Sessions

In the recent years, we have seen strong technological advancements in additive manufacturing. Manufacturing companies can now build on the technology to form distributed production networks to make their operations more efficient, more resilient, and greener. We discuss design choices to identify most suitable applications for distributed manufacturing. We address critical issues like IP protection and certification and business viability. The presentation also includes case studies of manufacturing companies starting the journey and service providers in the field

3D printing can have significant impacts for businesses working across a diverse range of industries through saving development time, tooling production, bespoke parts and complex geometry production. This session will help you to navigate the rapidly evolving landscape of additive manufacturing (AM) technologies and materials, and discover how to exploit the capabilities of AM through additive design principles and economics.

Introducing the Advanced Prototyping Facility based at Aston University and the expert advice and services available to help you to unlock new business opportunities and realise exciting innovations.

Whether you’re new to AM and looking how to get started, or to find out how you could better exploit the advantages and avoid the pitfalls of embedding AM in your processes then this may be a very good use of your precious time.

To validate the performance of an additively repaired fan rotor, a structural integrity process uses a stepwise assessment that treats the component as a new design. The two laser DED additive repair processes under assessment are wire fed and blown powder. Validating the performance requires a series of tests and associated models for four steps: laboratory specimens, subcomponents, components, and the entire engine system. Considering the potential and likelihood of certain failure modes, the series of tests at each step vary in the material performance being assessed. Experimentation on laboratory specimens acquire properties such as tensile strength, elongation, low cycle fatigue (LCF), high cycle fatigue (HCF), crack growth rate, and fracture toughness. Subcomponent test articles fabrication occurs by sectioning an operational IBR into individual blades for vibration HCF assessment. Component level testing focuses on LCF and overspeed strength acquired from spin rig testing. The full turbine engine system with the rotor mainly focuses on HCF, which many consider the most critical mode of failure, and the engine performance. The proposed talk aims to walk through the steps, the results, and the implemented decision gates that allowed for validation of the additively repaired component.

Metal additive manufacturing technologies have evolved and advanced over the last several years. Comparing powder bed fusion (PBF) to ElemX liquid metal jetting
(LMJ) showcases two vastly different approaches to producing a metal part. Here we discuss the variations between PBF and LMJ technologies focusing on the overall
operational functionality of each by simple comparison per common application vetting processes. In many cases, LMJ typically delivers 40% cost savings while also providing quicker cycle time. Safety concerns revolving around PBF have been a major drawback of that specific technology whereas LMJ provides a much safer work environment. The results of this competitive evaluation suggest that LMJ advantages outweigh several PBF benefits in a variety of applications.

The Making of a Concept Car
Manufacturing Complex Designs From Multiple Materials With the Form 3L
Complementing CNC Machining for Mechanical Parts With the Fuse 1
Creating High Fidelity Concept Cars With 3D Printing

Meltio offers a revolutionary directed energy deposition process that marries 3D printing, welding and cnc machining. The bulk of the 3D printing process is built around wire, the safest, cleanest and most affordable metal feedstock. Meltio's novel dual wire functionality delivers cost effectiveness and performance enhancements by combining two materials in a single part. The wire switching process is quick, automatic and clean.

Design-to-manufacturing innovation in automotive applications

• Preventative maintenance 
• Digital warehouse of existing products
• Stock of products for down time

Production tool jigs - VW/Nissan Case Study 
Modular, Mulit material sections 

•    Aerospace applications of 3D technologies

Generative design with metal and polymer applications - 
Minifactory aarni system/materials

•    Healthcare 3D technologies 

Dental (Resin/BASF)
Orthotics/Prostetics
Pre surgical Examinations (Boyd UM Case study)
Stent production through BMF (HUGE BENEFITS!)  

•    Industry-specific 3D applications
Feel free to throw whatever applications you like in here.


•    Intellectual property 
Decentralised manufacturing/warehousing 
OEM increase buy in to reduce overheads

•    ROI on 3D technologies  
What we do, Site scan, standard applications. Looking at logistics manufacturing costs. Photocentric up to 84k parts cheaper the Injection Moulding. 
HP customisations - Porsche seats, mini interior. Generative products - less material more strength.

•    Materials and processing 
Filament scope (benefits) 
Resin freedom
Metals

•    Geo-focus perspectives 
As below? 
•    Sustainability and environment
De-centralised manufacturing, Local production. Quality materials (HP Having a certified process including OEE) 


•    Supply chain challenges 
Brexit restraints.
International firms who share models saving shipping costs
Manufacture local with same materials as traditional methods

•    Software/Hardware for product development 
Teton Smart Slice 
Additive Flow 
Autodesk Fusion Generative design 

VLM (BCN3D) 

Production Life cycle graph - How additive is fitting into all the sections of the product development cycle.


•    Metrology 
Scanning to the depths of using reference/reverse engineering to assessing product integrity. What does it look like? 


•    Standardisation and regulations
BSI PAS6001 - https://shop.bsigroup.com/products/factors-to-be-considered-in-making-and-assessing-the-business-case-for-additive-manufacturing-and-3d-printing-guide/standard

Factors for considerations when using Additive


•    Post-processing
Electroplating
Debinding and sintering for metals
Spraying and Dying 
Support removal (dissolving) 


•    Workforce management 
Cloud operations - Digital Factory, BCN could, PrintandGO technology 
Fusion collaboration spaces for users



 

What is Micro Additive Manufacturing? Who uses it and will it require special design rules? 3D printing has changed manufacturing, and Micro-AM is propelling this growth.
Now, with new boundaries for parts complexity, details and features – This is where our Next-Generation technology delivers. We are changing the way things are made. If you are a product designer or an engineer, chances are you'll need to make a custom micro part at some point.
The ever-growing need for precise micro-parts is restricted by current technological limitations. Now, new technologies enables sub-micron accuracy and surface finish combined with a set or precision materials marks a new age in digital mass manufacturing.  So, whether you manufacture molds, inject parts for your customers or develop your own product in-house, getting the perfect part fast is a pivotal step forward.