More information on our speakers and lectures are updated continuously!
Davide Abate, Chief Technologies and Infrastructures Officer
Franco Pinna, Head of Innovation and Advanced Technologies
Ferrari
Abstract will follow shortly!
Davide Abate is Chief Technologies and Infrastructures Officer since January 2022.
Previously he held the position of Head of Technologies at Ferrari since October 2020, and various managerial roles in the manufacturing area such as Head of Prototype Construction from 2017 to 2020.
Prior to joining Ferrari in 2012, he covered technical managerial roles at Ducati Motor Holding.
Mr. Abate holds the Ferrari Corporate Executive MBA from the Bologna Business School and a master in Process Engineering at Bocconi School of Management, as well as a masters’ degree in Automotive Engineering from the Turin Polytechnic.
Franco Pinna is Head of Innovation and Advanced Technologies since January 2023.
Previously he held the position of Head of Foundry and Machining Technologies at Ferrari since december 2022.
Prior to joining Ferrari in 2008, he covered technical and production roles at Brembo Brakes for a period of about 10 years.
Mr. Pinna has more than 30 years of experience in the field of Aluminium based materials, working on product and process development and application in the Automotive sector. He is also driving the development of Additive Manufacturing Technology at Ferrari GT.
Combining additive manufacturing and crafting; printing modelling clay
Christoph Doerffel
Head of project, Steinbeis Innovationszentrum Automation, Prozesstechnik, Leichtbau
What is it about?
Modelling clay is a classic material for creative and artistic design processes. The compound, which is based on filled waxes, allows almost completely free shaping without tools by means of craftsmanship. It can be used both directly as a model and as a mould for silicone moulded parts. New application potentials open up with regard to the reproduction of even complex geometries with undercuts and filigree elements in combination with the technologies of additive manufacturing and 3D scanning. The simple manual post-processing in combination with the renewed digitisation of the model makes it possible to proceed in iterative loops in design and development processes. The direct recyclability of the material without external processing is another positive effect, which both avoids waste and reduces material costs. The modelling clay can be returned to the printing process directly after use, sorted by colour if necessary.
The basis of the printing technology for modelling clay is a comprehensive understanding of the mechanical, thermal and rheological properties of the modelling clay. The development of a suitable printing system is based on this understanding. This enables a process-safe layer build-up and the reproducible production of moulded parts.
Markus Bähr, Specialist team leader for chemical and structural materials
Anja Rupprecht, Development engineer
Diehl Defence GmbH & Co. KG
What is the issue?
In the wide business range of Diehl, AM offers remarkable solutions concerning new assignments within the most different departments of the Company.
Today, we would like to show how the diversity of AM can be reasonably structured despite all conceptual challenges.
We will talk about the current state of the art, about what is needed, which topics might show up in the near future, and where this could be leading to. The way of Diehl.
Markus Bär
Professional experience
Specialist team leader for chemical and structural materials; Diehl Defence GmbH & Co.KG
Development engineer; Diehl BGT Defence GmbH & Co.KG
Working student in the system design of rail vehicles; Siemens AG
Working student in the field of Vehicle Safety; Bertrandt AG
Geometry controller and project manager; Kennametal Inc.
Education
Master studies in mechanical engineering (FAU Erlangen)
Anja Rupprecht
Professional experience
Development engineer, Diehl Defence GmbH & Co. KG
Technical Trainee, Diehl Defence GmbH & Co.KG
Education
Master's degree in Materials Science and Engineering, Friedrich-Alexander University Erlangen-Nuremberg
Development of a manufacturing guideline to increase the dimensional, form and positional accuracy of L-PBF components made of 316L powder material
Peter Husemann
Project engineer / scholar. Employees, Fachhochschule Südwestfalen
What is it about?
Due to high temperature gradients during the production of components with the additive L-PBF
manufacturing process, residual stresses are induced in the components to be produced.
Macroscopic residual stresses, which distort the dimensional accuracy of the component geometry,
can be measured in part based on the external component distortion. In this project, the problem is
counteracted by various approaches with the aim of providing a manufacturing and design guideline
to enable additive manufacturing of dimensionally stable components with the lowest possible
residual stresses. The focus is on developing a suitable heat treatment to reduce residual stresses
before the component is separated from the build platform. Continuing, the adjustment of the
process parameters and the scanning strategy during the process will be investigated so that residual
stresses can already be reduced during remelting of the powder. FEM simulations are performed
prior to the manufacturing process to calculate compensating pre-deformations as accurately as
possible. In addition, warpage-critical areas are identified, which is used to develop adapted scanning
strategies that can locally reduce deformation. By manufacturing suitable reference geometries, such
as the cantilever beam established in this research area, the influence of the different approaches on
component distortion and mechanical properties is determined directly. Thus, it can be directly
validated that the approaches have no negative influence on the strength. The developed
manufacturing and design guidelines are currently being tested on the basis of realistic
demonstrators and their methodology should finally be universally applicable.
How 3D-printing solves problems before they arise - AMS - Additive Manufacturing Solutions
Ralf Anderhofstadt
Head of Center of Competence Additive Manufacturing, Daimler Buses – EvoBus GmbH
Daniela Rehm
Product & Marketing Management 3D-Printing, Daimler Buses – EvoBus GmbH
What it is about?
Additive Manufacturing has become a central standard in various industries, so that nowadays we talk mainly about industrial 3D-printing.
The Center of Competence 3D-printing of Daimler Buses and the resulting consulting unit "AMS- Additive Manufacturing Solutions Daimler Truck AG" deals with the development and expansion of industrial additive manufacturing with a significant added value.
That includes especially the increasingly change towards digital business models, in which the digital twin in particular plays an important role along with the digital warehouse and the evolution to a 3d printing licence shop.
In addition "AMS - Additive Manufacturing Solutions Daimler Truck AG" offers services along the entire 3d printing value chain as a reliable all-in-one provider.
Ralf Anderhofstadt
Ralf Anderhofstadt is Head of the Center of Competence Additive Manufacturing and the Consulting Unit "AMS - Additive Manufacturing Solutions - Daimler Truck AG" as well as Project Manager of the cross-functional 3D printing project within Daimler Truck AG.
At the same time, he is active in the VDI expert committee “Legal Framework Conditions of Additive Manufacturing”, works as a lecturer with a focus on 3D printing, is active as a trainer for numerous training courses within the business field of additive manufacturing and is also a member of the advisory board of the German 3D Printing Association.
In August 2022 his first book "Disruptive 3D Printing" was published by Hanser Verlag, in which the great potentials and opportunities of additive manufacturing for different industries are presented using practical examples. The English version of "Disruptive 3D Printing" will also be published by Hanser Verlag at the beginning of the second quarter of 2023.
Daniela Rehm
Daniela Rehm is responsible for the complete marketing and product management within the Center of Competence Additive Manufacturing and the consulting unit "AMS - Additive Manufacturing Solutions Daimler Truck AG".
After successfully completing her Bachelor of Arts degree in Business Economics, she worked as an event manager at Daimler Buses and in this capacity already formed the interface to the Center of Competence AM as a project member of the cross-functional 3D printing project at Daimler Truck. At the same time, she is currently managing all product management activities for industrial 3D printing within Daimler Buses as Scrum Master. As a “one-face-to-the-customer”, she also takes on the role of agile sales coach and sales representative in the consulting unit “AMS”.
How new technologies in product development can shape the future of manufacturing
Ewald Egel
Technical Solution Executive, Autodesk GmbH
What is it about?
Companies are under pressure to bring new levels of innovative products to market in less time. Typically, the product development process is tied to the creator’s imagination, their experience or existing designs. Generative design enables designers and engineers to explore a large variety of ideas and optimize designs for specific materials and manufacturing techniques. Combining generative design with additive manufacturing, companies can save time, improve the quality of their products and reduce the usage of raw materials.
In this lecture, you will learn from practical examples which projects companies have realized.
Professional practice
Technical Solutions Executive & Sustainability Lead, Autodesk AG
Technical Sales Specialist, Autodesk AG
Working student in the field of Integration Management and Portfolio Strategy, Siemens AG
Training
Master's degree in Industrial Engineering (FAU Erlangen)
Building a greener future through 3D printed wood
Gürsel Demircali
Vice President EMEA, Channel Sales, Desktop Metal
What is it about?
▪ The Forust process upcycles waste byproducts from conventional wood and paper manufacturing processes – sawdust + lignin
▪ Applying the speed, precision and quality of binder jetting to produce strong, lightweight wood components
▪ Re-materializes functional wood to replicate a range of woods colors and finishes (including randomized wood grain)
▪ Suitable for a broad range of applications, including home goods, luxury interiors, furniture and architectural accents
▪ Significant sustainability benefits without sacrificing quality and premium feel
▪ Manufacturing wood at-scale with digital inventory and cost-effective mass customization
WORK HISTORY
VICE PRESIDENT SALES CHANNEL EMEA
08/2022 – ongoing
TERITORY/CHANNEL MANAGER CENTRAL + EASTERN EUROPE
10/2021 – 08/2022
STRATEGIC SALES DIRECTOR – EUROPE
04/2019 – 10/2021
BRANCH MANAGER WEST/NORTH-WEST/SOUTH-EAST, SOLIDCAM GMBH, GERMANY
05/2009 – 03/2019
PRODUCTION MANAGER, INTEC GMBH, BRUCHSAL, GERMANY
07/2006 - 04/2009
TEAM LEADER DEPARTMENT CNC MANUFACTURING, DAIMLER AG, WOERTH, GERMANY
02/2005 – 06/2006
EDUCATION
BACHELOR PROFESSIONAL OF METAL PRODUCTION AND MANAGEMENT, ERHARDT-SCHOTTSCHULE,
SCHWETZINGEN, GERMANY
05/2009 – 09/2013
Digital Orthotics
Niklas Hamann
PhD student and lecturer, Bauhaus-Universität Weimar
What is it about?
The presentation "Digital Orthotics" provides a comprehensive insight into a research
project under the same title at the Bauhaus University Weimar. The current status of
the project, which will run until 2024 and is being carried out with the practice partner
"Rosenkranz Scherer" from Bad Homburg, will be shown. Project manager and
lecturer is Niklas Hamann.
The aim of the research is to explore the possibilities and potentials of combining
digital data acquisition, computational design and 3D printing for body-related and
medical applications. The essential object of investigation and application is the field
of orthotics. Here, the focus is on the development of novel lower leg-foot orthoses
for the indication of diabetic foot syndrome ("Charcot foot").
Specifically, the lecture will present essential parameters, strategies and methods for
the generation of geometrically complex orthoses. The focus is on the one hand on
the computer-based generation and manipulation of corresponding geometries and
components in dependence on three-dimensionally recorded body data, and on the
other hand on the optimization for additive manufacturing by means of 3D printing.
In this topic, the focus is on the advantages and disadvantages of specific geometric
typologies, the algorithmization of bespoke components and functional areas. To
this end, the talk will provide specific insights into the application of computer-aided
design (CAD) software such as McNeel Rhinoceros 3D as well as corresponding
(visual) programming through parametric and algorithmic approaches in
Grasshopper. In addition, results from different 3D printing technologies, such as
HP's "Multi Jet Fusion" process, will be presented.
Additive Manufacturing, large metal parts for railway vehicles at ALSTOM
Dr.-Ing. Uwe Jurdeczka
Senior Expert Additive Manufacturing, Alstom Transport Deutschland GmbH
What is it about?
ALSTOM is using the potential of additive manufacturing for large metal parts.
Selected use cases are presented:
Aspects of production, approval, application.
Outlook
Uwe Jurdeczka studied metallurgy at the Bergakademie Freiberg from 1985 to 1990 (after schooling in Borna near Leipzig and Lobstädt, vocational training in the steel and rolling mill Brandenburg and the Abitur at the evening school in Borna).
In 1993 Jurdeczka went to the Research Centre for Steel Application (OCAS) in Zelzate (Belgium) as a scholarship holder.
From 1994 onwards, several positions in industrial companies followed, each with reference to the automotive industry.
He has brought this experience to ALSTOM Transport Deutschland GmbH since 2009, initially in quality assurance and currently in work preparation.
In 2017, after four semesters, he completed his doctoral dissertation with a “Contribution to the Model-Based Completeness Testing of Attachments to Steel Structures” at TU Braunschweig.
In it, he succeeded in describing a largely device-based completeness check using 3D scanning.
Jurdeczka is investigating new applications for additive manufacturing.
In addition to the DSLM process, hybrid manufacturing processes and WAAM also play a role.
In 2021, the ALSTOM competence centre for additive manufacturing, especially with metals, was established at the Salzgitter site.
He was and continues to play a major role in this.
In 2022, he was appointed Senior Expert for Additive Manufacturing.
Design solutions and opportunities for AM
Sebastian Hess
Founder and CEO, DQBD GmbH
What is it about?
DQBD is showcasing latest AM design solutions in medical and healthcare products as well as in personal protection. Within every design and development process we always evaluate the benefit we could have from any applied production technology and material. When it comes to fulfilling homologation standards for personal protection we consider AM solutions as highly attractive as we can manipulate geometries and therefore influence the characteristics of one uni-material piece in a very efficient and elegant way while the downside is still mostly the cost side of this process. Also in medical and healthcare devices and in the fields of wearable technologies we consider AM solutions for parts with electric conductivity as game-changing solutions which should be further kept in focus by the AM industry.
- 2021/2022: Showcase von SAM_Saddle additive manufactured
- 2020/2021: Close cooperation with Stratasys
- 2020: Foundation of the company SPEEDFAB GmbH as shareholder
- 2016: Collaboration between DQBD (Advanced Innovation Partner) and SPORTSGEAR Group, one of the world's largest shoe factory group
- Since 2015: DQBD works for the world's leading brands and companies in their respective sports product areas
- 2015/2016: AM Milestone IV: Showcase of AM components in the footwear sector
- 2015: AM Milestone III: Showcase of a bicycle saddle with integrated AM components
- 2015: AM Milestone II: Showcase of a cycling helmet with integrated AM components
- 2014: AM Milestone I: Collaboration with AUTODESK, STRATASYS, BASF on the e-FLOATER, a vehicle for "last mile" solution
- 2014: Foundation of the design and development company DQBD GmbH in Schorndorf nearby Stuttgart.
- 2011: Introduction of additive manufacturing and installation of the AM Lab at Alpinestars.
- 2010-2014: Working for ALPINESTARS in Italy/USA as Senior Designer and responsible for Technical Personal Protection as well as head of the Advanced Innovation Lab
- 2007: Founding of the Hess Design Studio in Heidelberg with focus on sports protection
- Studies at the Academy of Arts and Design in Offenbach to become a product and industrial designer with diploma
Extrusion-based 3D printing with polypropylene
Prof. Hans-Werner Schmidt
Co-founder of PPprint GmbH, PPprint GmbH
What is it about?
For successful extrusion-based 3D printing (FFF, FDM, and FGF) of polypropylene, three critical components are essential. First, the 3D printed material should have low warpage and high bond strength between layers. Second, a support material is needed to fabricate more complex structures. Third, the 3D print bed must enable reliable printing and non-destructive removal of the product. PPprint GmbH, the specialist for 3D printing with polypropylene, has solved these three challenges and is the only company worldwide to offer a complete package for successful 3D printing with PP.
Freedom - How 3D printing opens up new perspectives for caravans
Mario Meszaros
Entwicklungskonstrukteur, Knaus Tabbert AG
What is it about?
The use of 3D printing is of enormous importance for motorhome manufacturers. It enables us to respond flexibly to the ever-changing requirements of our customers. However, the variety of different camper models makes it difficult to produce individual parts in small quantities, which leads to problems in production, logistics and cost-effectiveness.
In our talk we will show how we have set up our own 3D printing factory within the company and which applications we use. We also explain where the development is going and what we expect from the future of 3D printing. Our goal is to optimize our processes by using 3D printing and to respond even better to the needs of our customers. Let's find out together what opportunities 3D printing offers for the motorhome industry and how we can take advantage of them.
EDUCATION:
2011-2015 Kecskemeter University of Applied Sciences B.Sc. Mechanical engineer
Specialization Production Engineering (CAD-CAM)
WORK EXPERIENCE:
2016- today
Knaus Tabbert AG
Development designer Design of mechanical / kinematic elements and assemblies Design of plastic and metal parts Set-up of a small AM centre
2015-2016
Desis Pro Kft
Mechanical Design Engineer Development of interior components in the automotive sector
I'm responsible for this.
parts to construct production to prepare AM manufacturing process to carry out logistics to organize processes and parameters to optimize development of strategies
New possibilities in multi-material applications using blue lasers
David Scheider
Development Engineer Material Development/Additive Manufacturing, DMG MORI Ultrasonic Lasertec GmbH
What is it about?
The production of multi
material components is often cited as one of the main advantages for the
use of Directed Energy Deposition (DED) in various industries. Combining multiple materials in
one component offers the opportunity to improve component properties by selecting material
properties to meet the necessary requirements in different areas of the component. This
advantage is even greater the more different the materials are.
In the DED sector, laser radiation in the infrared range is mainly used as standard. This has
severely limited the use of copper alloys in DED due to their reflective properties. New process
strategies make it possible to coat copper components. However, more complex geometries and
the high material costs of copper make it desirable to use copper not only as substrate but also
as powder material. Recent advances in the laser industry have made it possible to use blue
lasers in DED machines. By using blue lasers, a higher portion of the energy can be used to melt
the material, especially for copper alloys.
The latest advances in the processing of copper alloys and their economic advantages will be
presented. Two multi material applications will be shown, one from aerospace and one from die &
mold.
Since 8/2021: Development Engineer in Material Development/Additive Manufacturing at
DMG MORI Ultrasonic Lasertec GmbH
–
Material and process development for Directed Energy Deposition (DED)
–
Qualification of powder materials and suppliers
6/2021: Master's degree in Materials Science at the University of Stuttgart
RAPID TECH
Ontologies for the open handling of material properties of additively manufactures metals
Tom Lahmer
Head of department, Materialforschungs- und -Prüfanstalt Weimar
What is it about?
As part of the BMBF’s call for proposals for “MaterialDigital”, a consortium of research institutions has been established that pursue various additive manufacturing processes for metallic materials, including extrusion of composites, wire melting and powder bed processes.
It is important for the consortium to create a common knowledge base (Ontology) that allows a clear description of the material properties of the additive-fabricated structures. Static characteristics and those obtained under cyclic loads shall be considered. The process dependency of the parameters as well as their statistical dispersions are also to be recorded.
A short excursion covers the software-technical realization of the databases for the decentralized recording of the characteristic values.
3D printed spareparts - additive manufacturing @ ÖBB
Sebastian Otto
Head of Additive Manufacturing, ÖBB-Technische Services-GmbH
What is it about?
With more than 237000 ordered spare parts for more than 6600 trains per day, OeBB-Train Tech faces the daily challenge of handling this huge range of items. Obsolete Components, no standard suppliers leading to delivery times over months and high costs per part. This are the challenges in the spare parts business.
In OeBB Group, OeBB-Train Tech is responsible for the maintenance and maintenance of the rolling stock.
To meet the high demands in the spare parts sector, the project “3Dprint@OeBB” was founded in 2018 to be able to exploit the potential of the promisingly additive manufacturing technology in the company.
Since then, this new technology has been developing at a rapid pace in the company and has made it possible to produce much more than just prototypes. In recent years, more than 300 applications were found, and more than 35000 spare parts has been printed. As a result, costs were saved, delivery times were shortened and “standstills” were prevented.
From a small sensor mount up to an entire 3D-printed dashboard down, the range of spare parts is huge and almost every spare part has the potential to cause a train to fail.
Preventing this and ensuring 100% material availability is one of the most important goals of the 3D printing team.
Sebastian Otto has been working for the ÖBB Group since 2019 and in 2021 took over the Additive Manufacturing project management in the Supply Chain Development (SCD) area at ÖBB Technische Services GmbH, which is responsible for the maintenance and servicing of rolling stock within the ÖBB Group. Prior to that, Sebastian set up the series production of a small ski manufactory as production manager. He completed his studies in Sports Equipment Technology at the University of Applied Sciences Technikum Wien with a focus on machine elements and materials science. In the role of project manager for additive manufacturing at SCD, he is responsible for the implementation of additive manufacturing into series production.
Additive Manufacturing in the Air Force - Experiences
Tobias Gärtner
Head of the Design Office of the Weapon Systems Support Center 2, Bundeswehr
What is it about?
The lecture presents the work of the design office of the Weapon Systems Support Center 2 in Wunstorf. Using illustrative examples, the elaboration allows a rough overview of the work with additive manufacturing and the application of the resulting components. Essentially, the civilian professions of mechanical engineer and technical product designer in the public service of the Bundeswehr are touched upon.
Professional background
2003 - 2007 Mechanical engineering studies FH Hannover
2007- 2008 Schörling-Brock GmbH, production planner
2008 Volvo Construction Equipment, Equipment Designer
2009 – today Bundeswehr, Head of Air Force Design Office in Wunstorf
Qualifications
• Dipl.-Ing.(FH) Mechanical engineering
• DVS welding designer
• International welding engineer
• International welding quality testing engineer MT, PT, RTFI, VT (all methods: level 2 according to ISO 9712)
• European Adhesive Engineer
• Visual inspection inspection according to DIN ISO 19828
• CE coordinator according to TÜV Nord
• PZA testers for
o DIN EN ISO 9606 Steel construction
o DIN ISO 24394 Aerospace engineering
o DIN EN ISO 15618-1 Underwater welding
• Deputy Chairman of PZA Aerospace (DVS-PersZert)
Bringing Digital Transformation to Composite Manufacturing with Cast In Motion technology
Avi Cohen
Vice President Sales and Marketing, Massivit
What is it about?
3D printing is not something new. As a matter of fact - all technologies are already out there.
A real breeze in this industry is the new Cast In Motion (CIM) technology.
A technology that open up the door for all industries - and rapid.tech is the platform to share it.
The case in Motion is a new ability to make casting as you print. This enable automated mold production and tooling for composite manufacturing. They empower composite fabricators to directly print industrial, complex molds within a matter of hours, instead of weeks.
Rapid.Tech 3D is one of the most important information events in the field of generative manufacturing processes - and we will be proud to present this new innovative technology there to the audience; have them learn for the first time as per different and alternative way for 3d printing.
Avi Cohen’s career started in sales, marketing, and high-level management positions in various companies, his over 24-year association with the additive manufacturing sector beginning in 1999 when he joined Stratasys (formally Objet). At Stratasys for 16 years, Cohen became Director of Healthcare Sales and Marketing, focusing his expertise on evangelizing about 3D printing technology, with a special concern for the medical and dental sectors. Cohen comes to Massivit after a 5-year stint as the Vice President at XJet Ltd a position he took up after moving on from Stratasys in 2015, and over two years at Nano Fabrica (acquired by Nano Dimension). Working at the forefront of the digital manufacturing revolution, Avi Cohen commands the respect of the entire international 3D printing community, and he is recognized as a strategically astute technology leader.
Frank Rinderknecht, CEO
Rinspeed AG
What is the issue?
Everyone is talking about the mobility turnaround. But does it really happen and if so, what is its impact on the functions and design of the vehicles and mobility of tomorrow? Which factors or technologies are causing the really big changes? Who will leave the race as a loser and who as a winner?
FRANK RINDERKNECHT
CEO, Rinspeed AG
The impact of 3D printing in next-generation processes for sustainable chemical and pharmaceutical industries
Prof. Carlos A. Grande
Associate Professor of Chemical Engineering, KAUST Catalysis Center, Saudi Arabia
What is it about?
The chemical and pharmaceutical industries of the future will be composed of a series of intensified processes where sustainability and energy consumption are optimized. Shape customization is perhaps the most powerful technique for process intensification. The possibilities to tailor shapes of reactors and separation units to specific applications result in units with enhanced mass, momentum and/or energy transfer. In this context, 3D printing is the perfect manufacturing technique one it allows the production of units or internals with customized shapes that can unlock new operation modes. In this presentation, I will show examples of reaction and separation units where 3D printing can be a game-changer in chemical and pharmaceutical industries.
Carlos Grande is Associate Professor in King Abdullah University of Science and Technology (KAUST) since September 2021. Before joining KAUST, he worked as Senior Scientist in SINTEF Industry (Norway) for 10 years. He has a PhD from Porto University in Portugal (2005) where he also worked for 5 years as a Research Assistant. He graduated as Chemical Engineer in South University in Argentina (1998).
He works with process intensification applied to separation and reaction processes with strong focus on digitalization of processes and novel manufacturing techniques like 3D printing.
He has over 115 publications in international journals (h-index = 47) and 7 patent applications. He was coordinator of 2 European projects implementing 3D printing in chemical reactors (PRINTCR3DIT) and pharmaceutical industries (NESSIE).
About Giants and Dwarfs in Rail - and how instant printability and costing helps save millions!
Ruben Meuth
co-Founder & co-CEO, 3D Spark GmbH
What is it about?
3D printing service providers spend a lot of time responding to requests for quotations, particularly with regards to printability analyses and cost calculations. This ties up sales staff and technology experts who could otherwise be generating revenue.
Large OEMs face the challenge of making 3D printing accessible to many of their tens of thousands of employees in order to realize the full potential of the technology in terms of cost, delivery times and CO2 savings.
In this talk, I will use examples from the railway industry featuring giants and dwarfs to demonstrate how automation through software can help to answer daily questions from customers and employees regarding printability, manufacturing costs, and the selection of the most suitable manufacturing technology and material, resulting in validated savings of millions.
Ruben Meuth is one of the founders and CEO of 3D Spark. Previously, he was Head of Business Development at the Fraunhofer Institute for Additive Production Technologies (IAPT). At the same time, in addition to various automotive industry projects (including Fiat-Chrysler / Maserati, Lamborghini, Dana), he led the "3D Supply" research project to explore part screening software approaches, especially for the railway industry. Further professional stations were Olympus Surgical Technologies, Audi and Airbus. His academic background includes a master's degree in industrial engineering with a focus on manufacturing technology, with a thesis at Laserzentrum Nord on the topic of "Part-Screening Software for 3D Printing".
AddiMap – Data Economy for Metal Additive Manufacturing – efficient use of process parameters
Johannes Eckstein
Managing Director, NuCOS GmbH
What is it about?
AddiMap is the first open, privacy-compliant and secure B2B platform
ecosystem for additive manufacturing. The focus is on metallic materials, which
are processed with the PBF-LB process. The platform consists of a marketplace
for process parameters with the associated starting materials as well as the
resulting material data. The bulletin board gives users the opportunity to initiate
joint development projects for new materials and process parameters. The goal
is to drive the industrialization and market growth of additive manufacturing
technology for more sustainable production processes. The data sets are to be
used to offer so-called smart services by means of artificial intelligence and to
enable material and process innovations.
Experience
2017 - today Managing Director NuCOS GmbH, Stuttgart, Germany
2013 - 2016 Development Engineer, MBTech, Stuttgart, Germany
2009 -2012 Independent activity as project engineer – simulation,
Modelling and analysis
Training
2002 - 2009 Dipl.- Ing. Automation Technology in Production, University
Stuttgart Germany
Next Level in AM: Practical digitalization and automation in the additive manufacturing process
Uwe Schulmeister
Division Manager Additive Manufacturing, toolcraft AG
What is it about?
toolcraft is a medium-sized company that specializes in the production of high-end precision parts and components. Since 2011, the company has been manufacturing 3D printed components, mapping the entire additive value chain in metal.
Software is one thing - manufacturing practice is another. For this reason, we use, cooperate and further develop with software partners in order to make faster progress together and drive forward industrialization in AM.
In our lecture we will give you insights into the digitization of the additive process chain, the maintenance process, the simplified and automated re-machining as well as the use of Virtual Reality Software, with which we can pass on our additive manufacturing knowledge in a practical and self-taught way in our AMbitious training courses.
Joined the company since: 2002
2002 - 20011: Focus on machining
Since 2011: Focus on Additive Manufacturing (AM)
Since 2019: Focus of new business unit
Current position: Head of additive manufacturing
In process monitoring for Laser Powder Bed Fusion: challenges for automated failure analysis in industrial applications
Dr. Bernhard Wiedemann
Director Business Development, Carl Zeiss Industrielle Messtechnik GmbH
Dr. Claus Hermannstädter
Head of Additive Manufacturing Technology, Carl Zeiss Industrielle Messtechnik GmbH
What is it about?
Machine-integrated quality assurance is already a decisive success factor for the manufacturing industry. This trend is now increasingly entering the AM industry. ZEISS is addressing this trend with new in-process monitoring technology solutions, initially for the powder bed fusion based technology. The objective is to make the AM production process more stable, cost-efficient and flexible, and to make certain applications feasible in the first place. Initially, ZEISS offers solutions for the existing challenges in generating high-quality, reproducible digital QA data and fully automated data analysis using machine learning and algorithms for reliably determining defect types, characteristics, frequencies, etc., - without disrupting the production process. Furthermore, the challenge consisting of combining in-process monitoring data with CT data from special test objectes is addressed (ZEISS Parameter Development). This enables the entire production process to be significantly optimized.
Dr. Claus Hermannstädter
Experienced strategy, M&A and technology manager in the automotive, mechanical and high-tech sectors with over 10 years of management experience. Emphasis in digital transformation, (additive) manufacturing and semiconductor optics.
Stations:
Since 2014 Carl Zeiss: various positions in the areas of strategic Group development, venturing, M&A and post-merger integration,
Head of Strategy of the Division Industrial Quality and Research,
since 2022 Head of Zeiss AM Technology
The Boston Consulting Group: Strategy Consultant
Research Institute for Electronic Science, Hokkaido University, Sapporo, Japan: Post Doc & Research Group Lead
University of Stuttgart: Studies and PhD (Physics)
Dr. Bernhard Wiedemann:
In senior positions over 25 years of experience in the automotive, mechanical engineering, aerospace, measurement technology and consulting industries, among others in the field of Additive Manufacturing / Advanced Manufacturing, R&D, Strategy, Business Development, Transformation Processes.
Stations:
Since 2019 Carl Zeiss / Director Business Development AM
TMG Consultants
Daimler
Mercedes Benz Technology
Studies and doctoral studies / University of Stuttgart
Inspiring 3D printing for Medical Devices by Industrial Examples
Dr. Bart Engendahl
Managing Director, Chromatic 3D Materials GmbH
What is it about?
Chromatic 3D Materials produces flexible, functional and economical components by means of the
patented reactive liquid deposition, RX-AM Reactive Liquid Additive Manufacturing.
The smooth, non-porous polyurethane elastomer can be used for components up to in vivo
Applications.
The biocompatibility and stability of the materials are explained and illustrated with measurements of the
Surface area and porosity were compared. The pressure and the adhesion to the most diverse
Substrates are presented to be able to produce hybrid components. There will be new
Possibilities of manufacturing complex components are presented, in which many
Steps compared to traditional manufacturing processes can be saved and can be
open up new geometries for the manufacturer.
As another suggestion in the field of multi-material printing is presented. Here you can
Prints with different material properties can be realized in the same component.
This is particularly interesting in applications where a contact surface should be as soft and as
should be elastic, but at the same time high stability must be ensured.
Dr. Barthel Engendahl received their PhD in Engineering Chemistry at RWTH in 2009
Aachen. Since then he has employed both in industrial research laboratories
as well as in various start-ups with innovations in the field of chemical and
Plastics industry.
Mr. Engendahl holds several patents in the field of renewable polymer production,
Application of renewable chemicals in everyday life and 3D printing
of liquid systems.
He has been managing director of Chromatic 3D Materials GmbH for 3 years. He
deals with the application development of 3D printing for industrial
relevant components. He wants the knowledge he has learned about the successful application of the
Distribute 3D prints.
Design without boundaries
Bradley R. Rothenberg
CEO, nTopology
What is it about?
While 3D printing has moved from mainly prototyping to production over the last decade, we still use mostly the same design software and methods from the early 80s. CAD’s foundation is the BREP (boundary representation) that, when created, was ideal for digitizing drafting. CAD successfully replaced the drafting board for drawing, but what’s next? Rather than incrementally improving upon CAD, a totally new underlying model is needed, breaking boundaries between analysis and design, to handle the ever-increasing complexity of modern manufacturing. Implicit modeling + Field-Driven-Design is built for the future of product development and already today is enabling a wide range of products from more efficient turbine engines to zero-energy hydrogen-powered aircraft to lightweight, autonomous factory robots. Engineering is about breaking boundaries and exploring the art of what’s possible, and new software is the tool to enable us to deliver higher-performance products.
Bradley Rothenberg is the CEO and founder of nTopology, an engineering design software company based in New York City. Since its founding in 2015, nTopology has served the aerospace, automotive, medical, and consumer products industries with advanced engineering software that enables users to design, test, and iterate faster on highly complex parts for production with additive manufacturing. Bradley has been developing computational design tools for additive manufacturing for more than 15 years. He actively works to advance the industry, often speaking at industry events around the world including Develop3DLive, Talk3D and formnext. He is often quoted in trade publications, interviewed on industry podcasts, and has been included in Forbes Magazine. He studied architecture at Pratt Institute in Brooklyn, New York
Digital Assistance Systems for the Efficient Development of a New Product Generation
Dr. Stephan Ziegler
Managing Chief Engineer, RWTH Aachen University - Digital Additive Production DAP
What is it about?
In today's world of rapid technological innovations, customers demand products and integrated solutions that are always up-to-date, complete with the latest designs and technologies. That shortens established product life-cycles and drives demand, not just for frequent product updates and incremental improvements but also for complete makeovers and breakthrough technology innovation. The shortened life cycle and the need for up-to-date as well as for personalized products leads to a significant additional (personnel) effort in the development of these products. One possibility to (partially) automate the personnel-intensive product development is the use of smart digital assistance systems. On the one hand, these are able to reduce the effort and, on the other hand, to detect or avoid potential errors at a very early stage of the development. The presentation will provide an insight into the possibilities, both technological and economic, of using smart digital assistance systems.
Dr.-Ing. Stephan Ziegler is managing chief engineer at the Digital Additive Production at RWTH Aachen University. In addition, he is director for R&D with focus on systems engineering, process development and component design at the ACAM Aachen Center for Additive Manufacturing GmbH. He brings broad expertise in additive manufacturing, including materials, process chains, and approaches to digitization. He holds degrees in mechanical engineering, industrial engineering and business administration.
Minimally invasive implanted aortic stents - the better solution in emergencies
Matthias Kern
Project Manager Medical Technologies, FIT Production
What is it about?
The predicament:
- Thoracic aortic dissection (diseases of the cardiovascular system): high mortality rate despite advancing diagnostic and therapeutic techniques, fatal complications, therapeutic measures are associated with high risk and burden for the patient due to their invasiveness
The alternative:
- Aortic Gen-i stent: development of patient-specific additively manufactured aortic stents based on numerical methods.
- Innovation/uniqueness: the aortic stent as an additively manufactured high-risk implant, which has durable properties after plastic deformation
Content/Topics:
- Aortic stents in different stages of development as well as post-treatment conditions, geometry, modified manufacturing.
- FEM simulation of a balloon-expandable aortic stent, load models for fatigue strength
- Improvement of surgical technique, reduction of invasiveness, consideration of head vessels, reduction of surgical time
- Surgical risk can potentially be reduced, costs for treatment and post-treatment of the patient can be drastically reduced
- Example of successfully used and functioning AM process for 3D-printed aortic stents.
- The project is carried out in collaboration with, among others: Prof. Dr. med. Christof Schmid (Director of Cardiac, Thoracic and Cardiovascular Surgery at the University Hospital Regensburg) and Prof. Dr.-Ing. Thomas Schratzenstaller (Head of Laboratory for Medical Devices OTH Regensburg).
Matthias Kern is a Master of Applied Research in Engineering (M.Sc.) specializing in medical technology, quality management. Head of the medical technology division of FIT AG since 2018, he is responsible for the production of medical devices class I-III by means of additive manufacturing processes (EBM or PBF-EB/M, laser melting or PBF-LB/M, SLS or PBF-LB/P, PolyJet) and manages national and international customer projects as well as international R&D projects. His special competence is the customized volume manufacturing service ADM-CV.
3D printing in arm prosthetics - new supply options through digitization
Christoph Braun
Managing Director, schubert + braun prothesenwerk GmbH
What is it about?
Conventional cosmetic hand- and arm prosthetics are without any functions. They are made for the cosmetic restoration of the patient. If patients would like to add function to the prosthesis they have to accept a high decrease of the cosmetic outcome. Schubert and Braun have been closing the gap, while they developed passive movable hand- and arm prosthetics which are on the highest cosmetic level. It is possible because of integreated prosthetic hands, parts of the hand, wrist- and elbow joint, which are getting integreated into arm prosthetic devices. The products are produced by 3D-printing technology, after they are designed digital.
Training:
01.08.1995 - 28.02.1999 Orthopaedie- und Rehatechnik Dresden College:
15.08.2000 - 31.12.2000 Milwaukee Area Technical College, USA
Master degree:
01.04.2008 – 28.02.2009 Bundesfachschule for P&O, Dortmund
Experiences in foreign countries
01.08.2000 31.07.2001 17th CBYX program, USA
Work Experience:
01.03.1999 - 31.07.2000 Orthopaedie- and Rehatechnik Dresden 01.01.2001 - 30.06.2001 Orthotic Prostetic Center, Milwaukee, USA 01.01.2001 - 30.06.2001 The Natural Technology, Milwaukee, USA 11.11.2001 - 31.08.2002 Bauerfeind Prothetik, VS-Schwenningen 01.09.2002 - 31.08.2004 Brillinger Orthopädie, Tübingen 01.10.2004 - 30.09.2005 EproTec, Berlin
01.02.2006 - 31.10.2009 Orthopaedie- and Rehatechnik Dresden
01.11.2009 - 31.08.2013 Hans Sachs OST, Dresden
06.09.2013 - today schubert + braun prothesenwerk, Dresden
Scaling industrial 3D-Printing requires us to solve process complexity by making better physics-based decisions
David Hartmann
CEO/Founder, Helio Additive
What is it about?
This presentation delves into the challenges of scaling industrial 3D printing and how solving process complexity is key to unlocking its full potential. Making better physics-based decisions is crucial in overcoming these complexities. Drawing from extensive experience in the field and as the founder of Helio Additive, a deep-tech software company, David will provide valuable insights and practical solutions for attendees looking to drive the growth of their own 3D printing operations.
David Hartmann is a seasoned leader with a wealth of experience in international business. With over 16 years in the chemicals industry, he previously he served as the Senior Vice President of Growth Ventures at Covestro, where he led a global portfolio of high-tech materials businesses. As the founder of Helio Additive, David continues to tackle complex problems in the field of 3D printing. He is also the author of the 3D-printing science fiction novel, "Complexity is Free". With a deep understanding of the intersection of business and technology, David offers a unique perspective on the future of digital manufacturing.
Can Additive Manufacturing help Sustainability without damaging Profitability?
Alexander Herking
aPriori Technologies
What is it about?
Sustainability is a priority for many manufacturing businesses, and rightly so. The planet needs it to be. Additive Manufacturing offers some promise, but how do we ensure it makes sense over traditional methods regarding sustainability and profitability? Using a couple of example products/components, we will look at the difference in Cost and CO₂e emissions between a range of manufacturing processes, including additive manufacturing, and how the design and material play a huge role in optimizing this balance.
Alexander Herking is Principal Consultant, Expert Services at aPriori Technologies and holds over 30 years of experience in various roles and industries. Since joining aPriori in 2013, Alexander has led, over the past 10 years, international customer projects for aPriori by supporting manufacturers to unlock cost, manufacturability, and carbon insights resulting in increased product profitability and sustainability.
Prior to joining aPriori Alexander worked in various roles at has software service, Moldflow, Husky IMS, andagon, and Logica.
Dr. Steffen Beyer, Manager SprayLab Additive Manufacturing & Industrialization Expert
ArianeGroup (an Airbus Company)
What is it about?
An ultra-low cost reusable rocket engine, Prometheus is set to power Europe’s future launchers. Constructed using 3D printing technology, the core of the engine is the thrust chamber and in particular the combustion chamber. Cold Spraying (CS) was selected to sprayform the copper chamber liner and to deposit In625 for the load bearing structure (jacket).
ArianeGroup, the leader of Cold Spraying (CS) for rocket engine applications achieved decisive breakthroughs in the areas of coating and component design and stable long-term use of the process. Especially in the area of process robustness, significant development steps such as the introduction of a monitoring system for continuous in-process control and the development of a new generation of spray nozzles to minimize the so-called clogging effect could be achieved on the way to the industrialization of the cold spray process for space propulsion applications.
The use and application of the EHLA (Extreme High Speed Laser Application) process is currently being tested as a repair solution but also for the application of load-bearing structures at the ArianeGroup. The status of developments and an outlook for future use of the EHLA process for rocket engine applications are given here.
DR. STEFFEN BEYER
Manager SprayLab Additive Manufacturing & Industrialization Expert, ArianeGroup (an Airbus Company)
• 2008 PhD in the Area of Material Science @ University of Dresden (D)
• 2001 – 2018 Head of Production Technology – Materials and Processes @ ArianeGroup Ottobrunn
• 2017 - 2022 Industrial Leader “Thrust Chamber Assembly” for PROMETHUS Reusable Rocket Engine
• Since 2018 Manager of the "Rocket Factory – Cold Spray Additive Manufacturing” @ ArianeGroup Ottobrunn
• Since November 2019 Expert for Materials, Mechanicals Parts & Processes @ ArianeGroup Ottobrunn
• 28 Years of Heritage and Experience in the Space Business
How to fly - Certification of 3D-printed aircraft cabin interior parts - case study
Stephan Keil
Managing Director, The Aviation AM Centre
What is it about?
The certification of aircraft parts is subject to stringent regulation - the case study demonstrates the certification framework, compliance approach and approval of an exemplary aircraft cabin interior part.
PROFESSIONAL EXPERIENCE
Aug 21 – date The Aviation AM Centre, Managing Partner
Apr 20 – date AM Global, Director Industrialisation Lead AM Industrialisation Projects, Develop Business for AM in Aviation
Jul 19 – Mar 20 Aviation Consultant, independent
Jan 13 – Jun 19 ETIHAD Airways Engineering, H/o Production, Project Delivery & Innovation P21G Postholder of the EASA approved Production Organization
Mar 12 – Dec 12 ETIHAD Airways Technical, Senior Manager Product Development & Projects
Jan 09 – Feb 12 ETIHAD Airways Technical, Manager Cabin Reconfiguration Program
Nov 06 – Dec 08 EADS and AIRBUS Corporate Audit, Senior Audit Consultant
Oct 03 – Oct 06 AIRBUS Quality, Serial Processes Quality Manager A380 Program
Sep 02 – Sep 03 EADS European Aeronautic Defence and Space Company Trainee in Corporate Young Manager Programme (CYMP) page 1 / 1
STUDIES
Oct 95 – Jun 02 MSc in Engineering (Diplom-Wirtschaftsingenieur) Integrated Manufacturing Engineering and Business University of Paderborn, Germany
Nov 01 – Apr 02 PORSCHE, Stuttgart, Germany Diploma Thesis - Knowledge Management in the Automotive Industry
Apr 01 – Jun 01 RECARO Aircraft Seating, Schwäbisch-Hall, Germany Research Paper - Heat Treatment of aluminium in manufacturing of aircraft seats
Apr 98 – Jun 98 NIXDORF Institute, Paderborn, Germany Supply Chain Management – innovative software solutions
INTERNSHIPS
Jun 00 – Nov 00 MERCEDES BENZ USA, Montvale, NJ
Apr 99 – Jun 99 EADS Military Aircraft Division (GAF RECCE team), Munich, Germany
Nov 98 – Jan 99 BOFROST, Straelen, Germany
Aug 97 – Sep 97 DAIMLERCHRYSLER, Stuttgart, Germany
Jun 95 – Jul 95 STEINHOFF Kaltwalzen, Dinslaken, Germany Languages German - native speaker English – fluent speaking and writing French – fluent speaking and writing Spanish –business conversational
Post-processing and quality assurance - High-tech applications from printing high-pressure equipment to medical technology
Prof. Dr. Christian Seidel
Head of Additive Manufacturing, Fraunhofer IGCV, Hochschule München
What is it about?
This presentation gives a technologically broad and cross-industry overview of the state of the art in post-processing and quality assurance. Specific case studies will be used to highlight what can be achieved in combination with additive manufacturing and suitable post-processing and process monitoring equipment. One example will be the production of a pure copper component from the field of medical technology, which contains structures with a thickness in the range of a human hair. For process monitoring, an overview will be given of what can be achieved today with low- and high-cost equipment.
Prof. Seidel’s current positons are:
From 03/18 to 09/19 he served as Director “Strategy and Institute Development” and from 07/14 to
03/18 as Head of Department “Components and Processes” at Fraunhofer Institute for Casting, Composite and Processing Technology IGCV. From 04/16 to 02/22 he served as Chairman to German Association of Engineers (VDI) Committee on “Environment Health and Safety Issues in Additive Manufacturing”. He studied Mechanical Engineering at University Stuttgart, Technical University of Munich (TUM), and Stellenbosch University (South Africa). He received a doctorate from TUM for his Doctoral Thesis in the field of Powder Bed Fusion and served as part of the Management Board at Institute for Machine Tools and Industrial Management (iwb) of TUM while he was in charge of the “TUM-Cluster for Additive Manufacturing”.
He gathered industry experience at Gebr. Heller Maschinenfabrik GmbH (machine tool manufacturer, Nuertingen, Stuttgart area) and MTU Aero Engines (aero engine components manufacturer, Munich) before joining Fraunhofer in 2014.
Verification of AM parts for space applications
Dr. Marco Mulser
Technology Coordinator, OHB System AG
What is it about?
Additive Manufacturing offers exciting new possibilities for designing structural and functional components. Due to the low quantity of products in space industry, there are promising applications for satellites. The benefits of functional integration, mass and cost reduction are the main drivers for considering AM as an alternative to conventional manufacturing methods.
The presentation illustrates OHB's approach to developing and manufacturing AM components. In particular, the requirements for the verification of AM processes are highlighted for Laser Powder Bed Fusion (L-PBF), based on the standard of the European Cooperation for Space Standardization (ECSS). Testing and verification methods based on witness samples, destructive and non-destructive testing as well as surface treatments for opto-mechanical components are discussed. Recently developed AM parts are presented to demonstrate the advantages of AM over machining.
As Technology Coordinator, Dr. Marco Mulser coordinates the development & implementation of Additive Manufacturing at OHB System AG in Bremen since 2018. He established OHB's AM design & engineering capabilities and coordinates the manufacturing with OHB’s external suppliers for AM parts. Before his recent position at OHB, he was working for the Fraunhofer Institute for Manufacturing Technology and Advanced Materials. He holds a PhD in Production Engineering with a focus on Materials Science.
Challenges and achievements in post processing large RF Antenna Parts
Peter Finger
Project Manager AM, Oerlikon AM Europe GmbH
What is it about?
Additive manufacturing offers nowadays the ability to produce increasingly large parts. However, the post-processing of these parts presents several challenges, especially in the aerospace industry, where stringent requirements must be met. This presentation provides insight into the process chain for manufacturing radio frequency antenna parts for satellite communication. The challenges in the production of these parts include the additive manufacturing process itself, where the parts nearly fill the entire build chamber. Furthermore, milling the parts to precise tolerances relative to the as-printed geometries. Additionally, handling the parts between process steps and shipping them safely to the end customer are crucial aspects of the post-processing stage.
Studies 2009-2016
Technical University Dresden: Department of Mechanical Engineering
Focus areas: Production technology, machine tool development, methods of virtual product development
Research 2016-2018
Technische Universität Dresden: Institute for Machine Tool Development and Control Engineering
Main topics: Design of forming tools, machine simulation (MKS, FEM, DBS), Generative manufacturing processes
Change to the industry 2018
Urwahn Engineering: Innovative manufacturer of additive manufactured bicycles
Focus areas: Production monitoring and planning, quality assurance, qualification of additive processes for serial production
Change to Oerlikon 2019
First Operational Quality Management: Quality Management and Quality Planning, Complaints Management and Measure Monitoring, KPI Determination and Business Intelligence
Since 2021 Project Manager AM: Project Management, Start-up Management and Efficiency Improvement, Development of Process Chains
Advantages of higher acceleration voltage and electron optics for the next generation of electron beam powder bed fusion machines
Marcel Reith
Project Engineer Additive Manufacturing, Neue Materialien Fürth GmbH
What is it about?
At Neue Materialien Fürth, we transfer fundamental university research into industrial application. With our novel prototype PBFEB machine manufactured by probeam GmbH & Co. KG, we are able to process Ti based alloys and titanium aluminides without processing gas in vacuum conditions up to 1100°C. The prototype is capable of 150 kV acceleration voltage and 45 kW power and is equipped with electron optics (ELO) for insitu process monitoring. The higher acceleration voltage compared to conventional machines (60 kV) is beneficial for
pre heating and melting, shortening process times and enabling advanced scanning strategies.
As a result, the efficiency of the process and the final part quality is increased. The machine is controlled by software developed by the chair of Materials Science and Engineering for Metals at the Friedrich Alexander Universität , enabling full control over every single scan line. The ELO allows insitu monitoring of every single layer for defects, contamination or geometrical inaccuracy. This talk will explain, how the next generation of PBF EB machines will benefit froma higher acceleration voltage and insitu process monitoring vi a electron optics, making a huge step toward the broad industrialization of the technology.
NEX Aero - how we accidentally built the larges 3D-printed flying eVTOL prototype
Johannes Garbino-Anton
CTO & Co-Founder, NEX Aero GmbH
What is it about?
With NEX Aero we are developing the first hydrogen powered long-range eVTOL for passenger transport. During the development of our large scaled prototype we inherited fast-paced design iterations with additive manufacturing. This allowed us to bring the engineering validation vehicle to flight using less time and money.
In this talk we present our approach and lessons learned.
Studied aerospace engineering in Munich and Berlin (Master of Science). Training as a professional pilot (fATPL) and test pilot at the German Aerospace Center. Assignment as test pilot and development engineer on 11 different electric aircraft incl. two hydrogen fuel cell aircraft. Co-founder of NEX Aero Gmbh.
Canyon computer mounts: How automation technology and quality assurance processes at rpm guarantee the production of series AM products.
Brian Crotty
Business Development Manager, rpm rapid product manufacturing GmbH
What is it about?
For more than two years, rpm has been producing end-user products in Selective Laser Synthesis and has built a series of quality assurance processes to ensure their output. The rpm team will lay out the schematic they use at each stage of product development and production to ensure top quality.
A successful product begins with the design phase and optimizing for later processing alongside function. Strict production processes and controls are an essential second step. The third key is the advances in production and post-processing machines that allow for a validated, locked workflow. For validation of parts from specific batches, rpm relies on automated part scanning using the GOM ScanCobot system. And last but not least, a clear definition and execution of packaging allows rpm to deliver "sales ready" products directly to canyon without requiring any additional handling.
Even a few years ago, the machines and surrounding processes were not meeting the required milestones. Now each company in the AM industry is a few steps away from delivering reliable series products.
Brian Crotty is responsible for managing new business development in industries outside mobility and focusing on series additive manufacturing at rpm GmbH. In particular, he is focused on developing end-use parts for Carbon DLS applications and SLS parts in specialty materials.
In 2020, Brian joined rpm - rapid product manufacturing GmbH, one of the pioneers of laser-based 3D printing with 25+ years producing SLS parts, to satisfy a desire to produce concrete parts. rpm also has 20 years of experience with small series casting and injection molding of spare and specialty series parts. This gives them a unique view into what it takes to produce parts in series and what steps AM needs to get there. At 80+ employees, they also have the internal knowledge and quality assurance processes in place to produce in series.
His previous 5 years, Brian handled the marketing and product positioning for 3YOURMIND where he developed deep understanding for the true business cases in additive manufacturing. Prior to entering the AM industry, Brian came from a software and design background including coordinating designers, artists, programmers and producers to produce physical and digital artwork installations in some of the biggest new hospitals along the west coast of the United States as the operations director of a boutique artwork consulting company. He holds a degree in communications from at Northwestern University (Evanston, USA) and was part of the inaugural class for the certificate in Art & Technology program.
Cryogenic Rocket Propulsion Component development with Addtitive Manufacturing
Maximilian Strixner
Additive Manufacturing Senior Engineer, The Exploration Company
What is it about?
This presentation firstly gives an insight into rocket propulsion use cases and why AM is an applicable manufacturing technology for these parts. The focus here will be on cryogenic engines, which means combustion engines working with fuels and oxidizers at very low temperatures in usually fluid state (e.g. fluid oxygen and fluid methane). Possible materials and their selection criteria will be offered, while the whole development process is explained under aspects of thermo-mechanical considerations. A focus for this event is to work out the striking advantages of AM for these kind of applications as well as the special requirements and challenges. Finally, the actual market situation will be discussed and prospects into possible future developments are stated.
The Exploration Company
Senior Additive Manufacturing Engineer
Juli 2022 - Present (7 Monate)
Space Exploration
Design for AM (DfAM) MAIT
Application Engineering: Additive Manufacturing
Propulsion Systems
Aerospace Industry
AMCM GmbH
Application Specialist AM
Oktober 2020 - Juli 2022 (1 Jahr 10 Monate)
APWORKS GmbH
1 Jahr 11 Monate
Project Engineer AM
April 2019 - Oktober 2020 (1 Jahr 7 Monate)
Technical project lead for serial productions of metal materials in Additive Manufacturing
Application Engineer AM
Dezember 2018 - März 2019 (4 Monate)
Design for AM (DfAM) and RedesignApplication engineering: Additive Manufacturing data preparation
Process engineering Production engineering
EDAG
Design Engineer Lightweight Structures Automotive
Mai 2018 - November 2018 (7 Monate)
Design of lightweight structures automotive CAD: CATIA V5, CATIA V6
Process developing: Additive manufacturing integration into automotive serialproduction
Influence of Process Acceleration Methods, Automation and Digitization on Production KPIs of Additive Manufactured Large- Volume Aerospace Parts
Fabian Tieck
PhD Student, EOS GmbH
What is it about?
Additive manufacturing continues to evolve from prototyping and small series production to a factor for mass production. The Aerospace industry with highest quality requirements in production and large-volume parts particularly benefits from this. Maximizing the utilization and output of each AM system therefore plays a crucial role in this strategy. Every aspect of the manufacturing- and production-chain must therefore be investigated and optimized to achieve this holistic goal. First this presentation will show how the development of the additive manufacturing process can reduce the build time, using support reduction tools and laser beam shaping to increase build speed. As second important point the introduction of automation will then be discussed to optimize the production by reducing non-productive time and increase capacity utilization. Finally, the possibilities of digitalization are shown by using monitoring systems and data analysis tools to increase availability. All these findings can be displayed on different dashboards to measure production KPIs like OEE - productivity, availability, and quality. The use of these methods is contrasted with the classical approach to show the advantages and present the future of additive manufacturing, which is ready to take on large production targets and is here shown in aerospace use cases.
Since Mai 2020: PhD Student - Digital Twin AM Production
EOS GmbH: Digital Manufacturing
2019/20: Master thesis & student trainee
EOS GmbH: Production Simulation & Digitalization
2018/19: Seven-month internship
BMW AG Leipzig: Lean Management & Production
2018: Six-month internship
ZF Friedrichshafen AG: Technology Development
2015/16: Six-month internship
MAHLE Behr GmbH: technical purchasing
Investigation for the Application of a Material Tracing Technology to a Polyamide 12 Sinter Material in Selective Laser Sintering
Tom Eggers
PhD student, VW
What is it about?
Selective laser sintering (SLS) with polymers is currently in transition from prototyping to the production of functional components. As a result, the application capability is confronted with new requirements for reliability and reproducibility. This requires a deeper process understanding of material ageing processes in polymers. For a material traceability as well as an identification of defective components with subsequent cause tracing, the use of a material inherent marking technology represents a solution. Based on an increased process understanding and the compensation of scattering material properties, SLS in combination with a marking technology offers the possibility of reproducible and high-quality manufacturing. The work presents a method for in-process material characterization using a marking technology. Regarding the future application of material tracing in SLS, the integration of the marking technology into a polyamide 12 sinter material and evaluation of it in SLS is investigated. Potential effects of the marking technology on specific material and component properties are quantified and the traceability of the marking technology in different material conditions is demonstrated. Based on the investigation, current challenges and action recommendations for future implementation of the marking technology in SLS as well as further application options for the marking technology are identified.
Experience
2021 Volkswagen AG – PhD student
Additive manufacturing Technology planning
Plastic-based additive manufacturing & selective laser sintering
2019 - 2021 Volkswagen AG – Masterand
Additive manufacturing Technology planning
Binder Jetting
2019 Technical University of Braunschweig – Stud. Auxiliary
Institute for Joining and Welding Technology
Fibre composites & electromobility
2017 - 2018 Volkswagen AG – Bachelor's degree
Additive manufacturing Technology planning
Binder Jetting
Studies
2021 Technical University of Braunschweig
Institute for Machine Tools and Manufacturing Technology
Doctoral studies
2014 - 2021 Technical University of Braunschweig
Bachelor's and Master's programmes
General engineering
