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Metal AM Vol 3 No 3 7 1 THE MAGAZINE FOR THE METAL ADDITIVE MANUFACTURING INDUSTRY | contents page | news | events | advertisers’ index | contact | 0 2 N M U T U A 3 . o METAL N 3 . l o V AM in this issue HONEYWELL AEROSPACE DESIGN FOR AM: CASE STUDIES METAL POWDER RECYCLING Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 1 Published by Inovar Communications Ltd www.metal-am.com | contents page | news | events | advertisers’ index | contact | Publisher & Editorial Offices Inovar Communications Ltd 11 Park Plaza METAL Battlefield Enterprise Park Shrewsbury SY1 3AF, United Kingdom Tel: +44 (0)1743 211991 Fax: +44 (0)1743 469909 ADDITIVE Email: [email protected] www.metal-am.com MANUFACTURING Managing Director, Features Editor Nick Williams Tel: +44 (0)1743 211993 Email: [email protected] Publishing Director, News Editor Paul Whittaker Tel: +44 (0)1743 211992 Email: [email protected] Assistant Editor Emily-Jo Hopson Tel: +44 (0)1743 211994 Email: [email protected] Designing the value into Production Hugo Ribeiro, Production Manager Additive Manufacturing Tel: +44 (0)1743 211991 Email: [email protected] The knowledge that an engineer has to possess in order to Advertising successfully produce parts by AM differs fundamentally from Jon Craxford, Advertising Sales Director conventional manufacturing processes. For those new to AM, Tel: +44 (0)207 1939 749 Fax: +44 (0)1743 469909 the complexities of the Design for Additive Manufacturing (DfAM) Email: [email protected] methodology can be particularly daunting. Subscriptions Metal Additive Manufacturing is published on a Today, there is growing recognition amongst end-users that simply Making your quarterly basis as either a free digital publication putting a part designed for conventional manufacturing through or via a paid print subscription. The annual print an AM machine is doomed to failure. The skills and knowledge subscription charge for four issues is £95.00 required to create a part specifically for AM rely on the designer for Additive Manufacturing including shipping. Rates in € and US$ are embracing a completely new mind set that draws on a wide range DREAMS available on application. of previously unconsidered factors. Accuracy of contents for metal AM Whilst every effort has been made to ensure the Case studies are one way that those who are further ahead on accuracy of the information in this publication, the DfAM journey can share their experience and knowledge with the publisher accepts no responsibility for those who are new to the technology. In this issue of Metal AM errors or omissions or for any consequences arising there from. Inovar Communications Ltd magazine we feature two very different application-focused cannot be held responsible for views or claims reports, both of which offer invaluable insight into how companies expressed by contributors or advertisers, which have successfully leveraged DfAM to transform existing are not necessarily those of the publisher. applications. Advertisements Although all advertising material is expected Using AM for these applications has brought major benefits, from to conform to ethical standards, inclusion in performance improvements to weight reduction and, in one case, FLY this publication does not constitute a guarantee a dramatic reduction of the total number of components in a With Praxair powders, the sky isn’t the limit or endorsement of the quality or value of product sub-assembly from a hundred to one. Look to Praxair Surface Technologies for the metal such product or of the claims made by its manufacturer. powders, know-how, resources and supply to turn If your company is starting out on the AM journey and you your AM dreams into reality. Reproduction, storage and usage plan to visit the formnext exhibition in Frankfurt, Germany Single photocopies of articles may be made (November 14-17), please drop by our booth (3.0 G65). We’d be for personal use in accordance with national very interested to learn about your metal AM experiences. • Approved aerospace grade copyright laws. All rights reserved. Except as outlined above, no part of this publication may • Large lot sizes and R&D volumes be reproduced, modified or extracted in any form Nick Williams or by any means without prior permission of the Managing Director • Stock availability and custom offerings publisher and copyright owner. Metal Additive Manufacturing Printed by IT’S TIME TO DREAM BIG. Cambrian Printers, Aberystwyth, UK ISSN 2057-3014 (print edition) ISSN 2055-7183 (digital edition) praxairsurfacetechnologies.com/am Cover image Vol. 3. No. 3 Autumn 2017 An F125IN turbofan engine This magazine is also available for free manufactured by Honeywell Aerospace download from www.metal-am.com (Courtesy Honeywell) © 2017 Inovar Communications Ltd Contact us to find out how we are making more possible: 1-317-240-2650 or [email protected] 2 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Metal Additive Manufacturing | Autumn 2017 1 © Copyright 2017 Praxair S.T. Technology, Inc. All rights reserved. MetalAM June2017.pdf 1 6/5/17 7:26 PM | contents page | news | events | advertisers’ index | contact | Autumn 2017 METAL ADDITIVE MANUFACTURING 24 38 81 105 110 In this case study, Terry Wohlers and Professor Olaf Diegel, both of Wohlers Associates, reveal Contents how industrial mining machine manufacturer Atlas Copco has used DfAM to increase the value 5 Industry News of a hydraulic manifold. 81 Honeywell: Driving AM application 109 Design for AM: Transforming RF and supply chain development in the antennas through intelligent optimisation aerospace industry AM presents the opportunity to completely rethink With dedicated AM facilities in five countries, a product’s design, transforming its functionality Honeywell Aerospace is at the forefront of the and reducing manufacturing complexity. In the development of new commercial aerospace following article, Optisys LLC reveals how, through applications for AM, along with the supply chain intelligent design optimisation, the company has needed to implement series production. Dr Dhruv used Additive Manufacturing to develop the next Bhate visited Honeywell’s Phoenix facility and generation of RF antenna systems for aerospace met with Donald Godfrey, an Engineering Fellow and defence. at Honeywell and the person most credited with directing the company’s progress in AM. 115 AMPM2017: Understanding the impact of powder reuse in metal Additive 93 RapidTech + FabCon 3D: Innovations Manufacturing in binder-based AM and advances in An issue of significant current interest to conformal cooling the Additive Manufacturing world, which can From June 20-22, 2017, the German city of potentially impact both the quality and cost- Erfurt became a centre of gravity for AM, hosting effectiveness of built parts, is whether there the annual RapidTech conference and FabCon is a limit on the number of times that metal 3D exhibition. Dr Georg Schlieper reports on a powders can be cycled around an AM process. number of trends in metal AM process technology Dr David Whittaker reviews three presentations and applications, including binder-based AM on the topic from AMPM2017, the fourth technologies and innovations in toolmaking. annual Additive Manufacturing with Powder Metallurgy Conference, held in Las Vegas, USA, 103 Design for AM: Increasing part value June 13-15, 2017. through intelligent optimisation Paying the right amount of attention to Design 127 Events guide for Additive Manufacturing (DfAM) can make the difference between economic success and failure. 128 Advertisers’ index 2 Metal Additive Manufacturing | Autumn 2017 © 2017 Inovar Communications Ltd Vol. 3 No. 3 Vol. 3 No. 3 © 2017 Inovar Communications Ltd Metal Additive Manufacturing | Autumn 2017 3 | contents page | news | events | advertisers’ index | contact | | contents page | news | events | advertisers’ index | contact | Industry News industry news Digital Metal begins commercial program,” explained Don Godfrey, Engineering Fellow – Additive production of its high precision binder Manufacturing, Honeywell Aerospace. jet metal AM system “We believe this will also be critical to applications in other key areas of the broader aerospace industry.” Digital Metal®, Sweden, a Höganäs Ralf Carlström, General Manager, Digital Metal has also stated that Group company, has begun Digital Metal, stated, “Our heritage, it will provide all ancillary equipment commercial production of its high- knowledge and experience in required with each machine, as well precision binder jet metal Additive metal powders, combined with the as introductory and ongoing training Manufacturing system which it development and evolution of our and support. states can produce smaller and cutting-edge printer technology, has more intricate components than any enabled us to succeed where others Digital Metal adds titanium option previous technology. The DM P2500 have failed. With the DM P2500 we are In addition to stainless steels 316L has a 2500 cm3 print volume and bringing to market a tried and tested and 17-4PH, Digital Metal has also Sparking a new era manufactures parts in 42 µm layers 3D metal printer.” extended its material range to include at 100 cm3/h, without the need for Honeywell Aerospace and Digital titanium Ti6Al4V. Titanium is widely in design and manufacturing any support structures. This makes it Metal are said to be exploring a used in the Additive
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