Additive Manufacturing printable producible reproducible Philippe Reinders Folmer

Additive Manufacturing printable – producible – reproducible Philippe Reinders Folmer General Manager Benelux

About Renishaw World leading metrology company A FTSE 250 company with headquarters in United Kingdom Advancing operational performance Transforming manufacturing efficiencies and raising product quality Maximising research capabilities Improving medical procedures and patient outcomes

Vision “Over the years, John Deer and I have tried to build a company that is different to most others. Different in how we apply technology to real world problems; in how we invest for the long term; in how we manufacture rather than outsource; in how we treat our customers as partners. ” Sir David Mc. Murtry Chairman & Chief Executive

Our mission Provide leading-edge technology by encouraging innovation to address our customers’ needs. Design, manufacture, and supply metrology systems of the highest quality and reliability, enabling dimensional measurement to traceable standards. Strive for total customer satisfaction through superior customer service.

Highlights £ 436. 6 million sales in 2016 16% of revenue spent on engineering, including R&D in 2016 4, 286 35 countries with local subsidiary offices employees

Our expertise – Industrial metrology CMM probes, software and retrofits Machine tool probes and software Position encoders Automated gauging systems Styli for probes Machine calibration and optimisation Spatial laser measurement Additive manufacturing Metrology fixtures

Our expertise – Healthcare Neurological products and therapies Cranial, maxillofacial and dental products Raman spectroscopy

Renishaw’s approach = production process Use of vacuum chamber & pure Argongas • Material integrity • Ultra low oxygen level (<0, 01%) • Short start-up time (12 minutes from start) • Low gas consumption (average 30 to 50 ltr/hr) Glove access & external refill • Operator safety • Material integrity • Re-use and refill during process Off-line file preparation • File integrity & traceability • Machine exchangeability • Operator safety 9/10/2020 Slide 8

Suitable applications – where does it works best? Small bespoke series components dental crowns & bridges, implants etc Complex geometries & structures Thermal management, medical implants, transition to composite structures Hidden internal features conformal cooling, valve bodies etc. Nobel materials & alloys materials difficult to machine & hazardous to process via other methods Short series or one off components for test & development

Additive Manufacturing opens the box • Design what you can make or make what you design. . ? – Limitations by current production methods • Benefits for ‘Designing out of the box’: – Reduce the number of components and increase reliability – Optimise design (strenght, flow, heattransfer) – Increase functionality – Reduce weight and cost (manufacture, assembly, transport) • AM is a metalworking technique: – Like milling, turning, casting, wire erosion – To be used where appropriate – Will always need some form of post treatement: heattreatement, polishing, milling, turning 9/10/2020 Slide 10

AM examples – Tooling Material: • 1. 2344 tool steel Dimensions: • 170 x 46 x 18 [mm] Layer thickness: • 50 µm Build time: • 48 hours Post treatment: • Manual polishing Conformal Cooling Channels Finished Moulded handles – courtesy Gardenia

AM examples – Tooling Considerable reduction of cycle time • Ideal design of size, form and function of cooling channels • Quality improvement of injection moulding

Design for process – pump housing redesign Identify & position key features Create a structurally optimised design Consider part/process orientation demands 9/10/2020 Slide 13

Design for process – assembly front plate Original DFP 3 pump front plate part Aim • Weight Removal • Part consolidation • Reduction in manufacture and assembly time

Design for process – assembly front plate Improved flow path smoothness through CFD simulation of fuel flow velocity a) original flow paths b) redesigned flow paths Delphi

Design for process – assembly front plate • Pressure test = 2 mm wall section • Built on Renishaw AM 250 in Ti 6 Al 4 V • 54% reduction in volume • 21% reduction in overall packaging area • 5 non-value added assembly operations eliminated Delphi

Additive Manufacturing – the next phase – Mind shift: Manufacturing driven design Design driven manufacturing – Learning to handle the design optimising process This makes a workpiece ‘printable’ – Re-design with post-processing and assembly in mind – Focus on process control rather than 3 D production only Making the workpiece ‘producible’ – Design production with upscaling in mind – Incorporate AM in productionflow, -layout and planning Making the process ‘reproducible’ 9/10/2020 Slide 17

Empire Cycles Made to size of the rider Entire bike frame printed in titanium All parts on 1 buildplate Parts glued together (3 M) 9/10/2020 Slide 18

Robot Bike Co Made to size of the rider Frame lugs printed in titanium All parts on 1 buildplate Carbon tubes glued to lugs 9/10/2020 Slide 19

Land Rover BAR Manifolds and hydrolic parts printed in titanium Weight reduction for better weight distribution Parts inspected on the build plate before post processing Build plate used as fixturing during post processing 9/10/2020 Slide 20

Design considerations for production Manage the re-design process • Layerthickness & detail versus speed • Orientation & functionality versus nesting & quantity • Smart use of supports and shapes • Add fixturing items for post-processing 9/10/2020 Slide 21

Thank you 9/10/2020 Slide 22