Mobile Smart
Factory
Agenda
01 Company overview Bionic Production GmbH
02 Mobile Smart Factory
Reliable on-site production of spare parts and components on demand
03 System overview
Operating principle, technology and final products
04 Sales process
Get started with your Mobile Smart Factory
Lueneburg
Mobile Smart Factory – a division of Bionic Production GmbH
C O M P AN Y O V E R V I E W
Founded in 2015 as an independent service provider forAdditive Manufacturing (AM) Majority shareholding by the HHLA AG since 2019
Certifications: DIN EN ISO 9001:2015 / EN 9100:2018
Our principle: Your partner for Bionic Design and Additive Manufacturing
K E Y F AC T S B I O N I C P R O D U C T I O N
© Thies Rätzke
© Thies Rätzke
© HHLA/Thies Rätzke
Client selection Europe and Asia
C O M P AN Y O V E R V I E W
Our partent company, the Hamburger Hafen und Logistik AG (HHLA) is a leading European logistics company
C O M P AN Y O V E R V I E W
Together with its customers, HHLA develops logistics and digital hubs for the transport streams of the future. In doing so, it focuses on innovative technologies and sustainable solutions.
Foundation: 1885 Employees: 6.296
Revenue (2019): 1.38 Mrd. Euro
Service portfolio – Bionic Production
C O M P AN Y O V E R V I E W
Supporting you as a reliable partner in the exploration and implementation of 3D printing and its benefits
Ongoing practical & strategic support TECHNICAL SERVICES PRINTING AS A SERVICE
Education program
Overview and business opportunities
Part screening and potential analysis Introduction 3D printing
Technology overview and business opportunities
Part screening and potential analysis
Design as a service
Bionisation (remote / on-site)
AM-Engineering
Prototyping
Technology selection
Functional analysis and engineering
Topology optimization
Test part and feasibility check
Serial manufacturing
Engineering (e.g. Bionic Design)
Serial parts production
Quality assurance
PRINTING ON-SITE
Factory in a box
Container-based quick and flexible setup or -extension
WAAM (available)
Other AM-methods (under development)
Business case preparation and feasibility analysis
Post-commissioning training
G-Code services
Virtual storage concepts
On-site / remote (Augmented Reality) maintenance service
Upgrades
Bionic Design realized with 3D-Printing
O U R O F F E R – TE C H N I C AL S E R V I C E S
Lightweight
Higher robustness
Cost reduction
Better quality
Short delivery times
No tooling
Advantages
Re- Engineering
Topology optimisation
Bionic Design
Reverse- Engineering
Optimal functioning
Resouce efficiency and lightweight design
Increase in performance
Efficiency improvements
Part screening – By going through a screening process, suitable parts can be identified
O U R O F F E R – TE C H N I C AL S E R V I C E S
Preparation
Part screening workshop
Potential analysis
Build up AM know-how in your company
Common identification of printable parts
Identification and assessment of part with
the greatest AM potential
Substantial know-how along the entire process chain
O U R O F F E R – P R I N TI N G AS A S E R V I C E
Optimized design for high quality and cost efficient production
Material qualification for used manufacturing method
Guarantee of quality through the complete process chain
Serial production or production on order Qualification of AM process
Part design Material Process Quality Serial
production
A V A ILA B LE MA T E R IA L M ET AL
Titanium: TiAl6V4 (Grad 5) Steel: 1.4404, 1.4835 Aluminum: AlSi10Mg Inconel: In718 More: upon request
P L AS T I C
Polyamide: PA12, PA12 FR Polyurethane: TPU
More: upon request
A V A ILA B LE MA C H IN E C A P A C IT IE S M ET AL
Building space: max. 500 x 280 x 235 mm³ Number of lasers: 1 - 4
Laser power: 100 - 1.000 W
P L AS T I C
Building space: max. 550 x 550 x 500 mm³ or 340 x 340 x 620 mm³
Bionic success stories by utilizing industrial 3D printing
RAILWAY INDUSTRY
T E R M IN AL B OX
Reduced stock through virtual storage and printing on-demand
Guaranteed product availability
Possibility of re-engineering of spare parts (e.g. functional integration)
Fast delivery time of 4 to 5 days
B I O N I C P R O D U C T I O N S U C E S S S T O R I E S
AUTOMOTIVE INDUSTRY
8-P IS T ON M ON OB L OC C AL IP E R S
World's largest additive manufactured titanium part
New bionic architecture minimal caliper weight with maximum component stiffness
Weight saving, even with higher load capacity
Much more powerful than aluminum
90%
less storage costs
41%
weight
reduction
Bionic success stories by utilizing industrial 3D printing
LOGISTICS INDUSTRY
C OM P ON E N T QU AL IF IC AT ION U S IN G AM F OR S P AR E S
Project goals
‒ Simplification of the spare parts supply
‒ Elaboration of approval processes (QS) for 3D-printed spare parts
‒ Examination of the framework conditions for the digitisation of storage and demand planning
B I O N I C P R O D U C T I O N S U C E S S S T O R I E S
AVIATION INDUSTRY
E X OS K E L E T ON
Low weight and high stiffness through bionic design principles
Increased safety through a 50 % higher fit factor
Function integration such as a microphone holder directly through 3d printing
CONSULTING
CONSULTING
50%
higher fit factor
Agenda
01 Company overview Bionic Production GmbH
02 Mobile Smart Factory
Reliable on-site production of spare parts and components on demand
03 System overview
Operating principle, technology and final products
04 Sales process
Get started with your Mobile Smart Factory
Reliable on-site production of spare parts and components on demand
M O B I L E S M AR T F AC T O R Y
Mobile and modular container factory, equipped with 3D printing devices
It covers the entire Additive Manufacturing process, including pre- and post-processing, for on-site production of metal and plastic parts
Individual repair services for damaged parts and components
Flexible expansion of production capacities with a high degree of automation
Pre- processing
Production / 3D printing
Post- processing
Quality assurance Digitisation /
Programming
M O B I L E S M AR T F AC T O R Y
P R OD U C T ION U N IT (E X T R AC T )
20 ft. container (CSC-certified)
METROM 6-axis hybrid machine
Customized chassis with isolation
Control unit for machine & container
OP E R AT IN G U N IT (E X T R AC T )
20 ft. container (CSC-certified)
MarkForged X7 polymer printer
Creaform 3D-Scanner
Climatic office with PC workstation
Storage room
D IM E N S ION AN D WE IGH T
External dimension in cm (L x W x H) 605.8 x 243.8 x 259.1
Operating container: approx. 12 tons
Production container: approx. 15 tons
Established components, smartly connected and controlled in a container concept
OT H E R
IT-operating and data system
Augmented-Reality (AR)-maintenance concept
CAD / CAM software
Overall climate, energy and exhaust system
Modular container unit based on your individual needs
M O B I L E S M AR T F AC T O R Y
Reliable & fast supply of metal and polymer parts
Reduced logistics efforts and cost
Flexible & efficient production capacities through “Plug & Print”
Digitised & efficient production
Agenda
01 Company overview Bionic Production GmbH
02 Mobile Smart Factory
Reliable on-site production of spare parts and components on demand
03 System overview
Operating principle, technology and final products
04 Sales process
Get started with your Mobile Smart Factory
The Mobile Smart Factory covers the entire Additive Manufacturing process, including pre- and post-processing
S Y S T E M O V E R V I E W
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
A wide range of materials is available for parts production
Steel
1.2343 (tool steel)
1.2367 (tool steel)
1.3346 (hard application steel)
1.4718 (tool steel)
1.4316 (corrosion-resistant steel)
1.4370 (corrosion-resistant steel)
1.4332 (corrosion-resistant steel)
1.4430 (corrosion-resistant steel)
1.4462 (high-alloy duplex steel)
1.4551 (corrosion-resistant steel)
1.4718 (hard application steel)
1.6834 (low alloy steel)
Aluminum
3.0805 (Al99,5Ti)
3.2245 (4043 AlSi5)
3.2315 (6082 AlMgSi1)
3.2371 (4018 AlSi7)
3.3206 (6063 AlMgSi0,7)
3.3536 (5754 AlMg3)
3.3548 (5183 AlMg4,5Mn)
3.3556 (5356 AlMg5)
3.3546 (5087 AlMg4,5MnZr)
Non-ferrous metal
3.7165 (Ti6Al4V/ Grade 5)
2.0921 (copper basis)
S Y S T E M O V E R V I E W
Ni-based material
1.3912 (nickel 36)
2.4856 (alloy 625)
2.4668 (alloy 718)
M E T AL
Onyx FR
Nylon
Carbon Fiber
Fiberglass
Kevlar
HSHT Fiberglass
POLYMER
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
© Markforged
Success story: Impeller for the shipping industry
S Y S T E M O V E R V I E W
C OM P ON E N T IN F OR M AT ION
Application: Turbocharger for marine diesel engines
Conventional manufacturing technology: milling
Problem with conventional procurement:
Very high chip volume high milling cost
High storage cost of geometry-dependent wrought material
Long delivery times
T E C H N IC AL D AT A
Dimension [mm]:
Diameter: 290
Height = 120
Wire: 1.4370 I Ø 1.0 mm
Printing mass: 19.4 kg
Printing time: 7.0 h
Benefits
Fast, flexible and just-in-time procurement of the near-net-shape blanks as required
Reduction of manufacturing time
Material / cost savings due to reduction of chip volume
Economically provision of small batches
WAAM P R OC E S S
C AD /C AM mo d el 1
M e t a l p ri n t e d p a rt 2
F i n i s h e d p a rt 3
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
Success story: Wheelset bearing cover for the railway industry
S Y S T E M O V E R V I E W
C OM P ON E N T IN F OR M AT ION
Wheelset bearing cover of Deutsche Bahn, one of the world’s leading mobility and logistics companies
High priority part
Conventional manufacturing technology: casting
Problems with spare parts requirement
High minimum purchase quantities
Delivery times of the spare part: several months
T E C H N IC AL D AT A
Dimension: OD = 382 I ID = 147 I h = 70
Wire: 1.4430 I Ø 1.0 mm
Printing mass: 13.20 kg
Printing time: 7.0 h
Benefits
Fast and flexible procurement of the near-net shape blank
Reduction of manufacturing time Cost and material savings
Economically provision of small batches
WAAM P R OC E S S
C AD /C AM mo d el 1
M e t a l p ri n t e d p a rt 2
F i n i s h e d p a rt 3
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
The on-demand production starts with the digitisation of a part
S Y S T E M O V E R V I E W
P R E -P R OC E S S IN G
Preparation of the machine and 3D printing job
D IGIT IS AT ION
Digitisation and storage in virtual database
D AT A T R AN S M IS S ION
Data preparation and transmission to machine
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
Metal and polymer functional end-use parts on site
S Y S T E M O V E R V I E W
B U IL D IN G S P AC E M E T AL S
Diameter: 700 mm Height: 450 mm
B U IL D IN G S P AC E P OL YM E R S
Width: 330 mm Height: 200 mm Length: 270 mm
M AT E R IAL S
Virtually all weldable wires and polymers
AP P L IC AT ION R AT E
Up to 600 cm³/h
Steel: approx. 3.5 kg/h
Aluminium: approx. 1.6 kg/h
C AD /C AM mo d el 1
F i n i s h e d p a rt 3
M e t a l p ri n t e d p a rt 2
W AAM PR O C ESS
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
Combining Wire Arc Additive Manufacturing with milling and drilling
S Y S T E M O V E R V I E W
P R OD U C T ION P R OC E S S
Layer-by-layer structure of the part using arc welding
Fusing of a metal wire with the aid of a welding torch forms the blank
Finishing of the fully built component by CNC-milling
M ETR OM 6 -AXIS H YB R ID M AC H IN E
Robust process
Well-established and easy to handle
High building rate
Low residual stress in the component
Qualified processes ensure the highest quality
3D printing with integrated finishing
Benefits
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
Easy to handle, modern and high quality QS and maintenance concepts
S Y S T E M O V E R V I E W
Training
Learn more about the system, its components and workflows
Production
Guided step-by-step instructions for workflows
Support
Provide help in case of malfunctioning or arising of issues Tactile measurement
for quality inspection 1
Quality inspection 2 with 3D scanning system
Application Digitization / Programming Pre-processing Production and
post-processing
Quality assurance / maintenance
QU AL IT Y AS S U R AN C E / M AIN T E N AN C E AU GM E N T E D R E AL IT Y P L AT F OR M F OR M AIN T E N AN C E
Agenda
01 Company overview Bionic Production GmbH
02 Mobile Smart Factory
Reliable on-site production of spare parts and components on demand
03 System overview
Operating principle, technology and final products
04 Sales process
Get started with your Mobile Smart Factory
Preparation
We fully support your Mobile Smart Factory implementation process
O F F E R
OP T ION AL
Part screening and test parts Feasability study
Business model and case
Customization, production and delivery
Set-up and production of your individual Mobile Smart Factory
Roll out concept (e.g. operation, service and maintenance processes)
Delivery to the place final place of destination
Deployment in daily operation
Delivery of tailored pre and post commissioning training sessions Ongoing support