Siemens AG, DE
Evaluation of hybrid AM technology chains considering the process accuracies for integration into industrial production
To integrate additive manufacturing (AM) into industrial production and to expand its range of application, the linking of these still new manufacturing processes with conventional technologies is necessary and is one of the important key developments, along with other developments such as “adaptive design”, to make additive manufacturing processes usable for large parts of the industrial sectors.
The presentation shows the planning of hybrid process chains and which requirements exists and still must be solved.
It is necessary to combine the different processes with each other in a sensible way and to adapt each other if needed. The underlying characteristic of AM processes, that basic materials are changed during the manufacturing of the products, requires a special approach for the production integration of these technologies besides the persisting challenges of anisotropy or the reproducibility of the processes.
“Coordination” is an essential part of hybrid manufacturing, especially regarding geometric alignment and material transitions. Accuracy and alignment aspects in particular must be taken into account here. Possibilities and challenges are highlighted.
Furthermore, there is a need to plan and evaluate technology chains. This also requires a broad technology knowledge and corresponding databases. There is still a lot of groundwork to be done here. However, this planning is one of the building blocks to successfully implement the major future targets of the society such as resilient production or the circular economy.
The merging of technologies requires knowledge of the technical possibilities of the various AM processes, whose part sizes range from the sub-millimeter to the meter with accuracies from micrometers to millimeters (stereo lithography and 2-photon polymerization; “concrete extrusion”). Using these possibilities and combining them with traditional processes to form process chains is one of the working areas of hybrid manufacturing. With adapted interface execution it is possible to use the advantages of the different processes and to optimize the production in terms of product designs and material properties.
Examples from Siemens production will illustrate the potential of AM technologies.
Senior Key Expert Additive Manufacturing at the Research and Development Department of Siemens AG; Studies at the Technical University of Berlin “Technical Environmental Protection”; Diploma thesis: “Basic investigations on the recovery of copper from electroplating wastewater by means of liquid-liquid extraction”.
Since 1995 research engineer at Siemens AG: research work in the field of cleaning processes and material recycling.
From 2000 to 2014 responsible for the area of rapid prototyping resp. additive manufacturing with a focus on the development of AM processes and materials; e.g. stereolithography here especially “ceramic filled SL resins for the production of ceramic high-performance components such as casting cores in turbine construction”; as well as the powder-based laser melting process in the area of nickel-based high-temperature alloys; process integration of additive manufacturing into industrial production processes;
Since 2014 Key Expert Engineer “Additive Manufacturing”; Tasks: Development of strategic AM production concepts and projects as well as coordination of research projects in the AM field; Development of AM quality management especially on standardization and qualification of AM process and materials.
Since 2006 Chairman of the “European AM platform”.
Since 2010 Chairman of the DIN working committee “Additive Manfacturing” and “Chairman of the German mirror committee of the CEN/TC 438 Additive Manufacturing.
Since March 2021 Chairman of NA 145 DIN Standardization Committee on Materials Technology (NWT).