate Minimum mass Minimum cost Subtractive manufacturing

  • Low-weight products are

expensive

  • Material is too expensive to

remove

  • Exotic alloys used to

minimize weight

  • If we minimize processing

costs, material costs rise

  • Minimum cost achieved

by balancing material and processing costs

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SLIDE 15

21/12/2018 Slide 15

In AM, a lighter part is a cheaper part

Mass Unit cost

Minimum cost Subtractive manufacturing Additive manufacturing Minimum mass

  • In AM, we have a virtuous

circle: Lower part mass = lower part cost

  • The position and gradient
  • f the AM part cost-v-mass

curve depends on several factors:

  • Material cost
  • AM productivity
  • Post-processing
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SLIDE 16

21/12/2018 Slide 16

AM part cost-v-mass – material costs

Mass Unit cost

Lower alloy cost

  • High cost material results in a steep

cost-v-mass curve

  • Lower material costs make AM more

competitive vs subtractive manufacturing

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SLIDE 17

21/12/2018 Slide 17

Part cost-v-mass – process productivity

Mass Unit cost

Higher AM process efficiency

Multi-laser AM machines increase productivity and reduce build costs

  • Higher machine productivity (build

rate) reduces build time

  • Machine purchase and running costs

determine hourly costs

  • Part costs per kg are reduced as

machines become more cost effective

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SLIDE 18

Productive laser powder bed fusion

21/12/2018 Slide 18

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SLIDE 19
  • Post-processing costs affect the height
  • f the cost-v-mass curve
  • Elimination / simplification of

downstream processing through careful design for manufacture and processing efficiencies lowers AM part costs

21/12/2018 Slide 19

Part cost-v-mass – post-processing

Mass Unit cost

Reduced post- processing

Efficient finishing, machining and inspection reduces AM part costs

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SLIDE 20

Agenda

21/12/2018 Slide 20

  • Why do we need design for AM?
  • Innovative AM product design
  • Lightweight AM parts are cheaper
  • Ideal AM product positioning
  • Buildability considerations
  • Residual stress
  • Orientation
  • Supports
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SLIDE 21

21/12/2018 Slide 21

Typical market segmentation

Motorsport

Mass Unit cost

Minimum cost Subtractive manufacturing Space Aerospace Automotive Industrial (static) Industrial (mobile) Minimum mass

  • Products often used in

multiple market sectors

  • Same basic function,

performance, reliability

  • Different value assigned to

weight and space claim

  • Motorsport, space,

aerospace will pay more for lighter products

  • Automotive and industrial

sectors are more driven by cost

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SLIDE 22

21/12/2018 Slide 22

Viable product cost & mass combinations

Mass

Minimum cost Subtractive manufacturing Aerospace Viable AM product combinations for aerospace

Unit cost

Minimum mass

  • Each sector will be

attracted to products their either reduce weight, reduce cost, or both

  • e.g. Aerospace will be

attracted to products that fall into the blue region

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SLIDE 23

21/12/2018 Slide 23

Early AM solutions had limited appeal

Mass

Minimum cost Subtractive manufacturing

Unit cost

Additive manufacturing

  • Expensive materials
  • Long builds
  • Extensive finishing

Aerospace – baseline product Aerospace – early AM product Minimum mass

  • Appeal of an AM

product depends on:

  • Relative position of the

two cost-v-mass curves

  • How much we can

reduce AM part mass through good design

  • Early AM products

were lighter, but also expensive

  • Appeal limited to

weight-sensitive sectors

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SLIDE 24

21/12/2018 Slide 24

Ideal AM product positioning

Mass

Minimum cost Subtractive manufacturing

Unit cost

Additive manufacturing

  • Cheaper materials
  • Faster builds
  • Capable process
  • Simpler finishing

Single product suitable for all market sectors Minimum mass

An innovative product design made from the right material, with an efficient AM build and streamlined post-processing, could serve the whole market

  • One product instead of many
  • Simplified product

configuration & sales process

  • Reduced inventories
  • Streamlined servicing
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SLIDE 25

21/12/2018 Slide 25

Case study – industrial hydraulics

Domin Fluid Power

  • Direct drive servo values
  • Maraging steel valve bodies and spools
  • Lighter than best conventional product

and cheaper than minimum cost offering

Production build of servo valve bodies produced on RenAM 500Q industrial AM machine

50 l/min 0.35 kg

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SLIDE 26

Agenda

21/12/2018 Slide 26

  • Why do we need design for AM?
  • Innovative AM product design
  • Lightweight AM parts are cheaper
  • Ideal AM product positioning
  • Buildability considerations
  • Residual stress
  • Orientation
  • Supports
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SLIDE 27

Origins of residual stress

21/12/2018 Slide 27

  • Each new layer generated by moving focussed laser across powder bed
  • Layers fuse to each other
  • Heat flows mostly down into the substrate as weld track cools and solidifies –

very quickly

  • Cooling layer contracts, setting up shear forces with the layers below
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SLIDE 28

Reducing residual stress

21/12/2018 Slide 28

  • High temperature build
  • Cantilevers built at a range of pre-

heat temperatures

  • Residual stress reduces with higher

pre-heating

  • Over 70% reduction at 500 °C

0.5 1 1.5 2 2.5 3 3.5 4 4.5 170C 300C 400C 500C

Z-displacement (mm) Build plate temperature

Cantilever displacement as an indicator of residual stress

Baseline

  • 24%
  • 52%
  • 74%
  • Scan strategy
  • Stripes or

chessboard recommended for bulky parts

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SLIDE 29

Why orientation is important

21/12/2018 Slide 29

  • Each layer needs physical support from below, and a path to conduct heat away
  • Solid metal is much more thermally conductive than un-fused powder
  • Down-skin surfaces can be rough and misshapen
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SLIDE 30

Orientation and supports

21/12/2018 Slide 30

  • Supports required on overhanging

surfaces

  • Parts can be built in multiple
  • rientations
  • Select orientations that minimise the

need for supports

  • Nominate bulk areas as datums that

will be machined for precision

  • Build these directly onto the build

plate with additional machining stock

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SLIDE 31

Primary and secondary supports

21/12/2018 Slide 31

Primary supports are designed in CAD with the part Secondary supports are added in build preparation software Better control and maintenance

  • f design intent

Less controlled, non-parametric

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SLIDE 32

Design your build, not just your component

21/12/2018 Slide 32

Aim for self-supporting

  • Orientate the part to carry itself using

the minimum of material

  • Integrate supporting features into the

part design Design supports where necessary

  • Create crisp interfaces with designed

CAD supports to minimise materials and post-processing

Efficient build requiring no supports Supports designed to break off easily

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SLIDE 33

Design for AM case study – topology optimisation

21/12/2018 Slide 33

Design space (self-supporting) Topology

  • ptimisation

Refined design (avoid overhangs) Final design (self-supporting)

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SLIDE 34

Summary

21/12/2018 Slide 34

  • Design for AM is essential to produce profitable

applications

  • AM components must deliver high performance through

innovative design

  • Lightweight AM parts cost less to build
  • Good design and efficient AM production enable market

disruption

  • Buildability constraints must be considered
  • Companies that view AM strategically are investing in

good design for AM

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SLIDE 35

Thank you

21/12/2018 Slide 35

Renishaw.com/am-guide

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