Selective Laser Melting at its best, brought to you by.

Dr.ing. Voicu MAGER

INCAS, mai 2015

•

1. The company

Welcome to the

North!

Lübeck

, Deutschland, 53° 52´ N, 10° 42´ O, MEZ

5



SLM Solutions Group has exposure to attractive end markets

and has longstanding relationships with blue chip customers



The market continues the shift from rapid prototyping to

industrial applications



SLM Solutions Group is well positioned to capitalise on this

trend given SLM Solutions' technology and customer base

SLM Solutions Group is already operating in

key industries

Selected blue chip

customers

Aerospace

Automotive

Healthcare

Energy



General Electric Global Research



General Electric Aviation



General Electric Energy



Alstom



Siemens



BMW



Airbus Innovation Works (EADS)



NASA



BEGO



More than 60 universities and

research institutes



Polyshape



Citim



Fruth

SLM Solutions Group and its predecessors have a

history of innovation…

8

1996 – 1998

Basic Research F&S Stereolithography GmbH, Trumpf GmbH and Fraunhofer Institute for Laser Technology (ILT)

1998 – 2002

Fockele & Schwarze (F&S) research leading to IP with today more than 30 own patents and applications

2002

F&S/SLM Solutions

(a)

_{partner to develop, produce and market the SLM Technology to industrial requirements}

2003

Launch of first

Fibre Laser

technology with the MCP SLM 250

2006

Launch of SLM 100 as an entry model

2007

Launch of the

400 Watt

technology

2009

Launch of the new

SLM 250

HL

World Wide cross license agreement with Trumpf, EOS and Fraunhofer ILT

2011

Launch of

SLM 125

HL

_and

_{SLM 280}

HL

_with

_{hull and core (400W & 1000W) technology and 3D laser technology}

2012

Introduction

of SLM 500

HL

_{and the}

_{multi laser technology}

2013

Launch of SLM 500

HL

_{with additional}

_{automated powder handling devices}

(a)

In 2002 SLM Solutions Group was known as MCP. MCP changed its name to MTT Technologies Group in 2008.

MTT Technologies GmbH was renamed into SLM Solutions GmbH in 2010

SLM Solutions Group – a deep rooted 3D

printing heritage

Rapid prototyping

Since 1970

Development of SLM technology

1998 - 2002

Fibre Laser technology

2003

First company to process aluminum and titanium

2006

400 Watt technology

2007

2009

Hull–Core technology

2011

Multi laser technology & automated powder handling devices

2013



Drive industrial application of

3D metal based printing

technology

2014 onwards

SLM 500HL SLM 125HL SLM 280HL SLM 250HL

•

3. The technology

Productivity of selective laser melting (SLM)

Build part

Quality

Powder fed fusion: SLM process

18

Selective Laser Melting

is a disruptive technology with significant potential to

drive the evolution of manufacturing processes

Metal based 3D printing is for industrial

applications – direct part manufacturing

Data preparation for the

SLM-machine

a) Decide on orientation / .stl Dataset

b) Generate support structures

c) Cut the part in even slices digitally (slicing)

d) Generate the Laser operation info (hatching)

Accuracy

SLM Solutions Group‘s technology covers the

most relevant metals...

Aluminium

Cobalt-Chrome

Inconel

Titanium

Tool Steel and

Stainless Steel

Material Properties

 Light weight

 Good alloying properties

 Good processability (casting and pressing etc)

 Good electrical conductivity

 High toughness

 High strength

 Good bio-compatibility

 Good corrosion resistance

 High corrosion resistance

 Excellent mech.strength

 High creep rupture strength up to 700°C

 Outstanding weldability

 High strength, low weight

 High corrosion resistance

 Good bio-compatibility

 Low thermal expansion

 Good machinability

 High hardness and toughness

 High corrosion resistance

 Good machinability Applications  Aerospace  Automotive  General industrial applications  Dental  Medical implants  High temperature  Aerospace  Gas turbines  Rocket motors  Nuclear reactors  Pumps

 Turbo pump seals

 Tooling

 Bio-material for implants

 Aerospace

 F1 motor sport

 Maritime applications

 Plastic injection and pressure diecasting moulds

 Medical implants

 Cutlery and kitchenware

 Maritime

 Spindles and screws

Alloys  AlSi12  AlSi10Mg  AlSi7Mg  AlSi9Cu3  AlMg4,5Mn0,4 Other Materials on request

 Co212-f acc to ASTM F75  Inconel 625

 Inconel 718  Inconel HX (2.4665)  Pure titanium  Ti6Al7Nb  Ti6Al4V  Grade X materials on request  1.2709  1.4404 (316L)  1.2344 (H 13)  1.4540 (15-5PH) Other Materials on request

Propeller for racing boats as scaled model for flow measurements

Dental caps and crowns in cobalt-chrome

Turbine blade of latest generation with internal conformal cooling channels to improve performance of jet engines

Individual Hip Implant in Titanium made for an Australian patient

Mould inserts with integrated, surface conformal cooling channels. Photo with kind permission of Gardena AG

•

4. The products

SLM Solutions – German engineering

with a global reach

Key products

SLM 280

HL

SLM 125

HL Germany 32.9% Asia/ Pacific 22.5% EU ex Germany 20.0% US 16.9% RoW 7.7%

Total 2013: €21.6m

International revenues: 67.1%

Products

•

Produces highly complex metal

components using fine metal

powders from 3 D CAD-data files

•

Patented bidirectional loader

movement offers a safe filter

system and highly efficient

protective gas consumption due to

internal recirculation of inert gas at

laminar flow

•

Offers software to process CAT /

STL-data files as a standard feature

which is also used for slicing and

support generation

•

Can process most metals. Stainless

Steel, Tool Steel, Cobalt-Chromium,

Inconell, Aluminum and Titanium

have been processed successfully

already

20

SLM 125

HL

•

Provides a build chamber of 280 x

280 x 350 mm and an excellent

double beam technology. This will

improve not only the laser beam

profile but also the quality factor of

components

•

New bidirectional loader

movement, field-proven, latest

software does support a

production-oriented data

preparation for specific

applications and highly optimised

building processes

•

Covers a wide range of metals.

Stainless Steel, Tool Steel,

Cobalt-Chromium, Super Alloys,

Aluminum and Titanium have been

processed successfully already

SLM 280

HL

System Parameters

Build Chamber in mm (x/y/z)

125 x 125 x 125 (75)

Laser Power

400 W, YLR-Faser-Laser

Build Speed

15 ccm/h

Pract. Layer Thickness

20 µm – 75 µm

Min. Scan Line / Wall Thickness

140 – 160 µm

Operational Beam Fokus variable

70 µm – 120 µm

Dimensions in mm (B x H x D)

1350 x 1900 (2400) x 800

Weight

Circa 700 kg

System Parameters

Build Chamber in mm (x/y/z)

280 x 280 x 350

Laser Power

400 / 1000 W, YLR-Faser-Laser or dual 400 W

Build Speed

(a)

_{20 ccm/h / 35 cm/h}

Pract. Layer Thickness

(a)

_{20 µm – 75 µm / 150 µm}

Min. Wall Thickness

150 / 1000 µm

Operational Beam Focus

70 – 120 µm / 700 µm

Dimensions in mm (B x H x D)

1800 x 1900 (2400) x 1000

Weight

Circa 1000 kg

(a) Depending on material, position of the component geometry

Up to 2x 400 Watt Lasers

simultaneously!

•

Build chamber of 500 x 280 x 325 mm and excellent double beam technology.

Each of the two fibre lasers (400 + 1000W) operate on the powder bed by a 3D

scanning unit. Two of these units are working at the same time

•

The transport of metal powder is done by a continuous conveying system. This

automates the management of powder and eliminates the manual handling of

loads with bottles and containers

•

The system does offer a leading software in rapid prototyping. Magic AutoFab,

to process CAD/STL-data files as a standard feature which is also used for slicing

and support generation

SLM 500

HL

_{Up to 4 x 400 Watt Lasers}

simultaneously!

System Parameters

Build Chamber in mm (x/y/z)

500 x 280 x 325

Laser Power

2 x 400 W, optional 2 x 1000 W YLR-Faser-Laser

or 4 x 400 W Lasers

Build Speed

(a)

_{70 ccm/h}

Pract. Layer Thickness

20 µm – 200 µm

Min. Scan Line / Wall Thickness

160 – 180 µm

Operational Beam Fokus

80 – 150 µm / 700 µm

Dimensions in mm (B x H x D)

3000 x 2000 (2500) x 1100

Weight

Circa 2000 kg

22

Illustrative build-up speed and resolution of

selected powder bed fusion systems

(a)

(a) Based on 2012 Wohlers report

3

SLM 500

Maximum

build

-up

speed

in cm

³/

h

Low

_High

High

Resolution

(b)

EBM

Functionality

Speed

Surface finish

Accuracy

Performance

Low

Build speed advantage due to

multi laser technology

SLM 500 HL with PSX500 powder handling

and PRS 500

24

New PSX continuous

powder supply unit!

•

5. Target

World air traffic over 24 hours !!!

Leading industrial companies see the potential of

metal based 3D printing

GE quotes:

“By 2020 GE Aviation will manufacture

more than

100 additive parts

for

the GE9X engines.”

“In the next 5 years we will invest more

than

3.5 billion US$

in new equipment

to produce advanced components.”

“Complexity comes for free”

“Additive manufacturing is just a great

game changer!”

How much additional costs per Kg does the

industry accept for weight reduction ?

•

Aerospace projects 10.000,- € per Kg

•

Aircraft design 1.000,- € per Kg

•

Automobile industry 100,- € per Kg

Examples

Postmanufactured

partmade of Titanium alloy

Hydraulic valve

housing in wing

Topologically optimized aero bracket

30

Courtesy of LZN-Hamburg-Germany

Original design

Re-designed

aircraft bracket

• Height 342mm

• Material: Al and Ti

• Build time for

Industrial revolution: complexity!

x18

Weight

No. of components

Durability

-25%

-95%

5x

GE believes that ~

450kg

weight reduction per aircraft

Fuel nozzles

Yes, it can be Rocket science !

•

6. Target

medical

Building up dental bridges in high accuracy

Industrial revolution: cheaper!

Costs

SLM CASE STUDY MEDICAL HIP

IMPLANT

Acetabular cup

for Hip repair

Courtesy of

Royal Perth Hospital

•

7. Target

SLM CASE STUDY AUTOMOTIVE

Results 3D optical measurement

Part: Automotive heat shield

_{L: 285,17mm}

H: 192,78 mm

B: 160,92 mm

V: 141.10 cm³

Automotive

heat shield

ALUMINIUM!

As first tests

with exhaust

system detected

the need of

additional

shielding

Complex

Alu-parts was just

printed out in

SLM -machine in

complex shape

Large Structures and Designs

•

Re-designed automotive front

axle part

•

Height 320mm

•

Material: Al

Tire mould production with SLM

•

Design and build

mould segments

easily

•

Very thin details

possible

•

Material: Al, Steel

•

Fast build time!

•

8. Target

tooling

Industrial revolution: faster!

Cooling

channnels

Cycle time

-30%

42

Injection mould for GARDENA garden tool

Advantages

Reduction of cycle time

by 35 %

Ideal design of size, form

and function of cooling

channels

Quality improvement of

injection moulding

SLM production of tool insert

44

Vă mulţumesc !

[email protected]