Fabrication additive par procédé de fusion laser sur lit de poudre :vers la production de série Dr. Stéphane Abed CEO Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 1 : Our company Part 2 : What is our understanding of Additive manufacturing ? Part 3 :Evolutions of the process (Larger, Better, Faster) Part 4 :New design for new performances Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 1 : Our company 24 employees dedicated to direct manufacturing since 2007 (30 at the end of 2014) Located around Paris (500 m2) and Salon de Provence (1500 m2) Turn-over 2013 : 65 % exportation Poly-Shape SAS Aerospace and Engine parts production ISO 9001:2008 and EN 9100:2010 Poly-Shape SAS Medical, Aerospace and Engine parts production ISO 9001:2008 , EN 9100:2010 EN 13485 :2003 Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our organisation Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our technology : Powder Bed Additive Manufacturing (Laser or Electron Beam melting) Direct Laser Forming Applying new powder layer Melting by Laser 3D-CAD Model in layers New geometries out of serial metallic materials Standard Metal Powder Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Lowering of Build Platform Confidentiel Juillet 2014 Our technology : Additive Manufacturing (Selective laser and Electron Beam melting) • Use of standards materials • Layer-by-layer manufacturing Tool Steel Stainless Steel Titanium alloy Aluminum alloy Nickel Based alloys … Actually 18 different materials Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Metal division : Concept Laser Xline ARCAM Q20 EOS M280 Trumpf DLF250 EOS M270 04/2011 04/2008 03/2014 03/2013 07/2010 07/2012 Concept Laser M2 Concept Laser M1 12/2013 07/2014 06/2014 SLM Sol. 280HL SLM Sol. 500 Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our EBM equipment : the new Q20 from ARCAM The largest in the market, higher productivity, better surface quality TA6V Diam 350 mm and 380 mm high New PRS Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Polymer division : 9 machines for plastic parts • SLA SLS for production SLS for development SLA for production Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Quality department Internal Control laboratory Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our post manufacturing equipments : • several TTH ovens • 5 axes CNC • ….. Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Quality department Certifications : EN ISO 9001 : 2008 EN ISO 13 485 : 2004 EN ISO 9100 (March 2014) And Several Customer Qualifications (Aerospace, Medical, motorsport,…) Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 2 : What is our understanding of additive manufacturing? Our definition : Simultaneous creation of a near net shape component, material microstructure and properties through layered addition of material Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 What is our understanding of additive manufacturing? To qualify you need : -Understanding in the material science -Understanding in the process -Understanding in the design rules Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 3 : Evolutions in the process Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Twin laser system Higher productivity : reduce the cost and faster delivery Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Higher productivity for serial production needs machines with 2 lasers simultaneously : Higher productivity : reduce the cost and faster delivery Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Quad laser system Higher productivity : reduce the cost and faster delivery Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Higher productivity for serial production needs machines with 4 lasers simultaneously : Higher productivity : reduce the cost and faster delivery Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Durée de production : 48h Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Quality control on each layers : Picture of the powder bed On and off line control Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 2 : Large parts and high productivity Our Xline 1000 R machine : Only 5 in the world (one at Daimler and one at SNECMA for exemple) Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Xline 1000 R machine : Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Xline 1000 R machine : Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Xline 1000 R machine : Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Our Xline 1000 R machine : 5 Large Aluminium Parts for Aerospace application Total Melted volume : 3 800 cm3 Production time : 108 h Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Part 4 : New design for new performance Using special CAD software based on FEA and free form additive manufacturing technologies offers new opportunities for new performances Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Industrial cases Motor sport • Small series production Aerospace • Manufacturing of complex geometries • Very complexe geometry • Ligth weigth parts, integration of functions,… • Short delivery time Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Medical • Manufacturing of individual implants directly from CAD-data • Manufacturing costs independent • Reduction of manufrom shape complexity facturing times and improvement of medical • Ligth weigth parts, integration of characteristics functions,… Confidentiel Juillet 2014 Motor sport Optimisation of the steering wheel attachment using topological optimisation - material: aluminium - Integrated nut lock and steering angle sensor attachment - Mass reduction = 56 % (128g) Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Motor sport Optimisation of the suspension Rocker (TA6V) using topological optimisation The part is in the ENIM Formula Student car since this year Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Poly-Shape in the aerospace and aeronautical Aerospace 53 flying metal parts in the nEUROn since December 2012 Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Weigth reduction in an Helicopter part Aerospace Different designs for different loading cases Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Medical Poly-Shape in the medical Manufacturing of bone-like structures with SLM for implantology Ligthweight customised implant Material : TA6V Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Conclusion • Additive manufacturing process gives new opportunities Added value can be in a better buy to fly ratio, new performances, higher flexibility of the supply chain or reduction of NRC for example. • To use efficiently this new manufacturing process a deep and total understanding is needed (Design, Material and process) • One Risk is to believe that this is just a « push buton » 3D printing process Those process can be qualify for critical parts applications Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014 Thank you for your attention ! AddiCtive Manufacturing ®! www.poly-shape.com [email protected] Poly-Shape S.A.S Espace Green Parc. Route de Villepecle.France. www.poly-shape.com Confidentiel Juillet 2014
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