Vignat_-_Presentation_Additive_Manufacturing_CERN.pdf

Additive manufacturing (AM) processes have been
commonly used for rapid prototyping purposes during the
last 30 years.
• These technologies can now be used to manufacture
metallic parts.
• This breakthrough in manufacturing technology makes
possible the fabrication of new shapes and geometrical
features.
• They allow net-shape manufacturing of complex parts.
• They should provide improvements in terms of time-to
market, ecological impact and design compared to
traditional industrial processes. Beginning of the 80s: first additive manufacturing
technologies – Stereolithography (SLA) – Laminated Object Manufacturing (LOM) – Selective laser sintering (SLS) – Fused deposition material (FDM)
• 90s : metallic additive manufacturing technologies – Binded selective laser sintering(SLS) Direct Metal Laser
Sintering (DMLS) – Laser selective melting(SLM) – Electron beam melting (EBM) – Direct metallic deposition (DMD / CLAD)
Stereolithography (SLA) is the most widely used rapid prototyping technology. It
can produce highly accurate and detailed polymer parts. It was the first rapid
prototyping process, introduced in 1988 by 3D Systems, Inc., based on work by
inventor Charles Hull.

1. Challenges on Additive Manufacturing for High Energy Physics
CERN 5 November 2014
Additive manufacturing technologies
State of the Art
Frédéric VIGNAT
Associate Professor
G-SCOP - Grenoble- INP – University of Grenoble

2. 2
•Additive manufacturing (AM) processes have been
commonly used for rapid prototyping purposes during the
last 30 years.
•These technologies can now be used to manufacture
metallic parts.
•This breakthrough in manufacturing technology makes
possible the fabrication of new shapes and geometrical
features.
•They allow net-shape manufacturing of complex parts.
•They should provide improvements in terms of time- to-
market, ecological impact and design compared to
traditional industrial processes.

Introduction

3. 3
Introduction
•From soustractive manufacturing
–Several manufacturing operations
–Upto 95% of material removal
•To additive manufacturing
–Reduced material removal rate
–More freedom in parts shape design
–Less tooling

New design paradigm

4. 4
Reduced material removal rate
65345 mm
3
6848 mm
3
4081mm
3
16 x

1,7 x

Extruded
rough part
EBM part
Part

5. 5
AM revenue volume worldwide

6. 6
Additive manufacturing figures

7. 7
•Beginning of the 80s: first additive manufacturing
technologies
–Stereolithography (SLA)
–Laminated Object Manufacturing (LOM)
–Selective laser sintering (SLS)
–Fused deposition material (FDM)
•90s : metallic additive manufacturing technologies
–Binded selective laser sintering(SLS) Direct Metal Laser
Sintering (DMLS)
–Laser selective melting(SLM)
–Electron beam melting (EBM)
–Direct metallic deposition (DMD / CLAD)
–…
Some key dates
Rapid manufacturing
Rapid prototyping

8. 8
Additive manufacturing technologies
[KRUTH2007]

9. 9
•Stereolithography (SLA) is the most widely used rapid prototyping technology. It
can produce highly accurate and detailed polymer parts. It was the first rapid
prototyping process, introduced in 1988 by 3D Systems, Inc., based on work by
inventor Charles Hull.
SLA
Material type: Liquid (Photopolymer)
Materials: Thermoplastics (Elastomers)
Max part size: 59.00 x 29.50 x 19.70 in.
Min feature size: 0.004 in.
Min layer thickness: 0.0010 in.
Tolerance: 0.0050 in.
Surface finish: Smooth
Build speed: Average
Applications:
Form/fit testing, Functional testing,
Rapid tooling patterns, Snap fits, Very detailed parts, Presentation models, High heat applications

10. 10
•The first commercial Laminated Object Manufacturing (LOM) system was
shipped in 1991. LOM was developed by Helisys of Torrance, CA.
LOM
Material type: Solid (Sheets)
Materials:
Thermoplastics such as
PVC; Paper; Composites
(Ferrous metals; Non-
ferrous metals; Ceramics)
Max part size: 32.00 x 22.00 x 20.00 in.
Min feature size: 0.008 in.
Min layer thickness: 0.0020 in.
Tolerance: 0.0040 in.
Surface finish: Rough
Build speed: Fast
Applications:
Form/fit testing, Less
detailed parts, Rapid
tooling patterns

11. 11
•Selective Laser Sintering (SLS) was developed at the University of Texas in
Austin, by Carl Deckard and colleagues. The technology was patented in 1989
and was originally sold by DTM Corporation. DTM was acquired by 3D
Systems in 2001.
SLS
Material type: Powder (Polymer)
Materials:
Thermoplastics such as Nylon,
Polyamide, and Polystyrene;
Elastomers; Composites
Max part size: 22.00 x 22.00 x 30.00 in.
Min feature size: 0.005 in.
Min layer thickness: 0.0040 in.
Tolerance: 0.0100 in.
Surface finish: Average
Build speed: Fast
Applications:
Form/fit testing, Functional testing,
Rapid tooling patterns, Less detailed
parts, Parts with snap- fits & living
hinges, High heat applications

12. 12
•Fused Deposition Modeling (FDM) was developed by Stratasys in Eden Prairie,
Minnesota. In this process, a plastic or wax material is extruded through a nozzle
that traces the part's cross sectional geometry layer by layer.
FDM
Material type: Solid (Filaments)
Materials:
Thermoplastics such as ABS, Polycarbonate, and Polyphenylsulfone;
Elastomers
Max part size: 36.00 x 24.00 x 36.00 in.
Min feature size: 0.005 in.
Min layer thickness: 0.0050 in.
Tolerance: 0.0050 in.
Surface finish: Rough
Build speed: Slow
Applications:
Form/fit testing, Functional testing, Rapid tooling patterns, Small detailed parts, Presentation models, Patient and food applications, High heat applications

13. 13
Additive manufacturing technologies
Metallic
[KRUTH2007]

14. 14
Metallic particles biding mechanism
[Kruth2007]
SLS DMLS SLM - EBM - CLAD

15. 15
Layer Based Manufacturing
3D model (stl file) Sliced file
Slicer
Idea
Scan path generation
with process parameters
set
Scan speed, Beam Power, Scan
strategy, focusing…
Selective Melting
Blasting off the powder cake
Final part

16. 16
Layer based additive manufacturing
Deposition of a layer of
powder
Energy is brought by the
Electron beam to melt
the particles
The building tray is
moved down
Consolidation of the
powder

17. 17
•Laser beam
–Selective Laser Sintering (SLS)
–Direct Metal Laser Sintering
(DMLS)
–Selective Laser Melting (SLM)
Laser vs electron beam
[National Instruments] [Lu2009]
•Electron beam
–Electron Beam Melting (EBM)

18. 18
•Direct Metal Laser Sintering (DMLS) was developed jointly by Rapid Product
Innovations (RPI) and EOS GmbH, starting in 1994, as the first commercial rapid
prototyping method to produce metal parts in a single process.
•With DMLS, metal powder (20 micron diameter), free of binder or fluxing agent, is
completely melted by the scanning of a high power laser beam to build the part with
properties of the original material.
DMLS
Material type: Powder (Metal)
Materials:
Ferrous metals such as Steel alloys, Stainless steel, Tool
steel; Non-ferrous metals such as Aluminum, Bronze,
Cobalt-chrome, Titanium; Ceramics
Max part size: 10.00 x 10.00 x 8.70 in.
Min feature size: 0.005 in.
Min layer
thickness:
0.0010 in.
Tolerance: 0.0100 in.
Surface finish: Average
Build speed: Fast
Applications:
Form/fit testing, Functional testing, Rapid tooling, High heat
applications, Medical implants, Aerospace parts

19. 19
[POM]
Direct metal deposition
[IRRCyN]

20. 20
Research on additive manufacturing
•Research directions
–Technology
–Process improvement
–Environmental impact
–Design for additive Manufacturing
–Metallurgy
–Digital chain
–- …

21. 21
Process optimisation
•Yadroitsev, I., Ph. Bertrand, and I. Smurov. “Parametric Analysis
of the Selective Laser Melting Process.” Applied Surface Science
253, no. 19 (Juillet 2007): 8064– 8069.









fabrication fabrication

22. 22
Process optimisation
•Kruth, Prof.dr.ir. J.P., B. Vandenbroucke, Ing. J. Vaerenbergh van, and P.
Mercelis. “Benchmarking of different SLS/SLM Processes as Rapid
Manufacturing Techniques.” In Proceedings of the PMI, 2005.
•Ippolito, R., L. Iuliano, and A. Gatto. “Benchmarking of Rapid Prototyping
Techniques in Terms of Dimensional
Accuracy and Surface Finish.” CIRP Annals – Manufacturing Technology 44,
no. 1 (1995): 157– 160.

23. 23
Process optimisation
•Byun, Hong S., and Kwan H. Lee. “Determination of Optimal
Build Direction in Rapid Prototyping with Variable Slicing.”
The International Journal of Advanced Manufacturing Technology
28, no. 3– 4 (April 2005): 307– 313.

24. 24
Process optimisation

•Lu, Wei, Feng Lin, Jiandong Han, Haibo Qi, and Naisheng Yan. “Scan Strategy
in Electron Beam Selective Melting.” Tsinghua Science & Technology 14, no.
Supplement 1 (Juin 2009): 120– 126.

25. 25
Material properties
•Murr, L.E., E.V. Esquivel , S.A. Quinones, S.M. Gaytan, M.I.
Lopez, E.Y. Martinez, F. Medina, et al. “Microstructures and Mechanical Properties of
Electron Beam-rapid Manufactured Ti-6Al-4V Biomedical Prototypes Compared to
Wrought Ti-6Al-4V.” Materials Characterization 60, no. 2 (Février 2009): 96–105.
•Biamino, S., A. Penna, U. Ackelid, S. Sabbadini, O. Tassa,
P. Fino, M. Pavese, P. Gennaro, and C. Badini. “Electron Beam Melting of Ti-48Al-
2Cr-2Nb Alloy: Microstructure and Mechanical Properties Investigation.”
Intermetallics In Press, Corrected Proof





Typical small spherical
defect in EBM g-TiAl
specimens (a);
microstructure after EBM
(b); microstructure after
HIP (c); microstructure
after thermal treatment (d).

26. 26
Material properties
•Kruth, J.-P., B. Van der Schueren, J.E. Bonse, and B. Morren. “Basic Powder
Metallurgical Aspects in Selective Metal Powder Sintering.” CIRP Annals -
Manufacturing Technology 45, no. 1 (1996): 183–186.
•Choi, J., and Y. Chang. “Characteristics of Laser Aided Direct Metal/material
Deposition Process for Tool Steel.” International Journal of Machine Tools and
Manufacture 45, no. 4–5 (Avril 2005): 597–607.

27. 27
Architectured Materials
•Parthasarathy, Jayanthi, Binil Starly, Shivakumar Raman, and Andy Christensen.
“Mechanical evaluation of Porous Titanium (Ti6Al4V) Structures with Electron
Beam Melting (EBM).” Journal of the Mechanical Behavior of Biomedical
Materials 3, no. 3 (April 2010): 249– 259.
•Suard, M.; Lhuissier, P.; Dendievel, R.; Blandin, J.-J.; Vignat, F. & Villeneuve,
F. (2014), 'Towards stiffness prediction of cellular structures made by electron
beam melting (EBM)', Powder Metallurgy 57(3), 190--195.

28. 28
Architectured Materials
•Reinhart, Gunther, and Stefan Teufelhart. “Load-Adapted Design of Generative
Manufactured Lattice Structures.” Physics Procedia 12, Part A (2011): 385– 392.

29. 29
Environmental impact
•Azapagic, A., A. Millington, and A. Collett. “A Methodology for Integrating
Sustainability Considerations into Process Design.” Chemical Engineering
Research and Design 84, no. 6 (juin 2006): 439– 452.
•Kellens, Karel, Wim Dewulf, Evren Yasa, and Joost Duflou. “Environmental
Analysis of SLM and SLS Manufacturing Processes.” In Proceeding of the
17th CIRP International Conference on Life Cycle Engineering, 423– 428. 17
location:Hefei, China date, 2010.

30. 30
Design for additive manufacturing
•Kerbrat, O., P. Mognol, and J.-Y. Hascoet. “Manufacturing Complexity
Evaluation at the Design Stage for Both Machining and Layered Manufacturing.”
CIRP Journal of Manufacturing
Science and Technology 2, no. 3 (2010): 208– 215.
•Kerbrat, Olivier, Pascal Mognol, and Jean-Yves Hascoet. “A New DFM
Approach to Combine Machining and Additive Manufacturing.” Computers in
Industry 62, no. 7 (September 2011): 684– 692.

31. 31
Design for additive manufacturing
•Vayre, B., F. Vignat, and F. Villeneuve. “Designing for Additive
Manufacturing.” Proceeding CIRP 3, no. 0 (2012): 632– 637.
•Emmelmann, C., P. Sander, J. Kranz, and E. Wycisk. “Laser Additive
Manufacturing and Bionics: Redefining Lightweight Design.” Physics Procedia
12, Part A (2011): 364– 368.

32. 32
Design for additive manufacturing
•Emmelmann, C., P. Sander, J. Kranz, and E. Wycisk. “Laser Additive
Manufacturing and Bionics: Redefining Lightweight Design.” Physics Procedia
12, Part A (2011): 364– 368.
•Benjamin Vayre PhD.
•Koguchi, Atsushi, and Noboru Kikuchi. “A Surface Reconstruction Algorithm
for Topology Optimization.” Engineering with Computers 22 (July 5, 2006): 1–
10.

33. 33
Digital chain for additive manufacturing
•Bonnard, Renan, Pascal Mognol, and Jean-Yves Hascoët. “A New Digital Chain for
Additive Manufacturing Processes.” Virtual and Physical Prototyping 5, no. 2 (2010): 75.
•Computer-Aided Design Methods for Additive Fabrication of Truss Structures, Hongqing
Wang, David Rosen.
•Azman, A. H.; Vignat , F. & Villeneuve, F. (2014), 'Evaluating Current CAD Tools
Performances in the Context of Design for Additive Manufacturing ''Joint Conference on
Mechanical, Design Engineering & Advanced Manufacturing'.

34. 34
•Additive manufacturing will obviously take a large share of
manufacturing processes
•It is a breakthrough in manufacturing technology
•Still a lot of research and development to be conducted to
improve:
–Speed
–Quality
–Cost
–Size of parts
•Obviously an interesting technology from an environment
point of view
• Need to be taken into account at design stage for optimal
results 34
Conclusion

35. G-SCOP, Laboratory for Sciences of
Design, Optimization and Production
46 Avenue Félix Viallet
Grenoble, F-38031, France
www.g-scop.grenoble-inp.fr/
•Thank you for your attention !!!
•For more information:
•[email protected]
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