ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING TOPIC: EX: AM for Metal Parts – Project REProMag Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 Prof. Carlo Burkhardt, PhD OBE Ohnmacht & Baumgärtner GmbH & Co. KG

REProMag PROJECT DESCRIPTION REProMag = Ressource Efficient Production of Magnets 100% waste free production of Rare-Earth Magnets (Nd-Fe-B) from recycled material in a closed material loop Potentially available Nd-Fe-B magnets for recycling (2015, Germany only) Computer/Laptops >60 tons per year Passenger cars (ICE) >450 tons per year Electrical motors (industrial) >30 tons per year  today available>500 tons per year Outlook: Hybrid cars:>10 kg/ car Electrical cars: >30 kg/car Wind turbine>600kg/MW

REProMag PROJECT DESCRIPTION REProMag = Ressource Efficient Production of Magnets 33 Ni- Beschichtung (wird abgesiebt) Ni- Beschichtung (wird abgesiebt) NdFeB Pulver

REProMag PROJECT DESCRIPTION 4 Nd-Fe-B-Powder alternative: 3D- print (FFF) green part MixingExtruding Feedstock Binder Injection Moulding Green part

REProMag PROJECT DESCRIPTION 55 Nd-Fe-B-PowderMixingExtruding Feedstock Binder Injection Moulding Green part Solvent debinding Thermal debinding Brown part Sintering Nd 2 Fe 14 B Nd 1+e Fe 4 B 4 Nd-rich grain boundary phase

REProMag PROJECT DESCRIPTION 66

77 Additive Manufacturing Process: Fused Filament Fabrication (FFF / FDM) filament production as printed laser polished in the green part state ___ 1 mm green partsintered partsurface appearances in sintered state

Exploitable results (ERs) ER 1 Industrial production of hard magnets based on NdFeB with complex geometrical features 100% waste free from recycled material in a circular industry in large quantities. ER2 Industrial production of hard magnets based on NdFeB with complex geometrical features 100% waste free from recycling material in a circular industry in small quantities/ prototype scale without tooling for fast proof of concept. ER3 Applicability of the production method for Ti- and Ni-based alloys, ferrites (magnetic material), alloys with complicated microstructures (e.g. where longer diffusion processes and or liquid phase sintering required)

ER 1 Describe the type of result and the resulting innovation Demonstrator parts with high energy product and complex geometry Potential customers Industries using magnets and sensors Automobile Electronics Aerospace Medical Customer Benefits Better accuracy Higher performance New applications possible (miniaturisation)

ER 1 Technological Readiness Level 5 Milestones in the TRL progression up to TRL9 setup of demonstrator toolings (07/2016) complete qualification of the process (10/2017) Main technical challenges in this result Extreme reactivity of the material with C and O to form oxides and carbides magnetic alignment of particles Time to market (Mth/yr): Dec 2017

ER 1 IPRs Have you protected or will you protect this result before disclosing it? Processing technology and 2 typical applications (design features of electrical motor) How? International patents (PCT) When? Dec 2015

ER 2 Describe the type of result and the resulting innovation Demonstrator parts with high energy product and complex geometry Potential customers Industries using magnets and sensors Automobile Electronics Aerospace Medical Customer Benefits Better accuracy Higher performance New applications possible (miniaturisation) Fast proof of concept /quick time to market Solution for small quantities

ER 2 Technological Readiness Level 3 Milestones in the TRL progression up to TRL9 Qualification of the 3D printer (12/2016) Complete qualification of the process (7/2018) Main technical challenges in this result Extreme reactivity of the material with C and O to form oxides and carbides Selection of suitable feedstock formula Magnetic alignment of particles Machine technology to improve surface quality Time to market (Mth/yr): Mid 2018

ER 2 IPRs Have you protected or will you protect this result before disclosing it? Processing technology and surface treatment How? International patents (PCT) When? Dec 2015, April 2016

ER 3 Describe the type of result and the resulting innovation Applicability of the production method for Ti- and Ni-based alloys, ferrites (mag- netic material), alloys with complicated microstructures (e.g. where longer diffusion processes and or liquid phase sintering required) Potential customers Medical (Ti-Alloys) Automotive, Aerospace (Ni-based alloys) Tooling industry (hardened low alloy steels with better crack-stability) Customer Benefits Tailored microstructures Tailored surface features Better mechanical and thermal stability

ER 3 Technological Readiness Level 5 Milestones in the TRL progression up to TRL9 Setup of demonstrator toolings (12/2016) Complete qualification of the process (12/2017) Main technical challenges in this result Timeline Time to market (Mth/yr): Dec 2017

ER 3 IPRs Have you protected or will you protect this result before disclosing it? Yes, see ER 1 and 2 How? International patents (PCT) When? Dec 2015, April 2016

Expressions of Interest Expressions of interest in the results of the other projects M1-US-QuesTek ER2Commercial availability of one of QuesTek Innovations’ new Ti 6-4 Mod alloys that has greater strength and toughness vs traditional Ti-6-4 used in AM, with a stretch goal of meeting or exceeding the properties of wrought Ti-6-4. ER3Design of a new Co, Ni or other alloy tailored specifically for AM that can be applied to a range of industries such as medical, aerospace and heavy industry. It is readily agreed upon that the use of existing “off-the-shelf” alloys for additive manufacturing poses a number of manufacturing and material performance issues, and new materials designed to the unique processing of AM need to be invented.

Expressions of Interest Expressions of interest in the results of the other projects M1-US-EXOVA ER1Design allowables of 3D printed materials for product designers to exploit the introduction of new materials in critical applications. ER2Development of standard test and qualification protocols for raw material qualification/verification, process and machine qualifications, and product qualification and quality control. ER3Development of adequate surface finish to produce net shape parts and avoid machining or other expensive finishing processes.

Expressions of Interest Expressions of interest in the results of the other projects M13-EU-AATID ER1 Optimal processes for printing, welding and post-processing of Ti printed parts. ER2 Selection of the most appropriate (powder bed) printer and most worthwhile parts to be specific technology. ER3 Design rules of bionic parts based on topology optimization combined with printing technologies limitations.

Expressions of Interest Expressions of interest in the results of the other projects M14-EU-Nanotuned ER1Develop a raw material (metal powder) to be processed by additive manufacturing techniques (with powder bed fusion –selective laser melting (SLM) and electron beam melting (EBM))- based on a nanomodified Ti6Al4V alloy with enhanced structural performance versus standard alloy (tensile properties 30-40% better; hardness, fatigue and wear properties enhanced 20-30%,

Expressions of Interest Expressions of interest in the results of the other projects M6-SA-MEDAERO ER1Proven methodology for characterising Ti6Al4V powder and parts produced (through selective laser melting) with a view on qualification of materials and AM processes. ER2Validated post-processing treatments required to enhance the microstructure and mechanical properties (of selective laser melting) Ti6Al4V parts to comply with standard specifications for the wrought alloy. ER3Qualified process chains for producing Ti6Al4V medical implants and structural aerospace components (through selective laser melting)