Materials for Additive Manufacturing

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Evonik.

Power to create.

“Materials for Additive

Manufacturing”

3D-Additive Manufacturing

Herstellungstechnologie der Zukunft

Hessisches Ministerium für Wirtschaft, Energie,

Verkehr und Landesentwicklung

Sylvia Monsheimer

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Agenda

Page 2 3D-Additive Manufacturing| Hessen Nanotech | Evonik Industries

Short Introduction Evonik 3DP – a hype

Materials for AM

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Evonik Industries AG

Key figures 2013

Sales €12.9 billion

Adjusted EBITDA €2.0 billion

Profitability (adjusted EBITDA margin) 15.6% Return on capital employed (ROCE) 14.5% Employees as of Dec. 31, 2013 33,650

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Evonik Industries AG

Marl Site

Page | 4 3D-Additive Manufacturing| Hessen Nanotech | Evonik Industries

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Evonik Industries AG

A modern Structure

Evonik 2013

Consumer,

Health & Nutrition Resource Efficiency Specialty Materials Services

Inorganic Materials Advanced Intermediates Consumer Specialties Health & Nutrition Performance Polymers Coatings & Additives Segments Business Units

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Evonik Industries AG

BU-PP BL High Performance Polymers

Page | 6 C o s t D ri v e n P e rf o rm a n c e D ri v e n amorphous crystalline Engineering polymers High-performance polymers PET PBT POM PUR PC PPE Commodity polymers PA4.6 PPA PPS LCP FPs PEEK PA12 PA11 PAI PPSU PEI PES PSU PAR PA612 Transp. PA PA6 / PA66 PI PVC ABS PS SAN PE PP PMMA PMMI PMI

= Polymers from Evonik

PE-LD PE-HD = semifinished products from Evonik PA 610 PA 1010 PA 1012

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Evonik Industries AG – BL HP

Product Portfolio Integration

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3D-Additive Manufacturing| Hessen Nanotech | Evonik Industries

• CDT • CDAN • CDON • DDS • LL • COD • COE • VCH • TM-CDT • DM-COD • PA 12 • PA 612 • PA 1012 • PA 6-3-T • CoPA • PPA • PEEK • PMMA • PMI • PI • PVDF • PI fibers • PPS fibers • PMMA sheets • PMMA films • PMI foams • PI foams • PC films • PC sheets • PPSU films • PPSU sheets • PMMA -PVDF films Compounds & Powders Semi-finished goods Butadiene Building Blocks & Monomers Polymers

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Evonik drives innovation with a

global network

Global footprint

Major R&D centers

Innovation for attractive markets with high growth potential

Modern management, strong culture Regional focus of R&D activities are Germany, USA and Asia

Key statistics 2012

– R&D spend: € 393 m. (~ 3 % of sales) – Employees: ~ 2,500

– Facilities: ~ 35 – >26,000 patents – >7,700 trademarks

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Focus on existing technologies and markets

Short to mid term perspective Close customer orientation and strategic partnerships

Largest component of portfolio value

Structured R&D approach with high

output focus

Page 9 New/advanced applications ∼10% New products ∼40% Strategic research ~20% New/improved processes ∼25% €393m Other ∼5%

Dedicated entity Creavis on group level with special organizational units:

– Growth lines

– Project Houses (e.g. Light & Electronics, Taiwan)

Mid to long term perspective

Focus on new markets and/or new technologies and new business models

2 0 1 2 R & D e x p e n d it u re s B u s in e s s U n it b a s e d C o rp o ra te b a s e d

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3DP – some words about the

HYPE….

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3DP – some words about the

HYPE….

From the historical point of view the expression „

3DP

“

changed ist meaning several times :

1. MIT-process (binder is printed onto a powder layer)

2. Office friendly processes (independent from the technology used) 3. In the HYPE now: meaning not quite defined, covers all market

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3DP – some words about the

HYPE….

From Rapid Prototyping to a more segmented market

Prototyping

Concept Modeling

Additive Manufacturing

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Additive Manufacturing

additive process Working layerwise Creates a physical model 3D-results Arbitrarily shaped use of numerical data (CAD) process is quick process is flexible process is automated Merkmale

Characteristics of Additive Fabrication Processes

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SL LOM FDM MIT/3DP Inkjet SLS, LS

Additive Manufacturing

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Additive Manufacturing

Principle SLS

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Good mechanical properties no support structures necessary

arbitrary complexity of the parts possible big volume usable

High potential for real (small) series production Important features of the powder based processes:

Additive Manufacturing

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Motivation for the use of toolless fabrication processes

•Price issue for injection moulding of small series (dependent on the part itself) •Individual parts (needs software and handling etc)

•Impossible to produce by injection moulding (undercuts etc)

•Integration of several parts to one part (difficult to show)(whole production process)

Additive Fabrication: Motivation to use

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Technology and Economic Aspects

„Rapid“ is no longer important in the sense of Rapid Prototyping The whole production process has to be economically

Competition against injection moulding

Principle only

Dependent on the specific part

Small parts have higher break even values

Comparison 1:1, without using advantages like integrating functionality, or more freedom of design

AM Injection Molding no. of units Cost per unit AM superior over IM

3D-Additive Manufacturing| Hessen Nanotech | Evonik Industries

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BL High Performance Polymers

- Development of Materials for AM

Mechanical properties Surface quality

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Materials Development –

The Toolbox and Examples

Monomer

Polymer

Powder

Ink Formulation

Modification and Fractionation

Application Tests

Standards Committee

Polymer Testing

Reactive Systems

Analytics

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BL High Performance Polymers

- New Materials for AM

Seite | 21 O

O

Poly Ether Ether Keton = PEEK

Easy to process Sharp edges Rough surface

• Inherent flame retardant ; UL94 V-O • Low smoke density and no toxic gases

• High heat temperature resistance, excellent chemical resistance • Resistance against X-ray, beta – and gamma radiation

• High strength and flexibility

VESTAKEEP AM 9000

E modulus 3720 MPa

Elongation at break 2,2 %

Tensile strength 72 MPa

Melting point 340 °C

Continuous operating

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BL High Performance Polymers

- New Materials for AM

Comparison of material properties

standard grade new rubberlike material Vestosint Z2611 E modulus 1700 MPa (246.500 psi) 100 - 250 MPa (14.500 – 36.200 psi) Elongation at break 15 % >100 %

Tensile strength 45 MPa

(6.250 psi)

8 MPa (1.160 psi)

Notched impact strength 3,5 KJ/m2 _{No break}

Melting point 186 °C

(366 F)

150 °C (302 F)

Common refreshing rate 50 % 50 %

Shore A 90 Shore D 40

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BL High Performance Polymers

- New Materials for AM

New Material Grade

• Temperature Resistance

• High Impact Strength

• Improved Stiffness

Air Duct

With some integrated

functionality (heat shield,

injection nozzle)

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RealityTests of a new grade with

improved mechanical properties

Air Duct had been in

the car since

26./27.7. in

Hockenheim,

23./24.8. Red Bull

Ring in Austria,

6./7. 9. in Dijon

Good performance,

no failure!

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BL High Performance Polymers

Biobased SLS material

Pilot plant for omega-amino lauric acid (ALS) since beginning of 2013 Alternative to petroleum based laurin lactam

Material 100 % bio based Applicable to SLS

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BL High Performance Polymers

- QA for AM

• validated in 1997 under the EU Eco-Audit (EMAS) regulations. • certified according to ISO

14001:2005

• The management system-certified to ISO 9001:2000

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BL High Performance Polymers

- Where quality control of the powders

takes place:

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Fields of R&D - Value Chain

Page 28 Funda-mentals Pre Proces-sing Process Machine Material Post Proces-sing Assem-bly Applica-tion Develop ment

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Benefit of FEM

Tensile stresses and elongations as well as the movement of the tip can be reduced to an amount of 20 % - with the same amount of material used.

Modell Variation Volumen (mm³) σ_max N/mm²) ε_max (%) Auslenkung (mm) hakenvoll 1+5 mm Radius 5792 15,2 0,85 15,7 hakenvoll 5 mm dick, 1+5 mm Radius 9587 5,1 0,29 3,1 hakenhohl 3+5 mm Radius 4305 13,8 0,80 17,7 hakenhohl optimal 5766 3,3 0,18 3,2

Additive Fabrication Processes

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The OEM‘s perspective: GE‘s plans for AM

General Electric (

GE

) is expanding the uses of 3D printing and

expects the technology to be involved in

more than half

of its

manufacturing in 20 years.

GE uses

less than 10% of 3D printing in its manufacturing

processes today, but that share should rise to 20% to 25% in 10

years and 50% or more in 20 years

, says Christine Furstoss, GE's

technical director of manufacturing and materials technologies in an

interview with IBD

.

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Future Zone - AM

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Large steps forward need their time !!!

Big Bang

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Contact Information

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Sylvia Monsheimer

Director Additive Manufacturing Performance Polymers Phone +49 2365 49-5911 Mobile +49 151 151 010 55 Fax +49 2365 49-805911 sylvia.monsheimer@evonik.com Evonik Industries AG Paul-Baumann-Straße 1 45772 Marl Germany www.evonik.com

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