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This article discusses the importance of powder handling in Laser Powder Bed Fusion (LPBF) technology and introduces AddUp’s Autonomous Powder Module (APM) as a comprehensive closed-loop solution.

Written by: Mark Huffman, Application Engineer – Aerospace & Defense 

Laser Powder Bed Fusion (LPBF) technology has revolutionized the manufacturing industry by allowing the production of complex geometries with high precision and accuracy. LPBF technology involves the melting and solidification of metallic powder through the use of a high-powered laser beam, which fuses the powder particles layer by layer to create the desired part. However, the quality and reliability of the final part heavily depends on the quality of the powder used and how it is handled.

Powder handling is a critical aspect of the LPBF process that involves the transportation, storage, and handling of metallic powder. The quality of the powder can be affected by various factors such as humidity, temperature, particle size, and the presence of contaminants. The following are some of the reasons why powder handling is important when using LPBF technology:

The Problem

Quality Control

The quality of the powder used in the LPBF process has a significant impact on the final part’s quality and reliability. Therefore, proper powder handling procedures must be implemented to ensure that the powder is of the required quality. This includes proper storage conditions, such as temperature and humidity control, as well as regular inspection and testing to ensure that the powder is still meets your powder specification for PSD, chemistry and morphology that could affect the final part’s properties.

Process Control 

Proper powder handling also ensures that the LPBF process is consistent and repeatable. Inconsistent powder quality can result in variations in the melting and solidification process, leading to defects in the final part. Therefore, it is essential to implement powder handling procedures that ensure the powder is homogeneous, and the particle size distribution is within the required range.

Safety 

Metallic powders used in the LPBF process can be hazardous if not handled properly. Some powders are flammable, explosive, or can cause respiratory problems if inhaled. Proper handling procedures such as using personal protective equipment, good ventilation, and ensuring the powder is grounded can minimize the risks associated with handling metallic powders.

Cost

The cost of metallic powder used in the LPBF process is relatively high. Proper powder handling procedures can help minimize powder waste and ensure that the powder is used efficiently. This includes proper transportation, storage, and dispensing of the powder to reduce spills and contamination.

Powder handling procedures ensure that the quality of the powder is maintained, the LPBF process is consistent and repeatable, safety is prioritized, and costs are minimized. Continually implementing powder handling procedures, technology, and equipment that adhere to industry standards is essential to ensure that the LPBF process is optimized, resulting in high-quality and reliable parts.

The Solution 

AddUp’s Autonomous Powder Module (APM) is a game-changer in the LPBF process, providing several advantages over traditional powder handling methods. The APM has several capabilities that make it an ideal powder handling solution for LPBF technology.

Ensure Quality 

AddUp has designed the APM with quality in mind through Powder Reuse according to the ASTM F3456-22 standard which focuses on Traceability, Sieving, Powder Storage, and Used Powder criteria. The batch number traceability feature in the AddUp Manager Software allows for easy tracking and monitoring of the powder used, ensuring that the quality of the powder is maintained. The APM automatically sieves and regenerates the powder, ensuring that the powder is of the required quality, and reducing the need for manual intervention.

Maintain Process Control

The APM enables powder filling during production, which eliminates the need for operators to stop production to add powder, reducing downtime and increasing productivity. The APM fluidizes the powder, making it less cohesive, which improves the flowability of the powder during the LPBF process, ensuring that the powder is evenly distributed. The APM’s loss of powder traceability feature ensures that the powder is always tracked, minimizing the risk of loss or misplacement.

Increase Safety 

Complete inerting of the APM for powder storage, conveying, and handling with the use of a glove box during the loading and unloading of the powder, ensures that the powder is not exposed to the environment or to operators. The APM’s powder sample device allows for easy sampling of the powder at any time through the glove box, minimizing the risk of exposure to reactive powders. The APM’s automatic cycles for circuit purge and emptying ensure that the powder handling system is always clean, which also reduces the risk of contamination and exposure.

Minimize Cost 

The APM’s powder handling system allows for one-time filling, minimizing powder waste and ensuring that the powder is used efficiently. The APM’s closed-loop system ensures that excess powder is automatically recovered during production and regeneration, minimizing powder waste, and reducing costs of powder inventory. Additional cost savings are also possible through the elimination of the tracking powder quantities for builds in progress. The APM’s vacuum system eliminates the need for a separate device for vacuuming at the end of the production, reducing costs and increasing efficiency. The APM’s stocking coefficient of 1.4 ensures that the powder is stored efficiently, reducing storage space requirements and costs.

Overall, the APM provides a streamlined and efficient powder handling solution, improving the quality, cost-effectiveness, safety, and productivity of LPBF technology.

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The interview with Zeda’s Director of Additive Technologies highlights how the flexibility of the FormUp 350 platform helps develop challenging applications and maximize productivity. The AddUp partnership is driven by a shared goal of large-scale part production and a commitment to open collaboration.

As the AddUp and Zeda partnership continues to grow, we get insight from Zeda’s Director of Additive Technologies, Rachel Levine, on how the flexibility of the FormUp 350 helps her develop challenging applications and maximize productivity.

1. Why are you passionate about additive?

In my junior year of college I took a class called Rapid Prototyping. From that moment on, I was hooked. Up until that point, I thought I was going to join the toy industry after graduating, as I’d already begun pursuing that career with a co-op the semester before. Once I saw the potential that Additive held, I couldn’t go back to an industry that relied on older, established technologies. My favorite thing about Additive is that there are still so many unexplored applications… there are still new frontiers that only a handful of people in the world truly have the knowledge, resources, and skill to explore.

2. What excites you about the AddUp partnership and FormUp 350 platform?

This partnership feels novel in a lot of ways. Our teams have been working together now for almost a year, and rarely have I had the pleasure of working with another company that is truly willing to engage in a partnership that works towards a greater goal. Too often partnerships are constrained by mistrust and an unwillingness to share information, but the Addup team has really committed to the partnership with open minds and a shared goal to drive towards large scale part production. Not to mention the FormUp opens the door to productivity improvements with its quad laser setup, open parameters, and long life filter.

3. How does AddUp Manager’s open parameters help Zeda engineers achieve their goals?

The right parameters make all the difference when it comes to productivity, buildability, quality, and material properties. Zeda understands that high volume, fine-featured medical production may require different parameters than large space parts because they need to be optimized for different requirements. The ability to edit parameters for lattice or other specialized features is something we hope to leverage going forward. Of course, all parameters must be validated and qualified against the needs of the product; a process that we are well versed in.

4. How does the FormUp350 differ from other platforms on the market?

FormUp350 is one of the only machines on the market that can run both the typical LPBF powder cut and a much finer cut of powder. This gives us flexibility to meet certain challenging applications we may come across in the future. I’ve also recently been given a sneak peek of some future developments that make me even more excited about our partnership and the benefits we will be able to bring to our customers.

5. How does the FormUp’s 350×350 platform and 4-lasers unlock applications for Zeda customers?

As a contract manufacturer, we see a wide variety of parts. For small parts, AddUp’s full-field overlap quad laser system allows us to improve productivity. The size of the platform allows us to reach a wider range of larger parts.

6. How significant is powder management to the overall process?

Without powder reuse, Additive becomes cost prohibitive for almost all industries. With proper validation and quality monitoring, AddUp’s internal powder loop allows us to move towards infinite reuse. The validation of powder life within AddUp’s internal system is a key project Zeda will be engaging in with AddUp.

7. How does the FormUp’s Autonomous Powder Module change this for Zeda?

Powder reuse becomes somewhat of a nightmare to track once powder leaves a system where it can then be accidentally exposed to moisture or contaminated equipment. For alloys such as Titanium, the offline powder movement and sieving process can also be dangerous. FormUp’s internal, inert system removes the common contamination risks as well as the exposure and explosion risk to the operator.

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AddUp & Zeda Partnership: Interview with Rush LaSelle, AddUp CEO

The partnership between AddUp and Zeda is set to benefit key industries such as aerospace and medical sectors. With Zeda’s expertise in additive manufacturing (AM) and AddUp’s advanced FormUp350 print system, customers will have access to expanded capabilities, reduced costs, and improved manufacturing efficiency.

After the news of such a major deployment of FormUp 350 Powder Bed Fusion machines to Zeda, we wanted to sit down with AddUp CEO, Rush LaSelle to get his take on what this partnership means for AddUp, Zeda, and key AM industries moving forward.

Who is Zeda?

Rush LaSelle, AddUp CEO

Zeda is a leading technology solutions provider with the objective to better lives by investing in cutting-edge technologies, innovative companies, and groundbreaking ideas. The company’s foundation combines expertise from diverse industries, including AM, nanotech, precision manufacturing, and incubating new ideas. Greg Morris and the ZEDA team bring the experience of being the first to use metal additive, specifically Laser Powder Bed Fusion (LPBF), to revolutionize the way aircraft propulsion systems are designed and serviced today. The founding teams have expanded the use of additive to unlock an increasing number of applications within the aerospace and to accelerate the qualification of medical devices helping to improve patient outcomes.

What key industries will benefit from this partnership?

The key industries of focus will be the aerospace and medical sectors. The AM market within the medical industry was valued at $1.5 billion in 2020 and is expected to reach $3.7 billion by 2025, growing at a CAGR of 20.5%, according to a report by Research and Markets. The global aerospace AM market was valued at $0.9 billion and is expected to reach $3.3 billion by 2026, growing at a CAGR of 21.6%, according to the same report. With this industry progression and projected market growth in mind, we are excited about our partnership with Zeda, a company that specializes in these sectors.

How will AddUp help support the growth of AM in the medical and aerospace sectors through this partnership with Zeda?

For Zeda customers, adding the AddUp FormUp350 print system to their stable additive equipment expands their capabilities and reduces the cost to deliver metal components. Initial applications will focus on the use of Titanium, Inconel, Aluminum, and Stainless Steel. Leveraging the FormUp 350’s four lasers, novel recoating strategy & monitoring systems reduce processing time during printing, delivers improved fine features & internal channels all while providing industry-leading surface finishes. These benefits reduce the need for support structures and reduce secondary processing costs and time. These features together will lead to a more efficient process for manufacturing AM parts for Zeda’s customers.

Our commitment to safer, cleaner, and more efficient manufacturing provides a foundation from which to realize design freedom and accelerated time-to-market with true industrial compliance. AddUp endeavors to deliver positive manufacturing outcomes using proven additive metal technologies forged by the uncompromising quality demanded by the factory floors upon which our company is built.

What does this partnership mean for AddUp customers?

For AddUp customers, the partnership affords immediate access to not only qualified FormUp printers for medical (13485) and aerospace (AS9100) within Zeda’s 75,000 square feet of manufacturing space in Cincinnati, OH, but offers a broad range of processes that envelope the printing process. These include; design support, simulation, cleaning, post processes, heat treatment and the requisite quality systems and traceability for the most demanding applications. With Zeda’s successful track record of serving regulated markets and the largest aerospace and medical customers in the world, companies can trust that they will get to market quickly and cost-effectively.

Greg Morris, CTO of ZEDA and Rush LaSelle, CEO of AddUp standing next to a FormUp350 system at ZEDA’s 75,000 square foot facility in Cincinnati, OH.

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Quality, safety, productivity, traceability — these are crucial criteria for the medical industry, especially when manufacturing surgical implants via metal 3D printing. In this field, AddUp’s FormUp® 350 machine offers numerous advantages, addressing these vital needs effectively.

Read this blog to learn more about the diverse applications of Additive Manufacturing (AM) in the medical industry, focusing on how these criteria are met and surpassed in the production of surgical implants.

FormUp® 350

The market for surgical implants and patient-specific solutions is undergoing major changes. Manufacturers in this sector are seeking to provide doctors with more efficient and personalized devices, at costs acceptable to patients, while complying with particularly strict requirements for certification. New generations of 3D printers are achieving high levels of productivity/ quality and can produce parts in biocompatible materials like titanium. The new and improved printers allow implant manufacturers to consider the migration to metal additive manufacturing for many applications.

Diverse Applications of AM in Medical Procedures

Innovative Use in Prosthetics and Orthopedics:

Additive Manufacturing (AM) is revolutionizing the field of prosthetics and orthopedics. With the ability to create highly customized and complex structures, AM is being used to produce prosthetic limbs that are tailored to the individual needs of patients, enhancing comfort and functionality. Similarly, in orthopedics, AM is used to manufacture implants such as knee and hip joints, which are designed to mimic the natural movement of human joints more closely.

Dental Applications:

In the dental sector, AM is making significant strides. From crowns and bridges to orthodontic devices, 3D printing allows for rapid production and customization. This not only speeds up the dental restoration process but also increases the comfort and fit for patients.

Surgical Planning and Anatomical Models:

Surgeons are increasingly turning to 3D-printed anatomical models for pre-surgical planning. These models, created from patient-specific imaging data, allow surgeons to plan and practice complex procedures, thereby reducing surgery times and improving patient outcomes.

Bioprinting and Tissue Engineering:

A frontier area in AM is bioprinting, where living cells are printed to create tissue-like structures. This technology holds the promise for future applications like organ transplants and skin grafts for burn victims.

Customization and Personalization in Patient Care


Tailored Solutions for Improved Outcomes:

The ability of AM to produce customized medical devices is one of its most significant advantages. Custom-fit implants and prosthetics not only improve the comfort for patients but also reduce the risk of complications and improve recovery times.

Patient-Specific Implants:

With AM, implants are no longer one-size-fits-all. They can be designed to match the exact anatomical features of individual patients. This is particularly beneficial in complex cases where standard implants may not be suitable.

Personalized Surgical Instruments:

AM also allows for the creation of surgical tools that are specifically designed for individual surgeries or patients. This can lead to more precise and efficient surgical procedures.

Enhancing Patient Experience:

The customization capabilities of AM extend beyond physical devices to the overall patient experience. Take prosthetics, for example. They can be customized to do more than just fit perfectly; they can also be designed to match the patient’s unique style and personal preferences, adding a touch of individuality to each piece.

Future of Personalized Medicine:

As additive manufacturing technology advances, it’s opening the doors to an exciting new phase in personalized medicine. This means treatments and medical devices are crafted specifically for each individual, enhancing the effectiveness of healthcare and making it more centered around the patient’s unique needs

What is a machine designed for the medical sector?

The FormUp® 350 machine offers many advantages to meet the expectations of surgical implant manufacturers. Designed and produced by AddUp, a company created by the French groups Michelin and Fives, this 3D machine uses a technology called Laser Powder Bed Fusion (L-PBF). This process is particularly well suited to the production of complex, customized metal parts with high mechanical properties. It is also one of the most mature technologies in the metal 3D printing market. Several manufacturers, including AddUp, offer recipes for the use of biocompatible materials., In the medical implants field, the most common of these materials is a titanium alloy called Ti6Al-4V ELI, also referred to as Grade 23 Titanium.

AddUp’s L-PBF machine, the FormUp® 350, differs significantly from machines on the market in the following ways:

  • Medium or fine powder usage. The flexibility to use metal powders with a small particle size (less than 25 microns) allows the machine to build parts with low roughness surfaces, fine feature details, and “lattice” features that promote osseointegration.
  • The ability to use a variety of powder-spreading devices, including the roller device. The roller device creates a high-density powder bed that is suitable for the manufacture of unsupported parts, which greatly reduces the costs associated with post-processing operations. The roller recoater provides this advantage with both fine and medium powder sizes.
  • Safety is of the utmost importance to AddUp. . Titanium alloys, in powder form, present risks for both equipment and operators. This risk is mitigated in the FormUp® 350 because the powder is always in an inert environment. The FormUp® 350 is the only machine on the market that allows for the supply and recycling of the powder without any contact with the ambient air. This prevents the risk of user exposure while simultaneously and consistently building parts that meet or exceed industry standards.

Beyond these characteristics, AddUp’s LPBF machine exceeds the industry requirements and expectations of OEM’sgiven the demands of productivity, quality, repeatability, and traceability.

Productivity criteria

The FormUp® 350 machine was designed based on Michelin’s early adoption of metal additive manufacturing.  The challenge was not the technology but rather the consistency and throughput in a high-demand manufacturing environment. Developed by a manufacturer for manufacturers, the FormUp® 350 machine has been fine tuned to promote high productivity. One example is the use of large build plates (350 x 350 mm) with a quick loading and leveling system that avoids any loss of useful surface. In addition, four 500-watt lasers are used, each one with the ability to cover the entire surface of the build plate. The advantage for the user is great flexibility in the placement of the parts on the platform and in the assignment of the lasers (one or more based on need) to the parts to be manufactured.

The FormUp® 350 maximizes the portion of the 3D printing process where the lasers are firing and adding material to the parts making it more advantageous in a production setting. The entire process is designed to optimize downtime before the build commences, during the build, and in the post-production steps. The build setup is streamlined with automated build plate leveling and referencing. Inerting times are short as well.  Oxygen levels reach 500 ppm in 15 minutes. During the build itself, the bidirectional powder spreading system is 40% faster than the conventional method. Each of the four lasers works in unison over the entire build area to melt material as efficiently as possible. When the build finishes, the active cooling system kicks in to bring the heated platform down to a suitable temperature. That cooling allows for an earlier start of powder vacuuming, which is performed in the inert chamber through a glovebox. An additional benefit is the ability to supply new powder to the system and powder sample acquisition can happen without interrupting production.

Recoating system

Quality criteria

The AddUp platform possesses several solutions to ensure high-quality production parts, with additional technologies in development. One of the production features currently available is active monitoring systems, and the recoating quality control system.  These work together to analyze the surface condition of the powder bed in real time. Algorithms developed in-house assign a quality score to each new layer of powder. As soon as a defect is detected, for example, an unwanted deposit or a lack of powder, the system can restart a new powder spreading cycle immediately. This solution does not impact productivity, as the analysis is performed in a few tenths of a second. Most importantly, it prevents a whole batch of parts from being scrapped, which is the case when recoating defects are detected after printing. Every corrective action triggered by the machine is tracked and mentioned in the print report generated by the system after production.

Other active technologies include the fume collection system, which avoids possible drifts due to filter clogging thanks to an automatic filter cleaning system, and the Cross Jet device, which ensures the constant cleanliness of the laser windows during production.

AddUp also offers an in-situ solution to track the melting across the build. The system called “Melt Pool Monitoring” measures three essential parameters of the manufacturing process; the variation of the laser position, the variation of the power supplied by the laser, and the temperature of the melt pool. All this data is collected continuously during the printing process and is then mapped and overlaid on the CAD models of the parts. This allows not only to detect the presence of possible defects but also to locate them with great precision.  The location of a pore or defect can be considered to downselect a region of interest for non-destructive evaluation. This tool will also detect defects on support structures, which are often acceptable. In this manner, Melt Pool Monitoring can reduce the cost and lead time of post-process inspection.

Recoating monitoring

Repeatability criteria

Medical manufacturers are faced with severe constraints for the certification of their applications. The processes for certification are difficult to obtain and require manufacturers to control all the manufacturing parameters: they must prove that the process can deliver compliant parts and that the quality will be maintained throughout current and future production.

Among the technologies embedded in the FormUp® 350 that contribute to repeatability are the 3-axis laser scanning systems. Unlike passive systems that distort the focal plane of the laser beam, 3-axis systems are capable of dynamically adjusting the focal length of the beam to guarantee a homogeneous focusing quality and beam shape at any point on the platform, and thus a uniform fusion quality regardless of the position of the part on the build plate.

Another repeatability concern is the powder itself. On AddUp’s platform, the powder management module ensures that the powder is systematically sieved and dried before being sent to the manufacturing chamber, thus avoiding the variations in powder properties that can occur when the powder is stored and transferred through different containers. The module always handles the powder in an inert environment, reducing oxygen pickup as well.

Finally, the roller recoater on the FormUp® 350 is a more robust spreading device than a traditional hard blade or scraper. This means flatter, more consistent powder bed shapes from one production run to another.

Traceability criteria

AddUp Dashboard

Once certification authorities have approved the qualification of an application, implant manufacturers must implement systems to ensure seamless traceability of all parts produced. The PBF process is complex, with many influencing variables that control part quality.

To help manufacturers monitor all the production parameters, AddUp Dashboards offers a real-time solution for all the data production and visualization. More than 80 parameters are tracked, time-stamped, and stored without a time limit in a database. Users can then create custom dashboards, either for machine monitoring, detection, maintenance issues, and analysis of production hazards. They can also compare different identical productions to detect differences between them.

Unlike other systems, AddUp Dashboards also offers access to the specific project file identifier called the GUID (for Globally Unique IDentifier). This 128-bit label, created for every build job, automatically changes upon project edits. It reduces if not eliminates any traceability concerns in the quality process.

These machines have been designed from the very beginning to achieve high levels of productivity and quality, but they have also been improved over the years. Each generation of machine and software addresses previous pain points at every step in the additive manufacturing process. Thanks to the experience acquired in their workshops, AddUp experts use their machines to offer part manufacturing services to their customers in addition to being machine supplier. Today, the FormUp® 350 is used by one of the world’s leading implant manufacturers, which has equipped itself with the FormUp® 350 in production facilities in both Europe and the United States and carries out qualified and large-scale manufacturing.

All in all, the FormUp® 350 platform has inherited the experience of the Michelin group.  The machine has been tested in real-world manufacturing environments for many years.  Mass production of tire mold parts with global efficiency expectations is a solid pedigree that is now being applied to the medical sector.  The quality systems and production expectations for Michelin manufacturing and medical manufacturing are nearly identical. With a focus on quality, consistency, safety, productivity, and repeatability, this platform is easily convertible between industries

»Link to the Michelin Sipes case study

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Interview of WBA and AddUp Managers to explain the background and goals of a joint initiative of creating an AM Tooling Competence Center at the WBA in early 2023.

Original Interview by Martin Ricchiuti of FORM+Werkzeug

The WBA Aachen Toolmaking Academy supports tool and mold makers in developing technological innovations for the industry. AddUp, a joint venture established by Michelin and Fives, is a global OEM of multi-technology production systems and a market leader in additive solutions.

In the FORM+Tool interview with Prof. Wolfgang Boos, Managing Partner of the WBA, and Julien Marcilly, Deputy Chief Executive Officer at AddUp, the background and goals of the joint initiative of an AM Tooling Competence Center at the WBA, which will start in early 2023, are explained will start.

Finding Additive Solutions: Easy Entry to Additive Manufacturing 

AddUp will make its FormUp 350 additive manufacturing system based on the LPBF process available to the WBA. With additive manufacturing, the potential for local tool and mold making is to be tapped, and the process chain is further developed.

With the founding of the AM Tooling Competence Center at the WBA, Julien Marcilly from AddUp (right) and Prof. Wolfgang Boos from the WBA create a competence center for additive manufacturing in tool and mold making. © AddUp

FORM+Tool: Mr. Marcilly, what are the goals of AddUp with the new AM Tooling Competence Center, and what role does AddUp play in the cooperation?

Marcilly: With our AddUp GmbH, founded in April 2022 in Aachen, we are pursuing the strategic goal of opening up the German market for metal 3D printing for us. So it is only logical to enter into a partnership with the WBA. We know that there is comprehensive competence for the needs of tool and mold making, which can make a significant contribution to further advancing acceptance among users and the technology itself. We will install our latest PBF system ‘FormUp 350‘ (Powder Bed Fusion), in a dedicated hall within the WBA’s demonstration tool shop and make it accessible to potential customers. Once the plant is installed, we will place three to four application engineers and plant operators there to accompany interested parties with their first steps with metal 3D printing on our system and on the way to the first required parts with all our know-how. In addition, further developments in PBF technology are to take place on this machine together with the experts from the WBA.

FW: Prof. Boos, is 3D printing a new field of technology for the WBA that you would like to develop with the support of AddUp?

Boos: So far, the focus at the WBA has been on the classic five technologies in toolmaking. However, about four years ago, together with the partners in our toolmaking community, we started to explore the market for 3D printing in a targeted manner for high-potential solutions for the requirements of toolmaking. We were very pleased when, in the context of corona-related digital workshops and discussions with AddUp, it became clear in 2021 that an AM Tooling Competence Center represents a win-win situation for both sides.

Because for the WBA, it is a compellingly logical step to introduce this sixth technology in tool and mold making. If a partner as strong as AddUp enters the community and also agrees to install a corresponding system on which you can not only improve and optimize parts but also the process together with experienced AddUp experts for the benefit of the user, then this is a remarkably successful constellation. We look forward to working closely with you.

FW: You talk about optimizing the PBF technology. What do you mean by that?

Boos: I think it’s essential to develop a feeling for handling the materials and what performance can be achieved with the systems under optimized conditions. At the same time, however, there are also issues, such as digitization, that need to be addressed. What can be implemented as a connection? You have to get to know a lot more about the material and process. We have therefore agreed that, in addition to the two partners, AddUp and WBA, we will also involve the entire community with around 85 companies.

In this way, a much larger number of impulses and ideas come about in terms of powder, process, components, and applications. In this way, requirements are defined that can be specifically tested. This is the ideal start to act together as a problem solver in the AM context.

The ‘FormUp 350’ has up to four 500-watt ytterbium fiber lasers as a beam source and can build up parts with an edge length of up to 350 mm in layers in the cube. © AddUp

FW: The equipment and staff come from AddUp; what does the WBA bring to the cooperation?

Boos: We are also contributing a 3D printing expert from the WBA who has accumulated expertise over the years. However, our focus will be on acquiring components and addressing tool and mold makers. AddUp acts as a partner who supports us in working out the best possible process for the production of all the required components. In addition, with our classic methods, we can complete the process chain in the context of post-processing of 3D-printed components. The AM Tooling Competence Center will have a unique selling proposition because we will cover the entire process chain right through to the ready-to-use 3D-printed tool component.

Tool and mold makers can build on the extensive expertise of AddUp and the WBA in the new AM Tooling Competence Center in Aachen. The focus is on the entire process chain from design, analysis, and production to post-processing. © AddUp

FW: To arouse the interest of tool and mold makers: What specific problem cases do you want to tackle?

Marcilly: There is enormous potential for use in terms of minimized cycle times in injection molding. Our system can process fine powder with a small grain size, which brings advantages in the production of conformal cooling channels and, as a result, increases the cost-effectiveness of injection molding. We have also already developed a new tool steel and manufactured the first parts, but this is just the beginning. We are in the process of developing special steels for mold inserts in the field of stamping and forming tool construction. Looking ahead, the focus is also on tools for medical technology applications and die-casting tools.

FW: How does this cooperation support the strategic orientation of the WBA, especially with the aforementioned topic of digitization?

Boos: For about five years, WBA’s range of services has included not only the five classic technologies in isolation but also the manufacture of individual components through to complete tools. This enables us to generate up to one million euros in sales per year. We will now expand this with the sixth technology in the form of a comprehensive consulting and manufacturing service for all aspects of 3D-printed metal components. From my point of view, this includes, in particular, the entire Industry 4.0 topic.

Where currently only structure-borne noise sensors or shot counters are integrated, I am convinced that we can reach a completely new level with appropriately printed 3D components and sensors integrated into them. There are still numerous approaches and research goals that we want to pursue together.

With the involvement of AddUp in the AM Tooling Competence Center, the network of the WBA is expanded to include the key competence of 3D printing. © AddUp

FW: What appeal is made to the tool and mold-making industry at this point?

Boos: A characteristic of the classic tool and mold maker is that he has to see it first to believe that it works. Choosing to start with the component you actually need would only make sense on a case-by-case basis because that requires previous knowledge, such as a design suitable for 3D printing. As a competence center, we want to develop unique solutions together with our customers. Our offer should be an ‘Easy Entry to Additive Manufacturing, with the appeal: “Call us, no matter what it is about in the context of 3D printing.”

Marcilly: The alternative would be for the customer to buy a system. That would be a huge investment to be able to do the first steps and experiments. In practice, this hurdle is too high. In contrast, here at the AM Tooling Competence Center is the machine with the combined expertise of Add Up and WBA, which the customer can use to try their hand at parts or test materials and designs. As a service provider, AddUp prints metal parts worth around 10 million euros in France, so there is already a lot of application expertise that you can tap into and that we make available. With the first experiences and successes, the step is an easy one to invest in your first own add-up system.

FW: When will the AM Tooling Competence Center go online?

Marcilly: The system is currently being installed. We are making a presentation at the AM Tooling Competence Center on October 25, 2022, with the first applications for our AddUp project and development partners. On October 26, all WBA members will receive a tour and presentation at the WBA Annual Meeting. The official opening is planned for early 2023 with a festive kick-off event.

Boos: It’s good that we already have a kind of pre-opening at the end of October for special AddUp customers and the WBA community. On October 27th, we also have the toolmaking colloquium with the EiP award ceremony. Here we can already set the first marker for companies open to new technologies.

Marcilly: We are also presenting the FormUp 350 at the Formnext trade fair in November and look forward to seeing interested parties at our stand E01 in hall 12.0.

FW: Thank you for the interview!

WBA Aachen Toolmaking Academy GmbH

D 52074 Aachen

info@werkzeugbau-akademie.de

www.werkzeugbau-akademie.de

AddUp Global additive solutions

F63118 CEBAZAT

contact@addupsolutions.com

www.addupsolutions.com

Full interview in German read here

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With ten years of experience in additive manufacturing applied to complex products, particularly heat exchangers, SOGECLAIR Aerospace established a consortium to attack this project. SOGECLAIR is a high-tech engineering company in the aeronautical field. They lead the consortium, composed of AddUp, an additive manufacturer, TEMISTh, and the Von Karman Institute for Fluid Dynamics (VKI).

February 2017: among the many topics of the European Cleansky2 Call for Projects, one of them is attracting the attention of many entities, companies, and laboratories. Proposed by Liebherr Aerospace, it concerns the evaluation of improvements in new-generation heat exchangers using additive manufacturing.

With ten years of experience in additive manufacturing applied to complex products, particularly heat exchangers, SOGECLAIR Aerospace established a consortium to attack this project. SOGECLAIR is a high-tech engineering company in the aeronautical field. They lead the consortium, composed of AddUp, TEMISTh, and the Von Karman Institute for Fluid Dynamics (VKI). AddUp is a French industrial company specializing in metal additive manufacturing, TEMISTh is a French developer and supplier of customized thermal solutions, and VKI is a Belgian fluid mechanics laboratory.

SOGECLAIR’s consortium is working on project NATHENA, an acronym for New Additive manufacTuring Heat ExchaNger for Aeronautic. The project will last for four years with a total budget of €1.5M and will be 100% funded by the European Commission. Start date: March 2018.

CAD of a single flow channel and interfaces to the test bench

The objective is to develop two innovative heat exchangers for the aeronautical industry. The first one is a “pre-cooler,” allowing the pre-cooling of hot air taken directly from the turbo-engines of an airliner. It will be designed in Inconel 718 because it is subjected to very high temperatures. The second is a “cooler”, located further downstream in the air conditioning chain of the aircraft, allowing the air to be cooled again for later use. It will be designed in Aluminium AlSi7Mg, which performs well at the temperature range in the downstream location. The project aims to design heat exchangers as efficient as those made by conventional methods but with reduced mass and volume.

Single flow Aluminium 3D printed channel

The first step of the NATHENA project is to establish the state of the art of heat exchangers from the point of view of design, numerical simulation, optimization, bench testing, and the associated manufacturing techniques. This work allows us to build a solid database, a structuring element to guide and refine the architectural choices and the geometrical parameters of the future intensification structures developed and characterized during the project. These structures allow for an increase in thermal exchanges by extending the exchange surface.

CFD simulation of a single flow channel

The early technical studies led to the collaborative creation of the first CAD (Computer Aided Design) team of new intensification structures. To select the most promising geometries, the aim is to estimate their performance, factoring in manufacturing, mechanical, fluidic, and thermal perspectives. These are then integrated into the project’s standardized test channels, printed in Inconel and Aluminium on an AddUp’s machine, the FormUp® 350.

Instrumented single flow channel

Instrumented single flow channel

Less than ten channels are printed in each material, one channel per intensification structure. These channels are then thermally tested on a test bench, and the experimental results are compared to CFD numerical simulations (Computational Fluid Dynamics). The principle: air at room temperature is introduced at the entrance of the channels while the heat exchangers are heated by a flat electrical resistor attached to one of their walls. Multiple sensors then measure the gas’s pressure, temperature, and velocity at different positions in the channels. These measurements are then used to confirm the validity of the numerical simulation models and to compare the performance of the different structures.

Through simulation and testing, the consortium gains a better understanding of the flows and heat transfers in different structures produced by additive manufacturing. The manufacturability of such geometries with many thin walls is evaluated as well. These first very encouraging results allow us to outline the most efficient heat exchanger architecture, offering the best compromise between manufacturability, mechanical strength, thermal performance, and fluid performance. All these results continue to build on the already established database.

Single flow channel test results and comparison with simulations for one of the Aluminium samples – left: linear pressure evolution, right: heat transfer coefficient

This first study on the representative channels thus launches a campaign of similar tests involving two hot and cold fluids. The goal is to characterize the performance of the chosen geometry in a miniature heat exchanger in which the hot source is no longer an electrical resistor but a hot air flow. The channels here will be in a crossed configuration.

CAD of a double-flow channel

Three two-fluid channels are printed: two in Inconel and one in Aluminium, for which the parametric intensification structures are calculated and adapted according to the airflow characteristics. The manufacturing of a very large number of thin-walled fins (several thousand), with the associated printing quality, dewaxing, and finishing requirements, is a real challenge. The channels are then characterized on a test bench, allowing once again to correlate experimental tests and numerical simulations.

Instrumental dual flow channel

Instrumental dual flow channel

Thanks to a homogenization method, these thermo-fluidic characterizations have enabled the creation of metamaterials (“Equivalent Porous Media” or EPM with equivalent volume properties) which simplify the numerical simulations, lighten the models, and reduce the calculation time. Correlations between numerical simulations and tensile tests of specimens, also produced in Inconel 718 and Aluminium AlSi7Mg, allow us to refine these mechanical metamaterials. Indeed, a heat exchanger is a system with numerous small and complex geometries in a large volume. Simulating them numerically can be very computationally expensive if such techniques are not used.

Schematic diagram of the double flow test bench

The next step is to integrate the most efficient intensification structure in two larger prototypes of heat exchangers (one in AlSi7Mg and one in Inconel 718). As in the previous step, the objectives are to improve performance and better correlate the results between numerical simulations and experiments on the test bench. The aim is to generate as much data as possible and to increase the knowledge of additive manufacturing applied to complex thermal equipment.

Nestling of a double-flow channel
3D print simulation of a double-flow channel
Control tomography of a double-flow channel
CAD of a heat exchanger prototype and printed prototype in AlSi7Mg

All these simulations and experiments have enabled us to precisely determine the performance of the selected intensification structure and the internal architecture. The two final heat exchangers were designed to meet Liebherr Aerospace’s specifications accordingly. New tools and innovative methods had to be used to realize their CAD, considering the size of the designs and the very high number of integrated intensification structures (more than a million). The data generated by the test of the Aluminium prototype was also used to simulate the theoretical performance of the final exchanger and to generate a first CAD of the full part, with a volume corresponding to 12 printed prototype cells (see below).

Final aluminium heat exchanger

In order to meet the performance requirements of the final part, a focused study was carried out based on the initial data from AddUp and adapted to the specific needs of this project. The specifications expressed by the consortium contain 3 major points:

  • Thin waterproof walls in IN718 (between 100 and 300µm)
  • Productivity increase
  • Surface finish on fins and channels <6µm
Illustration of raw thin walls (Ra<6µm)

To master the constraints of this development, AddUp uses the latest generation machine (FormUp 350 – New Generation) allowing the use of 4 lasers as well as enhanced monitoring and tracking systems (sensor monitoring, recoating control, …). This data, coupled with the results of experimental measurements, have made it possible to define an operating range and a set of stable manufacturing parameters.

The complete heat exchanger was produced with a manufacturing strategy that allowed the simultaneous use of 4 lasers to increase the productivity of the laser powder bed fusion technology. This performance was made possible by the prior validation of the various key characteristics of the part (mechanical, thermal, dimensional).

CAD and prototype exchanger printed in IN718

Like the Aluminium exchanger, the Inconel exchanger was tested on a test bench to evaluate and validate the first models established for Aluminium. These experiments allowed us to study and highlight the impact of the roughness, but also to validate the first behavior models used during the simulations.

Illustration of thermal test bench (VKI)

The roughness-related deviation is considered in the heat flow simulations performed by Temisth. The calculations show a temperature distribution matching the data from the real measurements, validating the first models used.

Illustration of the simulated temperature fields on the cold side (left) and the warm side (right) _ Temisth
Experimental results on test bench – IVK

The size and details of the final complete exchanger (670x450x320mm) in Inconel 718 from the conclusions of the study show the possibility of integrating additive manufacturing for the realization of heat exchangers with performances at least matching that of current heat exchangers.

Final heat exchanger in Inconel 718

Technological hurdles overcome within the project :

  • Depowdering
  • Manufacturing strategy for thin walls
  • Manufacturing strategy to reduce surface roughness
  • Generation of a high air flow at -15°C
  • Temperature measurement mapping
  • Correlation between simulations and experimental measurements
  • Calculations based on experimental measurements to predict the aerothermal performance of fabricated exchangers
  • Management of large files
  • CAD methodology adapted to complex structures
  • Calculation methodology adapted to complex structures
  • The manufacturing strategy allows the use of 4 lasers on the same part

NATHENA: the consortium

SOGECLAIR aerospace

With its roots in aeronautics, the SOGECLAIR group designs, manufacture, and supports innovative solutions and products for transport in the civil and military fields.

Its R&D policy supports its participation in major future programs such as the development of the aircraft of the future and autonomous vehicles.

Its subsidiary, SOGECLAIR aerospace, is an international leader in the design and integration of high-value-added solutions for the aerospace industry. It designs, manufactures, and maintains the main components of aerostructures and aircraft interiors.

SOGECLAIR aerospace develops and deploys advanced materials and technologies such as thermoplastics and additive manufacturing.

With more than 1600 employees worldwide, SOGECLAIR aerospace has recognized know-how in:

  • Design and architecture of aerostructures and systems,
  • Design and manufacture of aircraft interiors,
  • Configuration management at the program, engineering, and industrial level,
  • Design and manufacture of simulated and embedded equipment.

AddUp

AddUp, created in 2016, is a joint venture between Fives and Michelin. It is a provider of complete industrial metal 3D printing solutions.

AddUp is involved in:

  • Design and manufacture of machines integrated into a complete production line, from powder management to the finished part,
  • Customer support for the production of metal 3D printed parts, to support investment projects in additive manufacturing for aerospace or additional production needs,
  • Cross-functional service activity, including the redesign of parts and additional services associated with the machine offering, helps companies find the most appropriate technical and financial solutions.

TEMISTh

TEMISTh is a company that specializes in developing and supplying customized thermal solutions. To do so, the company develops numerical simulation and optimization tools for automated heat exchanger design. This allows the company to develop new heat exchanger concepts to be produced by additive manufacturing.

Thanks to its location at the TEAM Henri Fabre Technocentre, TEMISTh offers various advanced manufacturing technologies such as metal and polymer additive manufacturing, foundry, machining, and assembly for function hybridization through brazing or friction welding. TEMISTh’s mastery of all these processes enables it to offer optimized and successful solutions to all its customers. All parts developed and produced can then be tested on TEMISTh’s thermal test benches.

The industrial fields in which the company operates are numerous: aeronautics, space, transport, oil and gas, and electronics.

Von Karman Institute for Fluid Dynamics

The Von Karman Institute for Fluid Dynamics (VKI) was founded in 1956 by Professor Theodore Von Karman as an international center combining education and research for the citizens of NATO countries under his motto “Training in research through research”.

Educational programs provided: Conferences / Courses / Colloquia, Short Courses, Master’s Thesis, Master of Research in Fluid Dynamics, Doctoral Program, and Applied Research Program.

The VKI undertakes and promotes research into experimental, computational, and theoretical aspects of liquid and gas flows in the fields of aeronautics, aerospace, turbomachinery, environment, and industrial and safety processes. Some 50 specialized test facilities are available, some of which are unique or among the largest in the world.

Research is conducted under the direction of faculty and research engineers, mainly sponsored by governmental and international agencies and companies.

Liebherr Aerospace

Liebherr Aerospace designs, develop, and manufactures air systems, flight control systems, and landing gear, as well as gears and gearboxes, and electronics for the aerospace industry. Liebherr Aerospace provides complete OEM customer services through a global network that offers equipment repair and overhaul, technical support and documentation, spare parts supply, and AOG service.

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