Christian Hinke

Direct photonic production: towards high speed additive manufacturing of individualized goods

World market competition currently boosts trends like mass customization and open innovation which result in a demand for highly individualized products at costs matching or beating those of mass production. This work focus on the resolution of the production related dilemma between scale and scope, e.g. either the low-cost production of high quantities or the high-end and thus cost-intensive low-volume production of individualized goods. One of the areas of greatest potential for the resolution of this dilemma are rapid manufacturing (RM) technologies due to their almost infinite geometrical variability and freedom of design without the need for part-specific tooling. Selective Laser Melting (SLM) is one of the RM technologies that additionally provides series identical mechanical properties without the need for downstream sintering processes, etc. However, the state-of-the-art process and cost efficiency is not yet suited for series production. In order to improve this efficiency and enable SLM to enter series production it is indispensable to increase the build rate significantly by means of increased laser power and larger beam diameters. To exploit this potential, a new generation production machine including a kW laser and an optical multi-beam system is developed and experimental results and real life components are shown.

Exploiting Process-Related Advantages of Selective Laser Melting for the Production of High-Manganese Steel

Metal additive manufacturing has strongly gained scientific and industrial importance during the last decades due to the geometrical flexibility and increased reliability of parts, as well as reduced equipment costs. Within the field of metal additive manufacturing methods, selective laser melting (SLM) is an eligible technique for the production of fully dense bulk material with complex geometry. In the current study, we addressed the application of SLM for processing a high-manganese TRansformation-/TWinning-Induced Plasticity (TRIP/TWIP) steel. The solidification behavior was analyzed by careful characterization of the as-built microstructure and element distribution using optical and scanning electron microscopy (SEM). In addition, the deformation behavior was studied using uniaxial tensile testing and SEM. Comparison with conventionally produced TRIP/TWIP steel revealed that elemental segregation, which is normally very pronounced in high-manganese steels and requires energy-intensive post processing, is reduced due to the high cooling rates during SLM. Also, the very fast cooling promoted ε- and α’-martensite formation prior to deformation. The superior strength and pronounced anisotropy of the SLM-produced material was correlated with the microstructure based on the process-specific characteristics.

Geometric complexity analysis in an integrative technology evaluation model (ITEM) for selective laser melting (SLM)

Selective laser melting (SLM) is becoming an economically viable choice for manufacturing complex serial parts. This paper focuses on a geometric complexity analysis as part of the integrative technology evaluation model (ITEM) presented here. In contrast to conventional evaluation methodologies, the ITEM considers interactions between product and process innovations generated by SLM. The evaluation of manufacturing processes that compete with SLM is the main goal of ITEM. The paper includes a complexity analysis of a test part from Festo AG. The paper closes with a discussion of how the expanded design freedom of SLM can be used to improve company operations, and how the complexity analysis presented here can be seen as a starting point for feature-based complexity analysis.

Integrative Technology Evaluation Model (ITEM) for Selective Laser Melting (SLM)

This paper focuses on the evaluation of manufacturing processes that are competing with Selective Laser Melting (SLM). In 3D-part production of serial parts SLM is starting to be an economic choice for manufacturing. An integrated technology evaluation model (ITEM) is presented that helps decision makers to determine the potential of SLM while comparing with conventional manufacturing technologies. In contrast to conventional evaluation methodologies the ITEM considers interactions between product and process innovations generated by SLM. The paper closes with a technical and economical evaluation of a test part from Festo AG to validate two important parts of the ITEM.

Digital photonic production along the lines of industry 4.0

The context of future laser applications in modern manufacturing can be summarized by Digital Photonic Production (DPP). “From Bits to Photons to Atoms” describes the vision of DPP: Designing a component or product in the computer and creating it directly by additive or subtractive photon based processes or production-systems.

Disruptive Innovation Through 3D Printing

Emerging technologies such as 3D Printing or Additive Manufacturing (AM) and especially Selective Laser Melting (SLM) provide great potential for solving the dilemma between scale and scope, i.e. manufacturing products at mass production costs with a maximum fit to customer needs or functional requirements. Because of the technology’s intrinsic advantages such as one-piece-flow capability and almost infinite freedom of design, Additive Manufacturing was recently described as “the manufacturing technology that will change the world”. Due to the complex nature of production systems, the technological potential of AM and particularly SLM can only be realized by a holistic comprehension of the complete value creation chain, especially the interdependency between products and production processes. Therefore, this chapter aims to give an overview on recent research in machine concepts and component design, which experts of the Cluster of Excellence “Integrative production technology for high wage countries” carried out.

Direct, Mold-Less Production Systems

Additive Manufacturing (AM) technologies in general—and in particular, Selective Laser Melting (SLM)—are characterized by a fundamentally different relationship with respect to costs, lot size, and product complexity compared to conventional manufacturing processes. There is no increase of costs for small lot sizes (in contrast to mold-based technologies) and none for shape complexity either (in contrast to subtractive technologies). Thus, only the holistic development of a direct, mold-less production system that takes all relevant interdependencies along the product creation chain into account provides the full economic, ecologic and social benefits of AM technologies in future production. The following six subjects of the product creation chain were examined: (i) New business models and customer willingness to pay for AM parts are revealed. (ii) The Product Production System (PPS) was totally revised regarding the adoption of SLM technology into conventional manufacturing environment. (iii) The SLM manufacturing costs were examined regarding different machine configurations. (iv) A high-power SLM process was developed for enhancing the process productivity. (v) High manganese steel was qualified for the SLM process. (vi) Finally, two lattice structure types and a design methodology for customer parts were developed.

How Can Reynolds Help to Improve the Performance of Production Systems? Fluid Dynamics and its Contributions to Production Theory

Future production systems need to cope with a high degree of flexibility in terms of fluctuation of demand, product variants, etc. without loosing sight of an increasing cost pressure. For the resolution of this dilemma this work focuses on the adaption of basic principles of similitude and fluid dynamics to production theory in order to increase the production velocity while avoiding regions of instability, or turbulence, at the same time. Subsequently, an experimental setup for the verification of this analogy model is developed and discussed.

High power selective laser melting: A new approach for individualized series production

World market competition currently boosts trends like mass customization and open innovation which result in a demand for highly individualized products at costs matching or beating those of mass production. Selective Laser Melting is one of the Additive Manufacturing technologies that enables the production of complex shaped individual parts with series identical mechanical properties without the need for part specific tooling or downstream sintering processes, etc. However, the state-of-the-art process and cost efficiency is not yet suited for large-scale series production. In order to improve this efficiency and enable SLM to enter series production it is indispensable to increase the build rate significantly by means of increased laser power and larger beam diameters. Hence, a new SLM machine including a kW laser and a multi-beam system is developed and first experimental results are shown.World market competition currently boosts trends like mass customization and open innovation which result in a demand for highly individualized products at costs matching or beating those of mass production. Selective Laser Melting is one of the Additive Manufacturing technologies that enables the production of complex shaped individual parts with series identical mechanical properties without the need for part specific tooling or downstream sintering processes, etc. However, the state-of-the-art process and cost efficiency is not yet suited for large-scale series production. In order to improve this efficiency and enable SLM to enter series production it is indispensable to increase the build rate significantly by means of increased laser power and larger beam diameters. Hence, a new SLM machine including a kW laser and a multi-beam system is developed and first experimental results are shown.