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FormUp 350

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Ready-for-Flight Antenna in Powder Bed Fusion

Thales Alenia Space is a french aerospace manufacturer that has played a significant role in space exploration for more than 40 years. As new technologies usher in the new era of space exploration, reducing overall lead time and increasing throughput becomes especially important in staying competitive in the growing market. Learn how Thales used the FormUp 350 and aluminum AS7 to achieve their additive manufacturing goals in this case study.

INDUSTRY

Space

CHALLENGE

Design and build a monolithic antenna using additive manufacturing that meets ECSS qualifications and supports the customer’s goal of achieving TRL 3 maturity for additively manufactured antennas.

KEY BENEFITS
  • Global distortions of the antenna: ±0.3mm
  • Reduced weight: less 600 gr
  • Production rate: 1 antenna /day /machine
  • Reduced post-processing
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Reduced lead time
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Creative Shape
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Printed in One Piece
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Thin Walls

History

Typically, Thales Alenia Space manufactures this type of antenna in multiple parts. Then, each piece is bonded or bolted together in complex and time-costly steps. While making precise components is not so difficult, assembling them into a precise antenna is time-consuming and has major impacts on global lead time and throughput for serial production. This is why Thales turned to additive manufacturing as a solution.

Challenge

Develop a 325mm diameter antenna with a 1mm wall thickness through additive manufacturing, ensuring minimal distortions and a surface finish that meets ‘ready-to-fly’ standards without requiring post-processing. By meeting these standards, TAS will be positioned to achieve a Technology Readiness Level (TRL) 3 for additive manufactured Cassegrain antennas.

Solution

AddUp worked closely with Thales Alenia Space to provide a counter-deformed simulation.

First a lightweight design was generated around initial specifications: main and sub reflectors surfaces, available design space, interfaces localization. Next, an isogrid structure was designed at the back of the main reflector to add stiffness to the system. Then a numerical simulation was done to anticipate the distortions of the antenna during the production.

Finally, a counter-deformed file is obtained from the initial simulation. The goal is to adapt the original design in the opposite direction of the simulated distortions. During the production, the distortions due to the internal constraints and the counter-deformed design cancel each other, keeping the real part as close as possible to the original design.

In order to get the best surface finish, requiring minimal post-processing, AddUp and Thales Alenia Space used their ECSS-qualified recipe on the FormUp 350, in aluminum AS7.

The performance of this recipe, coupled with the machine’s full-field 4 lasers, also enable high productivity. Series production simulations carried out by AddUp show a production rate of more than 2 antennas per day per machine.

Results

The final design achieved a lightweight antenna, weighing just 385 grams. The isogrid structure was meticulously optimized to minimize weight by varying the sizes around the reflector, thereby reinforcing only the necessary areas. The connecting arms between the main reflector and the sub-reflector were engineered and designed to minimize coupling effects in near field, optimizing overall antenna far field radiated performances. The distortions were successfully minimized, with a deviation of ±0.3mm over 90% of the antenna, which was well-received by both parties involved. Additionally, the global surface finish and roughness met the target of Ra 6.3 for both reflectors, achieving a completely satisfactory result.

Learn about Thales 3D Morocco’s FormUp 350 ECSS Qualification here.

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Discover how Michelin produces over one million tire sipes a year for their production molds using metal 3D printing

When Michelin found that the metal AM machines on the market did not meet their high-quality requirements for tire sipe production, they partnered with Fives to create a machine that met these requirements. Learn about the history of tire sipes, the challenges Michelin faced, and the solutions that resulted.

INDUSTRY

Automotive

CHALLENGE

Traditional manufacturing of tire sipes is costly and time consuming.

KEY BENEFITS
  • Limitless personalization options
  • Manufactured and replaced on demand
  • Significant weight and material waste reductions
  • Minimal post processing
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Creative Shape
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Lead Time
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Weight
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Performance

History

Siping was invented in 1923 by John F. Sipe, as a means to provide better traction on the bottom of their shoes. The process was not largely applied to tires until the 1950s as a means to improve traction. One of the technological innovations of the 2000s was the arrival of metal 3d printed sipes. Sipes for tires are designed to heavily improve road holding on wet or wintery roads, while still allowing the rubber to remain rigid, and maintain these levels of rigidity when the tire is new or worn. The shape and size of the sipes directly affect the tire’s noise pattern and traction characteristics. Using Additive manufacturing to create metal-printed sipes opened a new world of possibilities.

Challenges

Conventional manufacturing and installation of tire mold inserts involve a light metal casting of an aluminum-silicon alloy, which allows for rapid heat removal, shortening production time. Tire mold segments are made by casting or milling with finishing carried out manually. Broad sipes can be inserted into the mold segments, but narrow inserts less than 3mm are not easy to work with due to the hardness characteristics of the alloy. Steel sipes are used as inserts in their stead, made by stamping and cold bending; a major cost and time element of the process.

SOLUTIONS

Michelin has been utilizing AM since the early 2000s to manufacture tire sipes used within their tire molds. After years of using AM technology, Michelin found that the metal AM machines on the market simply did not meet their high-quality requirements for serial production. So, they partnered with another industrial manufacturing powerhouse, Fives, and sought to develop a Laser Powder Bed Fusion (L-PBF) machine that could build tire mold inserts and industrial parts with quality, accuracy, and repeatability. From this collaboration, AddUp was formed and the FormUp® 350 PBF machine was created.

AddUp’s high-precision, fully digitalized, and highly flexible process allows Michelin to produce the complex forms required to make molds and sipes for its tires. Critically important features to Michelin’s tire sipes:

  • resolution down to 0.2mm features
  • shallow overhangs as low as 15 degrees
  • surface finish as low as 4 Ra μm, as printed

The FormUp®350 is built to use extremely fine powders (5-25μm). This coupled with a roller recoating system enables support-free production and superior surface finishes. For Michelin, sipes can be manufactured and replaced on demand with minimal post-processing needed. This technique not only provides a quick assembly, but also provides weight savings, reduces raw material wastage, and provides limitless personalization opportunities.

Results

Today, Michelin produces over one million tire sipes a year for their production molds using AddUp’s FormUp® 350. Lead designers continue to create increasingly sophisticated sipe shapes to improve traction for wet and snowy conditions. For example, a winter tire mold can contain up to 3,000 sipes and over 200 different sipe designs! AddUp’s FormUp Powder Bed Fusion technology stands up to the task and can produce these sipe shapes efficiently and to the highest quality standards.

By completely transforming the processes used to produce parts, metal additive is changing manufacturing as a whole. Now there is no longer any need to go through several preliminary steps or assemble different components to obtain the desired part, instead, the final product can be produced in a single step. Digital files are the only information needed to reproduce the exact same part, and parts can be modified at any time to make the process more flexible than ever before.

Learn more about how Michelin is using Additive Manufacturing:

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AddUp optimized the design of a rocket nozzle to improve the performance of a micro-launch vehicle.

Metal additive manufacturing can lead to fuel and production savings in aerospace. In this case study, you will see how AddUp optimized the design of a rocket nozzle to improve the performance of a micro-launch vehicle. 3D printing is already the future of the aerospace industry. Read the case study about an optimized design of a 3D printed rocket nozzle.

INDUSTRY

Aerospace

CHALLENGE

To print an innovative rocket nozzle to optimize engine performance in space

KEY BENEFITS
  • Mass reduction
  • Printed parts with complex geometries
  • Resistance to high temperatures
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Mass Reduction
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Creative Shape
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Function Integration
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Performance

History: AddUp & Aerospace

In the aerospace industry, new design freedom that comes with additive manufacturing allows for lighter parts, leading to fuel savings. Customization opportunities and absence of tooling are also seen as an advantage in this industry, where production volumes are quite low. Aerospace experts believe that the performance gains and reduced production costs will lead to 3D printing taking over as the manufacturing method of choice in the industry.

One of the leading trends in the field of space transportation is the rise of smaller launchers, able to send payloads of less than 500 kg into orbit. It is one of the most promising aspects of the New Space: micro and mini launchers provide flexibility and responsiveness that make them a complementary solution to conventional launchers.

Challenges of printing innovative rocket nozzles

A nozzle is a component of a rocket responsible for producing thrust. Hot exhaust gases are accelerated from the combustion chamber through a tighter throat, then expanded out the exit. This process converts the energy in the combustion gases into kinetic energy.

The complete development of an orbital launcher engine is a long and complex process requiring several iterations of design, manufacturing, and static firing tests. This presents a demanding task from the project management side.

With the field of micro and mini launchers becoming such a competitive environment, rapid iteration is both a technological and commercial necessity.

Considering technical challenges: the high temperature inside a nozzle requires cooling the walls as close as possible to the heat source, to avoid any components melting. This cooling is usually done via tubes attached to the nozzle and becomes more complex when the nozzle is more compact to meet the propulsion needs of smaller launchers.

Solution for a 3D printed rocket nozzle

In rocket engine nozzles, the exhaust gases heat up to approximately 3000°C. During the design of the nozzle, it was important to keep in mind that any available alloys wouldn’t hold up when exposed to such high temperatures.

All the cooling functions where integrated into the nozzle, allowing it to conduct the hot gases while maintaining its shape and performance. Prior to combustion, the fuel acts as a coolant. The propellants are stored at low temperature and run through the internal channels of the nozzle before being captured and injected into the combustion chamber to be burned.

Results and benefits of additive manufacturing

The part was printed on a PBF (laser – powder bed fusion) machine, AddUp’s FormUp® 350. This system, with open parameters and an integrated powder recycling module promotes rapid iterations, reducing the time between builds by making build file preparation quick and easy. The several recoating systems (roller, brush, and silicon wiper) allow for minimal design constraints and a wide selection of metal powders. These advantages are crucial in the development of nozzles and other rocket components.

CAD-rocket-nozzle
Rocket-nozzle

  • Metal additive manufacturing made it possible to create complex, integrated cooling channels; something impossible with conventional techniques on small engines. This nozzle, which normally requires months of work with traditional welding methods, took only 49 hours to produce. The experts at AddUp chose to use Inconel® 718 to print this new nozzle. This material has excellent mechanical properties and can withstand very high temperatures.

    Rocket engine designers can now iterate faster to improve the nozzle shape, running more tests in a smaller timeframe. Engineers can also take advantage of the new design freedom brought about by additive manufacturing, enabling them to push further to optimize engine performance.

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This case study presents the development of multi-metal, multi-technology piston head The goal was to improve wear resistance and performance, as well as internal cooling channels.

INDUSTRY

Automotive

CHALLENGE

Utilize two different Additive Manufacturing technologies and materials to create a single part.

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NO SUPPORTS
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PERFORMANCE
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MASS REDUCTION

History

Pistons are traditionally manufactured using casting, where molten metal is poured into a mold and allowed to solidify. The piston will then go through machining operations such as milling, boring, and honing to achieve the precise dimensions and surface finish required for its use in an engine.

Challenges

Traditional piston manufacturing faces several challenges, including material selection, precision machining, waste generation, and energy consumption. Selecting the right material for durability and heat resistance is crucial. Achieving the needed dimensions through machining can be costly and time-consuming, leading to tool wear and maintenance issues. These processes also generate waste and have environmental impacts, making them less sustainable. Meeting cost and lead time constraints can be a significant challenge for traditional piston manufacturing.

Solution

A potential solution to address the challenges associated with piston manufacturing and performance is to adopt new manufacturing techniques. Additive manufacturing allows for intricate and customized piston designs with internal cooling channels, reduced waste, and improved efficiency. It can also enable the use of different materials and complex geometries not easily achievable through conventional manufacturing methods.  AddUp has created a concept part using both Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) to show the value and benefits Additive can bring to the manufacturing industry and using the right tools for the right job.  

Results

The piston was printed in two stages. The first stage used Powder Bed Fusion and the FormUp 350 to print the core of the piston. No supports were used during the entire printing process.

 

Lattice was added into the geometry to provide an overall lighter weight structure. Reducing the mass can lower stress on engine components, putting less stress on other engine components like the connecting rods and crankshaft. Fuel efficiency is also enhanced by reducing the mass the engine needs to move, leading to better mileage. Internal channels were added to increase the performance and improve heat dissipation, lowering the piston’s temperature, expansion, and emissions. These channels are essential for managing heat and ensuring the reliability, durability, and performance of internal combustion engines.

 

After the core of the piston was complete, the next stage was to deposit wear resistant ring grooves with Directed Energy Deposition. While the full part could have been printed fully in PBF, it would require support material on the rings. Without the use of supports and the need for powder bed recoating, DED was able to reduce both the print and post processing time required by depositing only the amount of material needed for the rings directly onto the base.

DED was able to deposit a second material with the ability to provide enhanced wear resistance and heat dissipation properties in the piston ring grooves. Not only can DED be used to add high performance material, but can also allow for the repair of piston ring grooves in damaged engine blocks by restoring the grooves to their original dimensions.

Watch the video showing the real piston in Powder Bed Fusion and Directed Energy Deposition here:

  • Internal cooling channels

  • Improved wear resistance and performance

  • Features added to existing part

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This case study presents the development of an optimized heat exchanger for the Form Up® 350 machine. The goal was to improve heat dissipation and adapt the dimensions for easy installation.

INDUSTRY

Aerospace

CHALLENGE

To reduce production costs and lower lead time while optimizing neat dissipation for a neat exchanger.

KEY BENEFITS
  • 64% reduction in size
  • Weight of the part divided by 6
  • Simplified installation
  • Reduced production costs and time
  • Enhanced reliability with monobloc design
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CREATIVE SHAPE
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INTERNAL CHANNEL
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MASS REDUCTION
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PERFORMANCE

History

The project to produce a heat exchanger for the FormUp® 350 machine arose from the desire to take advantage of the know-how developed by PrintSky, a joint venture created by AddUp, a manufacturer of metal 3D printing machines, and Sogéclair, a supplier of innovative solutions for cleaner, safer mobility. The aim was to assess the benefits of an optimized additive manufacturing solution by comparing it with the current system, produced by conventional methods.

The part chosen for this application is the cooler for the fusion fume exhaust stream. In an L-PBF machine, such as AddUp’s FormUp 350, an inert gas flow passes through the manufacturing chamber, evacuating the fumes generated during melting. This gas flow, which circulates in a closed circuit at high speed (several meters per second), requires an efficient cooling system.

Challenges

One of the main constraints of the project was to keep the production cost of the exchanger lower than or equivalent to the conventional solution while optimizing its performance to improve heat dissipation and adapting its dimensions to simplify installation in machines.

For this innovative project, the AddUp’s engineers started from scratch. They defined the level of performance to be achieved to design a heat exchanger that perfectly met the needs of the application, without conforming to market standards. The internal channels, fins and interfaces have been customized to optimize the compactness and the part performance.

Designers drew on PrintSky’s core competencies to optimize geometry, footprint, and production times (using high-productivity recipes). Internal channels, fins, and interfaces were customized to optimize part compactness while ensuring enhanced performance. All this was achieved by inte-grating AddUp’s experience in heat exchanger manufacturing.

Solution

AddUp and Printsky’s designers chose to optimize the exchanger’s geometry and footprint, as well as manufacturing times. To achieve this, they used high-productivity recipes and incorporated AddUp’s experience in the field of heat exchangers into each of their design choices. The shapes of the cooling fins, for example, were designed to facilitate the removal of unfused powder. This innovative exchanger and its connectors were designed in CATIA, and cooling was simulated using Altair software. The whole unit was designed to be printed in a single piece, thus reducing the assembly times compared with traditional mechanically welded exchangers.

Results

This new heat exchanger, optimized in terms of heat dissipation and pressure loss reduction thanks to Printsky’s in-house tools and expertise, offers a 64% gain in volume over the previous system, with its mass divided by six. The choice of aluminum has resulted in a compact yet efficient solution, adapted to all the constraints imposed by the FormUp 350 machine environment, at a price equivalent to a conventional solution.

Today, the cooler is in the final stages of industrialization and will be put through its paces in trials to assess its actual performance on the additive manufacturing machine. A final optimization phase is planned to adjust geometries and manufacturing choices based on these tests.

Designed in aluminum, a material that is both light and a good thermal conductor, the compact exchanger efficiently cools the hot gases from FormUp 350.

  • 64% smaller footprint.

  • Mass divided by 6.

  • Equivalent price.

  • Enhanced reliability with monobloc design.

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The goal is to demonstrate an interest in the PBF technology to create heat exchangers with improved compactness, good thermal performance, and metal 3D printed in one go.

Answering the aerospace industry’s issues on thermal gear through the Powder Bed Fusion technology (PBF process) is what Temisth and PrintSky – the AddUp SOGECLAIRE Joint-Venture – propose under a partnership with the European Space Agency. In this study, the aim was to meet the needs of the space industry. The part was produced in aluminum on a FormUp 350 machine provided by AddUp.

OBJECTIVE

Develop a heat exchanger using the full potential of PBF process

RESULTS
  • Good thermal performance for a smaller volume compared to “conventional“ exchangers
  • Printed all at once
DIMENSIONS
  • 116x116x60 mm Mass: 244 g Heat exchanging power: 2,3 kW (simulated result)

Context

PrintSky is a joint venture between AddUp group, an expert in metal additive manufacturing, and SOGECLAIR, specializing in the integration of high-value-added solutions in the fields of aeronautics, space, civilian and military transport. Temisth is specialized in the development of custom thermal solutions customized using additive manufacturing. The goal for PrintSky and Temisth was to demonstrate their interest in the PBF (Powder bed fusion – laser) technology to create heat exchangers with improved compactness.

The part from above

Used Means

Printsky has developed its own methodology for dimensioning heat exchangers to the given characteristics. In this example, the aim was to meet the needs of the space industry. The part was produced in aluminum on a FormUp 350 machine provided by AddUp.

Advantages of Metal 3D Printing

Metal additive manufacturing is relevant for thermal equipment. It allows for the creation of channels with complex shapes, thus improving thermal performance while reducing the volume. This heat exchanger has thin walls (250 μm) and double curvature channels that are impossible to produce by conventional techniques. The tests carried out on a test bench allowed us to validate the leak tightness of the part, as well as its performance, very high considering the compactness of the exchanger. PrintSky has obtained a partnership agreement with the ESA (European Space Agency) for the development of this aluminum part.

The AddUp Advantage

Metal powder in fine particle size, used here on the FormUp machine, allows surface conditions adapted to heat exchanges.

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