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Additive Manufacturing at Ge Research ADDITIVE MANUFACTURING AT GE RESEARCH Steve Duclos | Chief Scientist – Additive Manufacturing, GE Research Chip Cotton | Account Executive – Government Relations, GE Research Advanced additive technologies that enhance maintenance capabilities: • Shortening the design-to-print workflow • Lowering the cost of additive • Enabling a secure additive network © 2021 General Electric Company - All rights reserved GE Research – Additive Overview 70 FTE’s working additive technologies © 2021 General Electric Company - All rights reserved 2 Design and Build Prep: Optimizing in days vs weeks Topology Optimization & Generative Supports Build Simulation Distortion Compensation Producibility Shortening the design-to-print workflow: account for producibility & predictable disturbances © 2021 General Electric Company - All rights reserved 3 Controls, Sensing, & Analytics ONR Quality Made Project America Makes ALSAM Project Optimize the Meltpool for a Material Process Variation Control & Compensation Roadmap Sensor capability ALSAM Software analytics Developments Control algorithms Rapid qual & cert through sensor & models: Open control platform to enable multi-laser: Higher yields with advanced process control Accelerate builds & lower cost © 2021 General Electric Company - All rights reserved 4 Binder Jet ADVANCED BINDER UP TO UP TO 80% TECHNOLOGY, 100x CHEAPER RAW FASTER BUILD SPEED DISTORTION MANAGEMENT Compared to single laser LPBF MATERIAL FEEDSTOCK & CONTROL Compared to LPBF Print Process Post Process Properties vs. Cost Low cost Cost/Viability powder Target Property Process Complexity Understanding & Optimizing Finished Properties • Process Parameters • Thermal Profiles Critical mechanical properties • Powder / Binder • Sintering Improvements aligned to customer CTQs Developing materials & processes for low-cost, high volume binder jet manufacturing © 2021 General Electric Company - All rights reserved 5 Additive Secure Supply Chain Goals Critical Technology Milestones Near-term [] to Long-term [] development roadmaps Trusted • Develop and deploy secure digital trust supply chain Trusted Supply networks for secure data, transactions, analytics and Modeling Chain learning networks for additive manufacturing Trusted and System Data and Analytics • Defense and commercial digital supply chain needs Trans- Trusted actions Trusted Networks • Disrupting traditional manufacturing paradigms and Capability Platform disintermediating ad-hoc digital approaches Standards Time Tech Components Challenges & Gaps • Global, scalable digital trust fabric • Government and industry partnerships needed to • Secure networks (e.g. Quantum accelerate solution development and deployment secure) • Critical for national and economic security • Disrupting traditional, manual manufacturing systems and security Current Work solutions (e.g. “sneaker net”) • ONR: Digital Trust Nexus: Next-Generation Digital Platform for Manufacturing, Maintenance and Logistics Trusted digital supply chain technologies for a secure additive manufacturing ecosystem © 2021 General Electric Company - All rights reserved 6 GE Additive: A full ecosystem of additive offerings Machines Software • Design • Direct metal laser melting (Concept Laser) • Build Preparation • Electron beam melting (Arcam EBM) • Machine Printing • Binder Jet • Monitoring Powders Customer Experience Centers • CpTi grade 1 • Al-Si7-Mg (F357) Designed to host customers; to educate, train, collaborate and • CpTi grade 2 • Al-Si10-Mg demonstrate the processes, products and technology involved with • Ti-6Al-4V grade 5 • CoCrMo AM and how GE Additive can help them achieve their full potential. • Ti-6Al-4V grade 23 • 316L Stainless Steel • Ti-6Al-2Sn-4Zr-2Mo • M300 Stainless Steel • Ti-5Al-5V-5Mo-3Cr • 17-4 PH Stainless Steel • Munich, Germany (Europe) • Ni Alloy 718 • remanium star® CL • Ni Alloy 625 • rematitan® CL • Mitsubishi Customer Experience Centre (Japan)* AddWorks™ consultancy GE Additive Partners Workshops • Manufacturing Partner Network: Learn foundational knowledge and additive strategies in a classroom • Carpenter environment. Workshops typically run three to five days. • Protolabs Sprints • Binder Jet Development partners: Combine workshops, hands-on consulting and print services to fast-track • Cummins the path to full production. Sprints vary in length from one to 10 months. • Wabtec *Sales Partner in Japan © 2021 General Electric Company - All rights reserved 7 Additive Manufacturing – Research to Reality Advanced additive technologies that enhance maintenance capabilities • Shortening the design-to- print workflow • Lowering the cost of additive • Enabling a secure additive network © 2021 General Electric Company - All rights reserved 9 GE Research Steve Duclos - [email protected] Chip Cotton - [email protected].
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