Parts of Powder and Light - Fraunhofer Allianz Generative Fertigung

12
Rapid Prototyping
FUTUR 1–3/2010 13
Parts of Powder and Light
Over the past few decades, development of Generative Manufac-
Human-machine interface
Exposure of part contour
Complete assembly of a part layer
turing Techniques has made enormous strides. Originally applied to
Rapid Prototyping (RP) for the fabrication of functional and technical prototypes, their area of application has been vastly extended
by the introduction of Rapid Tooling and Rapid Manufacturing. The
The following SML processing runs in
►►Individualized Products
►►Potentials and Perspectives
range of substances they work with has also been broadened so that
three phases which repeat in cycles until
With SLM development goals that once
Even though there have been significant
»The range of substances SLM works
nowadays, apart from the ubiquitous synthetics found in the RP area,
the part is fully assembled. In the first
seemed far off and difficult to reach – such
advances in the surface quality of the
with has been broadened so that now­
standard metallic materials such as stainless and tool steels or alloys
phase the substrate plate is lowered by a
as replacement of expensive cumbersome
generated structures over the past few
adays standard metallic materials such
of titanium, aluminum, cobalt, chrome and nickel or even ceramics
preset thickness usually of between
tools by digital manufacturing; produc-
years, there is still a great deal of room
as tool steels or alloys of titanium can
can be processed. To engineer metallic parts that require no form of
10 and 60 μm. In the second phase a
tion of integrated functional parts; or the
for further improvement. For instance,
be processed.«
binding or other additives, in 2002 the Fraunhofer Institute for Laser
coating mechanism evenly distributes a
switch-over from serial mass production to
if surface roughness is not calibrated to
Technology (ILT) developed the »Selective Laser Melting Technique«.
layer of metal powder over the substrate
mass production of customized individual
allow for a better bonding of implants, it
Processing materials which are hard to
Fraunhofer IPK took this technology on board in its new »Generative
plate, while the third phase uses a laser
products – are now within easy reaching
now needs to be corrected using molding
machine are required in a wide range of ap-
Technologies« field of expertise and is now developing it still further
beam to completely fuse the powder layer.
distance. Particularly in areas which need
or milling techniques. To meet the increas-
plication fields, e.g. for die and tool making
in a series of targeted parameter studies.
The laser does not only completely weld
small parts in minimal series of batches,
ingly stringent requirements placed on
or for producing certain medical products.
the applied powder layer, but also partly
SLM technology is now a compelling
parts, their roughness, and their geometri-
Common manufacturing techniques experi-
►►Selective Laser Melting
welds the solid material layers beneath it.
alternative. Metallic underparts of dental
cal and dimensional stability need to be
ence extensive wear when working with
Selective laser melting (SLM) is an additive
In terms of set process parameters, the
crowns can be fabricated within a mere
increased while their degrees of warping
such materials. Selective Laser Melting is a
manufacturing process that uses 3D CAD
layer thus produced by metallurgic weld-
48 hours using SLM technology. In com-
and residual stress must be reduced.
promising technology for the required tasks,
data as a digital information source. In the
ing shows a relative thickness of almost
parison to the traditional process chain
next stage of process preparation (»slicing«)
100 percent. Both the physical and me-
with its complicated precision casting
Scientists at Fraunhofer IPK began
production series.
special software cuts the parts model into
chanical characteristics of parts produced
and lost moulds, this offers time savings
researching this technique in early 2010
Electrical Discharge Machining could be an-
superimposed layers of defined thickness.
by this method are the same as in their
of no less than five days. On top of this,
using MTT’s SLM 250HL selective laser
other solution. It produces contours of high
the enormous freedom of scope offered
melting machine. This unit has the most
geometrical complexity, form accuracy and
by the technology enables fabrication of
powerful laser now on the SLM market
surface quality. What’s more, this technique
constructs that would not be possible
and can bring up to 400 watt intensity to
can also be applied to electroconductive
with standard methods of manufacturing.
bear on its focus level. Engineers use this
materials no matter what their mechanical
Hollow cavities, undercuts and complex
machine to conduct parameter studies
material properties.
inner geometries such as close-contoured
with a view to reducing component warp-
cooling channels and intermeshed support
ing and residual stress in generated parts,
The final stage of data preparation
(»hatching«) involves cutting of each
layer into individual laser
­vectors.
counterparts produced by traditional casting which makes
the process suitable for serial
­production.
structures can all be fabricated using
Generative Manufacturing techniques.
but it is also predestined for small scale
Read more on p. 18
but also to enable targeted programming
of specific materials and characteristics
for parts. Another research focus is on
the qualification of new materials for the
SLM process. Parts will be built from these
Most diverse parts can be manufac-
materials and their quality then validated
tured in one SLM process.
in implementation studies.
Your contact
Dipl.-Ing. (FH) Kamilla Urban
Phone: +49 30 39006-107
E-Mail: [email protected]
Kurzprofil
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Sichere Identität
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Fraunhofer-Allianzen
AdvanCer
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und Schneidstoffe
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der Schulenburg
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Mehr Können –
Veranstaltungen 2011
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Modellierung technologischer und
logistischer Prozesse in Forschung
und Lehre
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PDM/PLM
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Rapid Prototyping
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Simulation
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