Beyond the Hype What does the journey to metal AM production really look like? August 2016 Adam Rivard ARivard@LAIco.com 207-756-5544
Beyond the Hype: How to get there? The Best Machine Control Integrate Quality Standardize Dig into the details Gartner.com
The Big Question Build Chamber Materials Monitoring Process Configuration
Build Chamber Envelope Size M280 SLM Q20 M400 ProX X Line 500 320 400 2000 HL R 9.9 14.2 10.8 15.8 19.7 31.5 x x 9.9 11.0 14.2 10.8 19.7 15.8 x 12.8 x 12.6 16.5 15.8 19.7
Why Go Bigger? >5000 Parts!
Is Bigger Really Better? >5000 Parts!
Is Bigger Really Better? IN718
Is Bigger Really Better?
Is Bigger Really Better? Qualified & Controlled
Build Chamber - Environment Inert Gas 7 18 Vacuum 8 N Nitrogen Ar Argon O Oxygen Laser Electron Beam & Laser
Build Chamber - Temperature Structure Stress Time
Process Configuration - Scanning 7 m/s 200 W 8000 m/s 3000 W
How Fast is Fast Enough? Source: Appl. Phys. Rev. 2, 041304 (2015)
Process Configuration Powder Distribution Build Platform
Process Configuration Powder Distribution Build Platform
Process Configuration Powder Distribution Build Platform
Process Configuration Powder Distribution Build Platform
Process Configuration Powder Distribution Build Platform
Rake Configuration Rigid Pros: Precision Thin Layers Consistency Cons: Unforgiving Build Platform
Rake Configuration Flexible Metal Pros: Forgiving Cons: Thicker Layers Variation? Build Platform
Rake Configuration Flexible Non-Metallic Pros: Forgiving Fine Detail Features Cons: Thicker Layers Debris? Build Platform
In-Situ Inspection Atmosphere Solidified Layer Beam Metal Powder Layer Thickness Melt Pool Previous Layers Build Platform
Material Availability Aluminum Cobalt Nickel Steel Titanium Gold? X Line 2000 R Pro X 400 Pro X 320 Q20 M290 SLM 280 HL M3 Mlab Understand & Characterize
Turnaround Time
Service and Support
You bought a machine. Now what? STL File Material Machine Geometry Material Machine Process themes Post Processing
Stop Building Start Producing Feedstock Material Contamination Control Calibration & Maintenance Equipment & Process Certification Configuration Management Build Analytics Build Pedigree Quality & Validation
Feedstock Material Contamination Control Calibration & Maintenance Standard Work People Material Specifications Reuse Strategy Consumables & Tools Process Related Above & Beyond OEM Recommendations
Equipment & Process Certification Configuration Management Build Analytics Machine Qualification Process Change Control Standard Work Models Build Files Hardware Software Themes Design Rules Design Report Lessons Learned
Build Pedigree Quality & Validation Start Finish Standard Work Machine Data Collection In-Process Monitoring Visual Inspection CAD Files Models Build Files Powder Input Build Logs Post Process Data Inspection Data Machine & Build Diagnostics Visual Inspection Standards Effects of Defects Understanding
Certification & Validation Align Contribute
A chain is only as strong as it s weakest link
Beyond the Hype What does the journey to metal AM production really look like? August 2016 Adam Rivard ARivard@LAIco.com 207-756-5544