Forum Automotive & Mobility

TUESDAY, 22 June 2021


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09:00 - 09:05
Welcome from the Rapid.Tech 3D Live-TV-Studio
09:05 - 09:15
Welcome from the Rapid.Tech 3D Live-TV-Studio
09:15 - 09:45
  • Presentation of the current status of Additive Manufacturing at Daimler Buses
  • Presentation of our 3D printing parts which have already been installed in our premium buses
  • Change of the current supply chain due to the 3D printing technology
  • AM Big Picture - Daimler Buses
Ralf Anderhofstadt and Janis Kretz | Daimler Truck AG / EvoBus GmbH - Daimler Buses

Ralf Anderhofstadt and Janis Kretz

09:45 - 09:50
Greetings from the Rapid.Tech 3D Live-TV-Studio
09:50 - 10:00
Break & Chat Roulette
10:00 - 10:30

Not least the Corona pandemic showed numerous industrial sectors how volatile not only markets but also supply chains can be and how sensitively a globalized production world reacts to such events. In the context of significantly shorter product life cycles and higher variant diversity, in some cases classic production processes are no longer able to meet the demands placed on modern production systems. Additive Manufacturing (AM) is a technology that opens up opportunities to respond to these challenges and changes. Although AM has been on everyone's agenda in the industry for some time now, this technology is still currently not out of its niche. This presentation will show the development of the use of additive manufacturing will be presented from Schaeffler's point of view, opportunities and limitations will be outlined and the necessary need for action for additive series production will be shown based on a concrete example from Schaeffler.

Carsten Merklein | Schaeffler Technologies AG & Co. KG

Vice President Advanced Manufacturing Technologies, Schaeffler Technologies AG & Co. KG
After graduating with a degree in materials science from Friedrich-Alexander University Erlangen-Nuremberg, Carsten Merklein has held various positions at Schaeffler since 1999. Since September 2020, as Head of Advanced Manufacturing Technologies in the Advanced Production Technologies division, he has been responsible not only for the sustainable implementation of additive manufacturing but also for the development of innovative manufacturing technologies for the Schaeffler products of tomorrow. 

10:30 - 11:00

The "WING3D" concept developed in the research project „OptiAMix“ is characterized by an aluminum bracket manufactured by LBM. It holds the SLS-manufactured short-fibre-reinforced rear wing and adjusts it with the help of an integrated hydraulic system. The concept could only be realized by using additive manufacturing. The hydraulic system moves a piston by means of oil pressure. The piston adjusts the angle of attack of the wing continuously in the range of 6° to 42° and thus enables an adjustment adapted to the driving situation as well as an aerodynamic braking function. A 3D-printed slide bearing insert reduces friction and enables maintenance-free kinematics. In addition, an electrical cable for a sensor and an LED brake light have been integrated into the bracket.  The "WING3D" system has been optimized in terms of lightweight construction and at the same time meets the high structural requirements in real-life applications. The focus was also on improved aerodynamic properties and a visually appealing design. For the multi-target optimization, the latest findings and methods from the "OptiAMix" research project, which is funded by the BMBF, were applied.
The system is designed as a small-series application for sports vehicles and is to be offered ex works or as an after sales solution. The WING3D system combines lightweight design, active aerodynamics, functional integration and a visually appealing design with the help of additive manufacturing.

 

 

11:00 - 11:30

The increase in additive manufacturing production volume in recent years has led, not only, to a need for an increased level of productivity during the build job, but also the optimization of other crucial steps in each respective technologies process chain. With HP’s Multi-jet Fusion technology relatively recent entry (2014) into a seemingly stagnant scene of industrial scale powder-based additive manufacturing, it presented itself as an ideal candidate for post-processing optimization using methods of machine learning due to its faster print time. 66% of the Multi-jet Fusion production process, from build job preparation and nesting to delivery of finished parts is comprised of its cooling process step. This cooling process step can take anywhere from 3 to 30 h, depending on a number of factors. While speeding up cooling does not come into question when processing semi-crystalline polymers, such as polyamides, knowing the necessary cooling time with relatively high accuracy, becomes crucial. In this study, a machine learning model was created to predict a significantly more accurate cooling time using a number of build job parameters. The optimized cooling model was trained using the measured cooling times of varying build jobs as output and build job height, number of layers, packing density, number of parts and room temperature as inputs. The machine learning model predicts significantly more accurate cooling times than the manufacturer predictions. Furthermore, as with all machine learning models, it was shown that an increased number of data, resulted in more accurate predictions. The implementation of the optimized cooling model at BMW’s AM production facility leads to increased transparency, leaner production and a higher overall economic viability of AM technologies.

Paul Osswald | BMW AG

02/2019 - 01/2022: Promotion - Doktoranden PROmotion Programm, BMW Group - Universität Duisburg-Essen
04/2015 - 09/2018: Masters of Science - Mechanical Engineering, Technical University of Munich
08/2009 - 05/2014: Bachelor of Science - Composite Materials Engineering, Winona State University-Winona MN, USA 

11:30 - 12:00

Using metal 3D printing in the automotive industry poses several major challenges for the technology. In addition to many potentials, the processes also carriy risks that need to be found and analyzed for use in the automotive environment. For example, vehicle production is a mostly cost-driven endeavor. In the case of components that are installed in large series in quantities of thousands, every penny often counts during production. So where are the potential applications for a component made using an expensive 3D printing process? Which processes can be considered for economical manufacturing? Which key enablers need to be addressed to bring metal 3D printing into volume production? I will address these and other questions in this presentation on the efforts being made at Volkswagen AG to bring the future into series production.

Anwar Shad | VW AG

 

 

12:00 - 12:30
Break
12:30 - 16:00
Live Stream: Forum "News from AM I" and Forum "Tool, Model & Mould Making"
16:00 - 16:45

Panel Discussion "AM and Sustainability"

Moderation: Bernhard Langefeld / Roland Berger
Volker Thum, Ralf Anderhofstadt, Volker Hammes | BDLI, EvoBus GmbH - Daimler Buses, BASF New Business GmbH

Volker Thum, Geschäftsführer BDLI Bundesverband der Deutschen Luft- und Raumfahrtindustrie e.V.
Ralf Anderhofstadt, Head of Center of Competence 3D-Printing - Daimler Buses, Daimler Truck AG, EvoBus GmbH - Daimler Buses
Volker Hammes, Managing Director at BASF New Business GmbH

16:45 - 17:00
Farewell to the Rapid.Tech 3D Live-Studio & handover to the digital award ceremony of the 3DPC
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