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Let Additive Manufacturing Inspire You New Thinking Unmatched Performance From pioneering high-end production to a global vision LayerWise 2014 1

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LayerWise LBM Technology Technology Development Drivers and Applications Future outlook


LayerWise Increase your added value through advantages of Metal Additive Manufacturing Therefore LayerWise offers its technological expertise realized by being technology developer as well as technology user

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LayerWise

1989

1991

2001

2007

Start of AM Research

Start of METAL Research

Phd P. Mercelis

Full Dense Metal Samples

RP

SLM SLS Sintering

Phd J. Van Vaerenbergh

2008

Thin Wall 0.5MM

Ti Grade 5 Ti Grade 23

0% Manufac turing

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2009

2010

2012

2014

Thin Wall Thin Wall Thin Wall 0.225MM 0.18MM 0.3MM

316L CoCr

10% Manufac turing

Inc 718 Maraging

17-4 15-5 AlSi10Mg

Tantalum Tungsten

50% Manufac turing

80% Manufac turing

90% Manufac turing


LayerWise Main Goal: Service Provider for metal additive manufacturing Tools: In house development of the technology In house development of new materials In house development of post finishing techniques

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LayerWise

ISO 9001 & 13485 certified

standard implants customized implants medical tools medical modeling

dental prostheses crowns and copings

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Chemistry Pharmaceutic Semicon High Tech Aerospace Tooling

Food Mechatronics Pressure & Gas Consumer Electronics Automotive


LBM Technology AM

Polymers

Metals

Powder

Powder

Bed

Deposition

Tech

Tech

EBM

LBM

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Ceramics

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Laser Cladding

Glass


LBM Technology

 Directly from 3D CAD  Layer-wise production  3D components by successive connection of thin 2D layers

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LBM Technology

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Technology Developments

“Can we apply 3D metal printing for volume manufacturing of critical components?”

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Technology Developments 1) Developing New materials: • First test samples – Microstructure Analysis • Parameter Optimization • Density • Mechanical Properties • Composing Certified MDS

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Technology Developments

Build Style • Laser Power • Scan Speed • Athmosphere

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Technology Developments LayerWise Metal AM Technology

– Homogeneous microstructure; grain growth across layer thickness – Combined α/β phases – Minimal fraction of rest porosity; may small gas inclusions Ti6Al4V

100µm

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60µm


Technology Developments 2) Tuning Existing materials: • Constant monitoring • Test samples during every AM job • Melt pool monitoring and control 3) Increasing part size • Without the loss of accuracy 4) Productivity enhancement • Reducing Manufacturing costs 14

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Technology Developments Melt-pool fluctuations • Tracking of melt-zone characteristics • High speed imaging and data recording

inert atmosphere 15

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air atmosphere


Technology Developments • Geometric influences

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2

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Technology Developments • Feedback control advantages: demonstrator

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Technology Developments Materials for critical applications

Standard implants Customized implants

Dental prostheses Implant supported and cemented

ISO 9001 and ISO 13485 certified

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Aviation Space

Chemical Pharma Food Pressure & gas

Mechanization Semiconductor Electronics Tooling Precision mechanics


Drivers and Applications

Additive manufacturing Same material Same characteristics

What is the added value?

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Drivers and Applications 1) Monolythic Construction

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Drivers and Applications 2) Flow Optimization

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Drivers and Applications 3) Miniaturisation

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Drivers and Applications 4) Add Functionality

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Drivers and Applications 5) Mass Reduction

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Drivers and Applications 6) Others: - First proto of a MiM-serial production - Very small complex products

10 mm

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Some more Applications

CFD analysis

Flow type Laminar Turbulent

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Channel shape Cross section 3D traject

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SLM Manufacturing

Pressure drop Variable sections restriction

Heatex Conformal Balanced


Some more Applications

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Some more Applications

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Some more Applications

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Some more Applications

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Future outlook

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Future outlook

Materials : super alloys, heavy metals (18+ materials) Cost : 2008 -> 2012 - buildrate x 4 Upscaling : max dimenions x 5 to circa 500 mm Surface control : Ra 5 -> Ra 0.9 & Ra 0.1 Feature size: min. wall 0.5 MM -> 0.2 MM (He 10e-11)

Pardigm shift: DfM-> design for function

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Contact details

LayerWise N.V. Kapeldreef 60 3001 Leuven Belgium tel: +32 16 29 84 20 fax: +32 16 29 83 19

www.layerwise.com info@layerwise.com

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