New ways of designing with Additive Manufacturing

New ways of Designing with AM
Thierry Dormal
Head of AM dept
ADD (1990 – 2013)
• 18 engineers and technicians
• Locations: Liège, Charleroi & Heverlee
In-house additive technologies
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Stereolithography (normal & hi-res)
Paste polymerisation for ceramics and metals (2 Optoform)
3D Printing of plaster and metal powder (Z-Corp, 2 ExOne)
Laser sintering of polymeric powder (PA,…): P360 – P390
Objet Connex 500: bi-material
Laser Melting (MTT) SLM 250 HL
EBM Arcam A2 (Titanium & CoCr)
Laser Cladding (Irepa Laser EasyCLAD)
3D Printing of wax (Thermojet)
MCOR
Makerbot Replicator
•3D scanning & metrology (GOM, Metris, Wenzel)
ASTM process categorization 2012
Material extrusion — the material is selectively dispensed through a nozzle or orifice
(FDM, MakerBot,…)
Material jetting — droplets of build material are selectively deposited
(Objet, Connex,…)
Binder jetting — a liquid bonding agent is selectively deposited to join powder materials
(Zcorp, Prometal ExOne)
Sheet lamination — sheets of material are bonded to form an object
(MCOR, Strato)
Vat photopolymerization — a liquid photopolymer in a vat is selectively cured by lightactivated polymerization (Stereo, Envisiontec; Optoform, Phidias,…)
Powder bed fusion — thermal energy selectively fuses regions of a powder bed
(EBM, LBM)
Directed energy deposition — focused thermal energy is used to fuse materials by
melting as the material is being deposited.
(Optomec, Irepa Laser, Beam, Ion fusion Formation,…)
World repartition 2011
Architectural Other:
5%
Military 3%
6%
Academic
Motor vehicles
institutions
20%
8%
Aerospace
12%
Sirris ADD 2014
Architectural
Academic
institutions
14%
Military
1%
3%
Consumer
Medical 15%
products
Other:
20%
2%
Industrial/busi
ness machines
Motor vehicles
Aerospace
11%
22%
Medical/dental
29%
Industrial/business
machines
Consumer
products/electronics
15%
3%
11%
AM service/production
ICT & Design
tool
developers
Material
developers
Leading-edge
users
Final
Application
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Intervertebral bone replacement (HA/TCP)
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[Sirris ADD]
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SIRRIS
EOS
Materialise MGX
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[Sirris ADD]
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SIRRIS redesign (Flying Cam - Compolight)
SIRRIS redesign (ESA Thales Alenia)
Stress verification
Flying Cam example (Compolight project)
Free space definition
Efforts repartition
STL file
Smoothing or redesign
based on the STL geometry
Weight reduction with the same mechanical result
 Dimensions:
208*175*38mm (L*W*H)
EBM
Machining
LBM
Machining
Machining
EBW
LBM
Initial mass ~ 400 g
New mass : 223 g
57.5% reduction
FLYING-CAM
UNMANNED AERIAL SYSTEMS
Most of the components produced by AM
44 parts in PA + C
31 parts in PA (white, black, painted or not)
1 part in Connex500
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