14 - 18 October 2018

Bilbao, Spain

Success Case Studies in Production and Future Preview of Metal AM

Session Chairs

Ralf Carlström

Claus Aumund-Kopp

Mr Ralf Carlström (Höganäs AB, Sweden)
Dipl-Ing Claus Aumund-Kopp (Fraunhofer IFAM, Germany)

Introduction

The metal AM industry is still showing impressive growth and technical development. Furthermore new technologies apart from powder bed fusion approaches have entered the AM world. In addition modelling and simulation of AM processes have become more and more important.

The special interest seminar will cover successful case studies describing new binder based metal AM approaches and modelling aspects, complemented by general descriptions of AM’s way into industry as well as towards its future.

Presentations

Adoption And Diffusion Of Disruptive Technologies: The Case Of Additive Manufacturing In MedTech Industry

Dr Sam Tavassoli; Prof Pia Arenius; Prof Milan Brandt, M; Prof Ivan Cole(RMIT University, Australia); Prof Olaf Diegel; Mr Babak Kianian (Lund University, Sweden); Prof Anne-Laure Mention; Prof Ma Qian (RMIT University, Australia); Mr Rob Wood (Stryker, Australia)

This paper provides the outline and preliminary findings of a newly granted two-years project investigating the adoption of disruptive technologies by focusing on the case of Additive Manufacturing (AM) in the Medical Technology (MedTech) industry particularly in implants application. The expected outcome of the project is a comprehensive guideline and/or an accepted regulatory framework for the adoption and diffusion of implants applications of AM among Australian firms. This is done by developing pathways for manufacturers of (patent-specific and off-the-shelf) implants to enable them to navigate through the existing regulatory frameworks by maximizing the pre-market approval from regulatory bodies (TGA in Australia). The impact of the project will be to unlock the potential of AM applications in the MedTech which will benefit potential new entrants to the industry incumbent firms health care system and patients in Australia.

From Powder to Real Parts

Dr Javier Diaz (ITP AeroEngines, Spain)

Thinking Beyond Printing for Full Additive Manufacturing Value

Dr Mikael Schuisky (Sandvik Additive Manufacturing, Sweden)

Additive manufacturing is steadily becoming a more and more accepted production technology for metallic components. The main industries driving the additive transformation have initially been aerospace and medical. However, in the last years more general engineering industries such as machining- and mining companies have also started to utilize additive manufacturing technologies as alternative production processes for components and tools. In this presentation, some of the advances that Sandvik has made for additive applications within the fields of metal cutting, mining and oil & gas will be described. Customer cases will be shared, such as advanced coolant clamps for turning applications, light weight mills for reduction of vibrations when machining with long overhangs, advanced sliding cases for down the hole hammers – as well as nozzles made in wear resistant cemented carbide, used as oil drill bits. In additive manufacturing, printing makes up just one of seven steps you need to master. The steps before and after the printing are equally important. At Sandvik we call our three phase process: Plan it, Print it – Perfect it.

Modelling Selective Laser Melting Machine Configurations

Mr Tom Anderson (VTT Technical Research Centre of Finland, Finland); Mr Tatu Pinomaa; Dr Anssi Laukkanen (VTT Technical Research Centre of Finland Ltd, Finland)

Many features in producing parts with selective laser melting (SLM) can still be somewhat unreliable and settings working in one machine might yield unacceptable result in another. Considering this knowhow of the process parameters that ultimately affect the properties of the produced part is needed. To investigate variations between machines a thermomechanical process model and a multiscale modelling concept for SLM are presented. The model is able to simulate and predict the effect of different process parameters by interfacing the model to SLM machine build and process files. We demonstrate a part being built with different machine configurations. Model can be used in the design phase to set process parameters and complete the actual design in such a way that minimises distortions porosity or unfavourable microstructural phases as well as investigate and in the future optimise support structures.

Manufacturing And Properties Of Metal Parts Made By Fused Filament Fabrication

Dr Ing Olaf Andersen; Dipl-Ing Sebastian Riecker; Dr Ing Thomas Studnitzky; Dr Ing Sebastian Hein (Fraunhofer IFAM, Germany); Dr Ing Uwe Lohse (Xerion Advanced Heating, Germany); Prof Dr Bernd Kieback (TU Dresden, Germany)

A complete process chain for the additive manufacturing of metal components by means of Fused Filament Fabrication (FFF) is being developed in a joint project. The final goal is to provide ready-to-use parts of industrial quality at moderate investment cost.This paper reports about ongoing work. A thermoplastic filament with a high metal powder loading of 55 vol% was developed and successfully processed on commercially available FFF printers. In order to achieve near full density metallic parts a debinding treatment is required that removes the organic constituents. Subsequently the individual metal particles are joined by diffusion in the solid state (sintering) and a fully metallic part is obtained. It was possible to print and heat-treat different parts in stainless steel 316L. Examples of achievable geometries and a strategy for dimensional and mechanical property monitoring is presented that provides information about the industrial viability of this process chain.

Patient Specific Stainless Steel 316 - Tricalcium Phosphate Biocomposite Cellular Structures For Bone Scaffold Applications Via Binder Jet Additive Manufacturing

Dr Kuldeep Agarwal; Mr Sairam Vangapally; Dr Alexander Sheldon; Mr John Ruprecht (Minnesota State University Mankato, USA)

Scaffolds are 3D biocompatible structures that mimic the extracellular matrix properties (mechanical support, cellular activity and protein production) of bones and provide place for cell attachment and bone tissue formation. Their performance depends on chemistry, pore size, pore volume and mechanical strength. This paper explores a new biocomposite manufactured using Binder Jet AM process. Stainless Steel and tricalcium phosphate are combined to form a biocomposite and used in different cellular structures and volume fractions to produce parts with varying densities. Layer Thickness, Sintering time and Sintering temperature are varied to study the effect of process parameters on the microstructure, dimensions and mechanical properties of the resulting structure. It is found that the resulting biocomposite can be tailored by varying the process to change its properties and mimic the properties of scaffolds in bone tissue applications. Patient specific scaffolds with properties tailored to an individual can be made by this process.

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