Additive Manufacturing with Open Source and Open Hardware M

ADDITIVE MANUFACTURING WITH OPEN SOURCE AND OPEN HARDWARE M. Sc. Dipl.-Ing. (FH) B. Eng. (hon) Ulrich Thombansen Fraunhofer Institute for Laser Technology ILT, Aachen

Brussels, 14.11.2019

Tooth caps © BEGO Guide Vane © Fraunhofer ILT

Motor block © Fraunhofer ILT 2 Combustion Nozzle © GE ® BEGO Medical 2002 © Fraunhofer ILT AM with Open Source and Open Hardware Demonstrator – Functional light weight structures

Lattice Structure Hollow Spheres

Laser Melting of powder material 2015

??? 2008

First series Production 2003

Lowering of Deposition of build platform First Implant powder layer 2001

1996 First Production

First Tool Insert ...from Prototyping Basic Patent Seite 4

1 AMable Services for SMEs

2 AM Machines from Desktop to Industry

3 AM Software for Design and Production

Digital Additive Manufacturing Innovation Hub for SME’s providing services from idea to market

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 768775

This document and the information contained are property of the AMable consortium coordinated by Fraunhofer ILT and shall not be copied or disclosed to any third party without prior written authorization. www.amable.eu AMable – Digital Additive Manufacturing Innovation Hub Supporting SMEs in the uptake of Additive Manufacturing

Digital Services for SMEs and midcaps  Three distinct platforms provide collated knowledge  On demand access to individual service modules  Entry from idea to suitable development stage  Tutor directs the experiment partner through the services arena

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 768775 7

This document and the information contained are property of the AMable consortium coordinated by Fraunhofer ILT and shall not be copied or disclosed to any third party without prior written authorization. www.amable.eu AMable – Digital Additive Manufacturing Innovation Hub The digital data chain - Digital Infrastructure for AM related information

AM Data Evolution across the value chain  Data enrichment from stage to stage  Data recording with Blockchain support for signed documentation  Data viewport per stage and stakeholder  Security requirements depending on application and actual stakeholders  Continuous documentation and transparent access  Respect for data ownership

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 768775 Seite 8 This document and the information contained are property of the AMable consortium coordinated by Fraunhofer ILT and shall not be copied or disclosed to any third party without prior written authorization. www.amable.eu AMable – Digital Additive Manufacturing Innovation Hub The digital data chain - Digital Infrastructure for AM related information

AMable IDS Connector – Trusted and documented data exchange  Paradigm of the Industrial Dataspace  Data remains with the data owner  Transactions can be documented in AMable Blockchain  AMable IDS Connector as a registered hardware device to connect between data owners and data users

Open Source Base  Hyperledger Fabric  ActiveMQ  Spring

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 768775 Seite 9 This document and the information contained are property of the AMable consortium coordinated by Fraunhofer ILT and shall not be copied or disclosed to any third party without prior written authorization. www.amable.eu AMable – Digital Additive Manufacturing Innovation Hub The digital data chain - Digital Infrastructure for AM related information

AMable IDS Connector – Trusted and documented data exchange Missing TPM Functionality  Paradigm of the Industrial Dataspace  Data remains with the data owner  Transactions can be documented in AMable Blockchain  AMable IDS Connector as a registered hardware device to connect between data owners and data users

Open Source Base  Hyperledger Fabric  ActiveMQ  Spring

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 768775 Seite 10 This document and the information contained are property of the AMable consortium coordinated by Fraunhofer ILT and shall not be copied or disclosed to any third party without prior written authorization. AM with Open Source and Open Hardware

1 AMable Services for SMEs

2 AM Machines from Desktop to Industry

3 AM Software for Design and Production

 Filament printers for the desktop

Manufacturer Type Price RepRap Filament ??? XYZ Printing mini Filament 221 Monovoxel Filament 380 © RepRap © XYZ © Lulzbot FlashForge Creator Pro Filament 600 MakerBot Replicator+ Filament 1400 Luzbot Mini Filament 1500 Ultimaker3 Filament 3600

 Open Source Hardware (OSH)

13 © Lulzbot

 Open Source Hardware (OSH) and Software

14 © Lulzbot

Direct Metal Laser Sintering (DMLS)

Laser-powder bed fusion (L-PBF) Selective Laser Melting (SLM®)

Same LaserCUSING® Laser Metal Fusion (LMF) Process

Metal Additive Manufacturing Direct Metal Printing (DMP)

Selective Laser Melting (SLMTM)

Seite 15

 Metal AM, Laser Powderbed Fusion (LPBF)

150.000 € – 800.000 €

500.000 * 1.000€ = 500M€ 800 * 600.000€ = 480M€

Source: Context Data / 3dprintingindustry.com Source: Wohlers Report 2016 Seite 17

Economy Metal Systems Low Cost Concept Scanner and Cartesian Axis and Fiberlaser Diode Laser INSTEAD OF

conv. LPBF Low Cost LPBF Goal: Reduction of machine costs

- X % / Part € Machine 1 Low Cost LPBF Components Data Laser 140 W Diode Laser Focus diameter 140 µm Build volume Ø = 140 mm und Z = 200 mm Machine size[mm] 1675*815*1500 [W*D*H]

Simpel LPBF reinvented – Machine technology that uses simple and affordable components

Economic Low Invest – leads to low cost of operation for SMEs and small scale production

Industrial Resilient Operation – enabled by industrial control technology for reliable production of functional parts

Simpel LPBF reinvented – Machine technology that uses simple and affordable components

Economic Low Invest – leads to low cost of operation for SMEs and small scale production Machinery Directive 2006/42/EG Needs to be adhered; too difficult for Industrial individuals; best handled open source Resilient Operation – enabled by industrial control technology for reliable production of functional parts

1 AMable Services for SMEs

2 AM Machines from Desktop to Industry

3 AM Software for Design and Production

Modeling Slicing Commercial Solution Providers for Industry . 3D Slash . Maya . Repetier . TinkerCAD . 3DS Max . Simplify3D . FreeCAD . Cinema 4D . Slic3r . SketchUP . OpenSCAD . Ultimaker Cura . 123Design . Modo . CraftWare . Blender . Fusion 360 . KISSlicer . SolidWorks . MoI 3D . ReplicatorG . Rhino3D . Wings3D . Skeinforge . Inventor . K-3D . 3DPrinterOS . DesignSpark . BRL-CAD

22 Source: 3dprinting.com

23 Source: 3dprinting.com

File Formats for Data Exchange Open Source converters for more transparency in data handling and openness of software eco-systems  Data file formats  *.STL Stereolithography File Format (de-facto standard) STL  *.AMF Additive Manufacturing File Format AMF (standardised)  *.3MF 3D Manufacturing Format (industrially supported, open source)

© Fraunhofer ILT AM with Open Source and Open Hardware percieved challenges good standards procurement What is needed in industrial AM? public money – public code Incubation work program lifecycle conflicts standards/solutions export regulation and license  Desktop Filament Printing  done. lifecycle of community projects  Industrial Powder-bed Printing  Building production machines requires fulfilment of regulations  open functional and certified machine technology modules; unit test for final system  Design & production software needs reliability in operation & result (“docker problem”)  sla; open test beds and validation labs  Product safety regulation requires the producer to take responsibility  create trust in the solutions; chain of trust  Data Handling  Data is the gold of the future  follow the paradigm of data sovereignty (IDSA/GAIA-X)  Assets need to be processable by any application software and to any machine  support

25 free and open data formats; assist in opening data chains for interchange