5. EOS-Altair Initiative for Additive Layer

Möglichkeiten der additiven Fertigung
Im Bereich Formula Student
Böblingen, September 2014
Tobias Kuhl
This presentation may contain confidential and/or privileged information.
Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
EOS: Technology and Market Leader for DesignDriven, Integrated e-Manufacturing Solutions
Family-owned, founded in 1989,
EOS Management
Headquartered in Krailling near
Munich, Germany
Integrated solution provider for
Additive Manufacturing
Solution portfolio: Additive
Manufacturing (AM) systems,
materials (plastics and metals),
software and services
Complete end-to-end solutions: from
part design and data generation to
part building and post-processing
Christian Kirner
Dr. Tobias Abeln
Dr. Hans J. Langer
Dr. Adrian Keppler
EOS Headquarters in Krailling, Germany
EOS enables competitive advantages
for a variety of industries, such as
medical, aerospace, tooling, industry,
lifestyle products and automotive
EOS is committed to:
Innovation – Quality – Sustainability
From prototyping to production | EOS | 2
EOS: Global Presence
EOS worldwide installed base
EOS global footprint
~ 1,400 Systems
Customers in 51 countries
EOS Sales & Service offices in 11 countries,
distribution partners in 22 countries
More than 500 employees worldwide
(74% Germany, 26% International)
Strong patent portfolio: More than 700 active
patents in nearly 100 patent families
R&D spendings of ~15% of Sales
⅓ Metal systems
⅔ Polymer systems
266 customers with more than 1 system
North
America
Europe &
Rest of World
AsiaPacific
15%
67%
18%
of global client base
of global client base
of global client base
Source: EOS. Installed base (includes purchased and rented systems) as per 12/2013. Staff figures as per 09/2013.
From prototyping to production | EOS | 3
EOS: A Success Story
140
Accumulated No. of Systems Sold (right-hand scale)
120
€
130
Gross Sales in m€ (left-hand scale)
Employees
1200
1000
113
100
99
800
80
72
60
600
62
61
63
54
40
43
44
400
48
200
20
0
162
177
208
232
252
284
328
332
390
463
520
0
2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12 2012/13
Source: EOS. Figures for EOS Group, for financial years ending 30 September. Number of Employees: Headcounts.
From prototyping to production | EOS | 4
EOS Additive Manufacturing: Functional Principle
From a 3D
CAD model…
Application of powder
Exposure by Laser
Functional principle for polymer and metal materials. Source: EOS
Lowering of platform
Re-application of powder
Exposure by laser
… to complete
parts
From prototyping to production | EOS | 5
From prototyping to production | EOS | 6
From block to advanced solution…
From prototyping to production | EOS | 7
Industrial Companies Face Similar Challenges –
Additive Manufacturing Offers Unique Solutions
Challenges of industrial companies
Additive Manufacturing advantages
Faster Time-to-Market combined
with shorter Lifecycle
$
Productivity increase:
Need for cost reduction
Flexible production
("factory around the corner")
Innovation →
Increase of customer value add
Productivity advantage
Rapid prototyping and serial
applications
$
Cost advantage
Integrated functionality
without assembly
Freedom of design
Lightweight
Complex component
Customisation of products
Focus on Sustainability
Customisation
Customer specific adaptations
Cost efficient small series
From prototyping to production | EOS | 8
EOS prioritizes special industries
Partnering with lead customers, listening and understanding specific industry
requirements, translating customer needs in to adequate offerings
Aerospace
Automotive
Industry
Lifestyle
Medical
Tooling
Sources (upper, left to right): Morris Technologies; M. Kandler, Frauenhofer IPA; Festo; (bottom l. to r.): WITHIN Labs/EOS; EOS; BKL
From prototyping to production | EOS | 9
Using plastic instead of metal – weight of a
gripper has been reduced by 80%
Example Kuhn-Stoff: new gripper design
Lightweight gripper
Application
Hole gripper for part handling
Weight of gripper: 19g
Handles up to 12kg parts
Integrated pneumatic membrane to
apply gripping force
Advantages
About 80% weight reduction
compared to conventional gripper
Printed in one shot - no final assembly
Geometry fully flexible and scalable
Tested to >5 mio. cycles
Source: Kuhn-Stoff, EOS
From prototyping to production | EOS | 10
Topology optimized wheel suspension with increased stiffness of 20% and reduced weight of 35%
Example lightweight
Wheel suspension
Application
Extreme light and stiff wheel suspension
Topology optimized & customized design
In cooperation with Within software
Product details
Weight:
Front 435g / Rear 390g
Max. forces: ca. 100MPa
Material:
Aluminum
Advantages
Weight savings 22% (front), 35% (rear)1)
Increased stiffness of 20%
Fast production and high accuracy
1) Compared to last seasons wheel suspensions manufactured with investment casting
Source: Rennteam Uni Stuttgart, Within, EOS
EOS – Corporate Capabilities | 11
From prototyping to production | EOS | 12
The freedom of design allows to integrate two
seperate functional parts in one design
Example freedom of design
Oil separator and cooler
Application
Integration of two usually
separated parts: Oil separator
and cooler
Upper part: Deposits oil from air by
centrifugal force (rough surface
enhances effect)
Lower part: Oil tank with maximized
surface for cooling-down effect
Reduction of space and weight
AM only way to build this part
Product details
Dimensions: ca. 450x260x180 mm
1) Compared to last seasons wheel suspensions manufactured with investment casting
Source: Rennteam Uni Stuttgart, EOS
EOS – Corporate Capabilities | 13
Car seats can be designed much lighter and
functions can be integrated
Example integrated functionality
Integrated functions
Example: Pneumatic actuator
Example: Seat ventilation
Source: M. Kandler, Frauenhofer IPA, EOS
From prototyping to production | EOS | 14
An innovative drive shaft design resulted
in more than 70% weight reduction
Example lightweight
Innovative drive shaft
Application
Drive shaft for formula student
race cars
Laser sintered twin walled end fittings
No failure for entire race season
Product details
Weight:
350g
Length:
50 cm
Material:
Carbon fibre & titanium
Advantages
Massive weight savings by 73%
compared to steel drive shaft (1,300g)
Steel (left) and
carbon-titan shift (right)
Source: University of Warwick, EOS
From prototyping to production | EOS | 15
Integrated cooling channels help to reduce
weight and increase performance
Example lightweight
Lattice structure break disk
Application
Conceptual break disk for formula
student race car
Integrated cooling channels to reduce
weight and optimize cooling effect
Product details
Dimensions: d 230 mm; t 5mm
Weight:
390 g
Material:
Cobalt Chrome
Advantages
Reduced weight by 25%
Significant increase of performance
due to controlled cooling flow
Rolling cooling channels
Source: ka.race.ing Karlsruhe , EOS
EOS – Corporate Capabilities | 16
A complete butterfly valve is built in one piece,
which improves the air flow behabior
Example integrated functionality
Butterfly valve
Application
Valve to regulate the air supply of the
combustion engine
Spare parts integrated already – no
montage steps necessary anymore
Product details
Dimensions: 297 x 90 x 66 mm
Weight: …
Material: PA12
Advantages
Optimized air flow behavior – no part
transitions
1) Compared to last seasons wheel suspensions manufactured with investment casting
Source: Formula Student Team Weingarten, EOS
EOS – Corporate Capabilities | 17
Accumulator air cooling system
Lightweight, airflow-optimized cell cooling distributor
Cell cooling distributor
Module container and
Cooling distributor in CAD
Cell cooling simulation
Application
Air flow over 3 channels
Integrated carrier of cooling fan,
isolation board, precharge, relays and
tractive fuse for pre-assembly
Product details
Weight:
77g
Material:
PA2200
Advantages
Pressure loss < 500Pa
50°C maximum cell temperature in
endurance mode with 25°C ambient
temperature
Cooling distributor (Alumide) in
assembly
Visualized cell cooling telemetry data
Source: DHBW Engineering Stuttgart e.V.
EOS – Corporate Capabilities | 18
Motor cooling jacket
with helix structured water channels
Integrated Design
Motor cooling jacket
Application
Motor cooling jacket for formula student
electric race car
Flow and heat transfer optimized water
channel structure increased cooling
performance by 37%
Product details
Dimensions: d 105 mm; t 123mm
Weight:
330 g
Material:
EOS Aluminium AlSi10Mg
Advantages
Reduced weight by 16%
Integrated design:
- Motor cooling jacket
- connects motor, gearbox and uprights
Source: Greenteam Uni Stuttgart e.V., EOS
EOS – Corporate Capabilities | 19
A cooperation between Formula Student teams
and EOS can generate a value add for both sides
Synergies between EOS and the race teams
Formula Student Teams
EOS
Marketing
Racing experience
Generate case studies for free
References for fares
Promote EOS brand and public
attention (press releases)
Engineering knowhow
Highly motived
Key engineers of
tomorrows
automotive industry
Human Resources
Get connected with high potential
employees
Educate future engineers
Component ideas
applying DMLM
Use for
races
Use for Races
Source: EOS
Process efficiency
Clear process to regulate FS activities
Significantly lower effort for the
application department
Valuable outcome
Use for Cases
From prototyping to production | EOS | 20
Within the last three years several automotive
case studies resulted from FS activities
EOS Formula Student activities for this season
Application form
130
teams
addressed
Mailing
1) Compared to 2013
Source: EOS
7 teams
submitted
21 ideas
2 ideas
realized
Selection
From prototyping to production | EOS | 21
EOS annual Formula Student timeframe
Activity
Mailing
Aug
Sep
Send out
2014
Oct
2015
Nov
Jan
Feb
Deadline
Send Feedback
Idea Evaluation
Organize Workshop
Dec
Send Invitation
Workshop Day
Application Support
Part Production
Prepare Case Studies
Press Release
Workshop
Source: EOS
From prototyping to production | EOS | 22
Laser Sintering offers high value compared to
traditional manufacturing processes…
Key differentiation criteria for laser sintering
Freedom of design
Lightweight
Static: weight of parts
Dynamic: moving,
accelerated parts
Complex components
E.g. alternative
structures of heat
exchangers
Cost advantage
Customization
Integrated functionality
Individualized parts
Embedded functionality Customer specific
without assembly
adaptations
Cost efficient small
series up to
'lot size one'
Time to market
Organization
Rapid prototyping
Fast feasibility feedback
of virtual models
Haptic feedback
Criteria to evaluate Formula Student ideas for parts:
Not manufacturable conventionally but additively (geometry, size)
New and innovative
Quantifiable advantage
Source: EOS
From prototyping to production | EOS | 23
Contact
Tobias Kuhl
(Strategy and Business Development)
EOS GmbH
Electro Optical Systems
Robert-Stirling-Ring 1
D-82152 Krailling (Munich) Germany
Tel:
+49 (0)172 1033 963
eMail:
[email protected]
web:
www.eos.info
From prototyping to production | EOS | 24

Download Report