Forum News from AM II

WEDNESDAY, 23 June 2021

Location: CongressCenter, ground floor, Room Carl Zeiss

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08:30 - 09:00
09:00 - 09:45

The aerospace industry is characterized by small quantities, the highest safety requirements and, more than almost any other industry, by the need to save weight. Every reduced kilogram of weight saves up to 3 kg of CO2 - and that on a daily basis. Moreover, the short-term supply of spare parts is quite challenging. That is why aerospace industry is ideal for the introduction of components that are topologically optimized and manufactured by 3D printing processes. For more than 10 years, parts have been converted from conventional design and manufacturing to additive processes. The results are clear: components become lighter, smaller and may even integrate more functions.

Nevertheless, the conversion process is progressing slowly. There are several reasons, starting first and foremost with the demand for maximum safety. With existing design and production processes, all necessary qualifications are available for the required safety of components. For 3D printing, unfortunately, we are still at the beginning and, therefore, invest a lot of time and energy in process qualifications. We have to ensure that the internal structures and the surfaces meet all the requirements for permanent, safe operations. In parallel, we are, of course, continuing to work on optimizing the processes, on new material combinations and design processes, because we are certain that 3D printing will be indispensable for the climate-neutral aircraft of the future.

Volker Thum | BDLI Bundesverband der Deutschen Luft- und Raumfahrtindustrie e.V.

Volker Thum

09:45 - 10:15
Coffee break & Visit to the exhibition
Session 1
10:15 - 10:45
10:45 - 11:15

The lasersystem ProFocus developed by OSCAR PLT offers a lot of unique features, which lead to a high flexibility and process stability. Due to the modular and compact construction the integration into any handling system is quite easy. Based on 6 single adjustable and coaxial arranged laserspots, which are generated inside the laser head, an axial wire- or powderfeeding is possible, leading to process direction independence. Furthermore the adjustable laserspots allow a unique variability in energy input, whereby the energy input per unit length can be reduced to a minimum. Hence cooling breaks
could be avoided. Numerous monitoring and control tools make the wire process very stable.
Due to the easy change between wire- oder powder feeding and the optional hot wire feature the operator has much flexibility in various applications. The integrated shielding gas coverage enables the welding of Ni-, Ti- or Cu-based materials for example.

Frank Silze | OSCAR PLT GmbH

Frank Silze

11:15 - 11:45

The evolution of Electron Beam Powder Bed Fusion (E-PBF) started in the 1990’s. It was discovered early that an e-beam directed towards a powder bed is prone to scatter powder particles into a powder cloud. This phenomenon is known as “smoke” and if it happens, it usually disrupts the build process. Preheating of each powder layer with a fast-scanning e-beam was later developed to prevent smoke. The preheating semi-sinters the powder and increases its electrical conductivity prior to melting. This laid the basis of the commercial E-PBF process successfully used for titanium alloys today. However, e-beam preheating is not a universal cure. Anyone who has experimented with new powders in E-PBF knows the effort of finding smoke-safe preheating parameters. This paper introduces ProHeat, a new preheating method using infrared radiation from a heating device positioned above the powder bed. The method eliminates build-up of electric charge in the powder and gives 100% smoke suppression. This opens up a wider range of powder compositions and morphologies for E-PBF, for example very fine particle size distributions and materials of poor electrical conductivity.

Ph. D. Ulric Ljungblad | Freemelt AB

Short Vita:
•    PhD in Physics from Gothenburg University
•    Has worked in the semiconductor industry for 10 years
•    Joined Arcam in 2006 and worked there with systems development until 2016
•    One of the founders of Freemelt in 2017
•    CEO of Freemelt since 2019

11:45 - 12:15


Christoph Lindner | Stratasys GmbH
12:15 - 12:45

The additive production of plastic components is becoming increasingly important for series production. Nevertheless, many applications have not yet been able to benefit from the advantages of additive manufacturing. The reason for this is the limited range of available materials. Especially for powder bed fusion, many applications require specific materials that cannot be met by PA12 and PA11. That applies to chemical industry, electric industry, automotive industry as well as mobility and aviation industry.
AM POLYMERS focussed since 2014 on making traditional standard plastics such as PP, PE, PA6, PBT, or TPU available for powder bed fusion as quality-controlled powder materials. With our powder materials, we meet your requirements while at the same time making them easy to process. Our extensive experience of many years result in batch-to-batch consistent powder materials and parts with particularly good properties. Our know-how considerably reduces your effort for running-in so that you can deliver high-quality customer parts within a few days. We act according to the principle "Plug & Play". For us, this means that we make sure that each of our materials can be applied to your AM machine without problems.
As new polymers we present: A PBT with good elongation at break that can be processed on standard machines and a new temperature-resistant high-performance polymer called Rolaserit® X.

Andreas Wegner and Timur Ünlü | AM POLYMERS GmbH

Andreas Wegner und Timur Ünlü

12:45 - 13:15
Lunch break and visit to the texhibition
13:15 - 15:45
Forum "Aviation II" in the room Carl Zeiss
15:45 - 16:15

The Presentation highlights opportunities and challenges of incorporating AM technology on the Boeing 777X Folding Wingtip System Secondary Lock Actuator.

The Case Study shows how Liebherr addressed challenges like thermal stresses in production, pressure drops in operation, surface treatment and wear surfaces of titanium cylinders.
Furthermore, an outlook will be provided regarding the challenges of the technology and the implementation to serial production of highly integrated components.

Alexander Altmann | Liebherr-Aerospace Lindenberg GmbH

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Tuesday, 22 June 2021