State of the Art and Future of Additive Manufacturing © 3T RPD Ltd 2015 – All Rights Reserved

Contents Additive Manufacturing (AM) Thinking AM State of the art Its Applications Thinking AM State of the art What does the future hold? © 3T RPD Ltd 2015 – All Rights Reserved

AM and its Applications © 3T RPD Ltd 2015 – All Rights Reserved

What is AM? © 3T RPD Ltd 2015 – All Rights Reserved

3D Printing or Additive Manufacturing Rapid Prototyping Machines less than £5K Additive Manufacturing Production components Machines more than £500K © 3T RPD Ltd 2015 – All Rights Reserved

Applications Aerospace Medical Motorsport © 3T RPD Ltd 2015 – All Rights Reserved

The Hype © 3T RPD Ltd 2015 – All Rights Reserved

Thinking AM © 3T RPD Ltd 2015 – All Rights Reserved

AM – the Key Points Design: completely different thought process Need to design for AM Focus on critical features: pathways/channels Reduced weight, scrap and cost Combine components Mounting holes and brackets built into the part. © 3T RPD Ltd 2015 – All Rights Reserved

AM – the Key Points Process: Not self supporting – may require supports Attached to platform and removed post-build May require post-processing to achieve finish required © 3T RPD Ltd 2015 – All Rights Reserved

Additive vs. subtractive example 1 2 3 4 http://www.manufacturingthefuture.co.uk/design-guidelines/ PDF version also available – Please contact me © 3T RPD Ltd 2015 – All Rights Reserved

Final Part Mass reduced to <30% of original Smooth flowing pathways Higher performance Manufacture lead time halved. © 3T RPD Ltd 2015 – All Rights Reserved

State of the Art © 3T RPD Ltd 2015 – All Rights Reserved

Materials Titanium: Ti6Al4V, TiCP Nickel: Inconel 718, Inconel 625 Maraging steel: 1.2709/M300 Stainless steel: 15-5PH & 316L Cobalt Chrome: UNS R31538 Aluminium: AlSi10Mg & Aerospace Grade Alloys © 3T RPD Ltd 2015 – All Rights Reserved

Machines – EOS M280 Key characteristics: Build volume 250 x 250 x 300mm 400W Yb fibre laser Spot size 100µm Layer thickness 20-80µm Wall thickness: 0.1mm Accuracy: ± 0.2mm or better Surface finish: As built 4-10µm  Post finishing 0.04-0.5µm © 3T RPD Ltd 2015 – All Rights Reserved

Machines – Renishaw AM250 Key characteristics: Build volume: 250 x 250 x 300mm 400W Yb fibre laser Spot size 70µm Layer thickness 20-100µm Wall thickness: 0.1mm Accuracy: ± 0.2mm or better Surface finish: As built 7-15µm  Post finishing 0.04-0.5µm © 3T RPD Ltd 2015 – All Rights Reserved

The Future © 3T RPD Ltd 2015 – All Rights Reserved

The Future - Markets Aerospace: GE’s New Leap Engine will have 9 AM parts Over 1,000 individual components Parts already flying in US military aircraft and in orbit in satellites Other components are in test for future missions © 3T RPD Ltd 2015 – All Rights Reserved

The Future - Markets F1: safety critical components already racing Further components and materials being tested Medical: optimised surface structures under approval by FDA Outer surface of acetabular cups Selective areas of hips and shoulder implants © 3T RPD Ltd 2015 – All Rights Reserved

The Future - Materials New material suppliers coming on line New materials can be sourced in weeks 3T building in pure copper In talks with CERN Potential materials: Tungsten, Niobium, Molybdenum, Copper alloys © 3T RPD Ltd 2015 – All Rights Reserved

Machines – EOS M400 Key characteristics: Build volume 400 x 400 x 400mm 1kW Yb fibre laser Spot size 90µm Layer thickness 20-100µm Wall thickness: 0.04mm Accuracy: ± 0.1mm or better Surface finish: As built 2-8µm  Post finishing 0.04-0.5µm All in one system  Production © 3T RPD Ltd 2015 – All Rights Reserved

Machines – Arcam Q20 Key characteristics: Build volume 350Ø x 400mm 3kW laser Spot size 180µm Layer thickness 20-100µm Wall thickness: 0.1mm Accuracy: ± 0.1mm Surface finish: As built 20-30µm  Post finishing 0.04-0.5µm All in one system  Production © 3T RPD Ltd 2015 – All Rights Reserved

AM and FCC RF components Tuners / Couplers / Antenna Spacers Complex novel WG Multiple WG’s combined Tuners / Couplers / Antenna Spacers Oxygen free materials Mixed materials © 3T RPD Ltd 2015 – All Rights Reserved

Summary New opportunities: Parts already in use for real application: Holes & channels, lightweight optimised structures, multiple parts built as one. Parts already in use for real application: Safety, flight & mission critical Materials being developed and supply improved New machines allow for more materials Machines no longer a limitation © 3T RPD Ltd 2015 – All Rights Reserved

Confidence in the technology is growing fast – With this we will see the development of new materials and machines © 3T RPD Ltd 2015 – All Rights Reserved

Questions Daniel France R&D Project Manager +44 (0)7917524544 Daniel.France@3trpd.co.uk

Questions Daniel France R&D Project Manager +44 (0)7917524544 Daniel.France@3trpd.co.uk