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HP: Eight Trends In 3D Printing

HP: Eight Trends In 3D Printing

HP has released its list of predictions for 3D printing and digital manufacturing in 2020. Informed by extensive interviews with a team of experts, this year’s research identifies top trends that will have a major impact on advancing Industry 4.0 such as the need for more sustainable production, how automation will transform the factory floor, and the rise of data and software as the backbone of digital manufacturing.

READ: HP-NTU Corporate Lab Showcases R&D Innovations And Announces Digital Manufacturing Skills Development Programme

“The year ahead will be a time of realising 3D printing and digital manufacturing’s true potential across industries,” said Pete Basiliere, Founder, Monadnock Insights. “As HP’s trend report indicates, digital manufacturing will enable production of users’ ideal designs by unlocking new and expanded software, data, services, and industrial production solutions that deliver more transformative experiences while also disrupting legacy industries.”

READ: Turning Additive Manufacturing Into Business

The 2020 3D Printing and Digital Manufacturing Predictions Are:

1)     Automated Assembly Will Thrive on the Factory Floor

Automated assembly will arrive, with industries seamlessly integrating multi-part assemblies including combinations of both 3D printed metal and plastic parts. There’s not currently a super printer that can do all things intrinsically, like printing metal and plastic parts, due to factors such as processing temperatures. However, as automation increases, there’s a vision from the industry for a more automated assembly setup where there is access to part production across both metals and plastics simultaneously.

2)     Coding Digital Information Into 3D Printed Textures Will Accelerate

Organisations will be able to code digital information into the surface texture itself using advanced 3D printing, providing a bigger data payload than just the serial number. This is one way to tag a part either overtly or covertly so that both people and machines are able to read it based on the shape or orientation of the bumps.

READ: HP Launches New 3D Printing Solution, Industrial Alliances, and Global Production Network

3)     Sustainable Production Will Continue to Be a Business Imperative

3D printing will enable the manufacturing industry to produce less waste, less inventory and less CO2 emissions. Engineers and designers will rethink design throughout the product lifecycle to use less material and reduce waste by combining parts and using complex geometries to produce lightweight parts. This further reduces the weight of vehicles and aircraft to improve fuel efficiency which can reduce greenhouse gas emissions and energy consumption.

4)     Demand for Students Who Think in 3D Will Increase

Higher education is at a crossroads, challenged with competing for enrolment, changing demographics and the need to adequately prepare students for the future of work. What’s needed is a complete mind shift to prepare for Industry 4.0.

READ: Five Reasons Why Companies Are Turning to AM

5)     Mass Customisation Will Fuel New Growth in Footwear, Eyewear and Dental

The consumer health sector will fuel digital manufacturing growth and adoption, as footwear, eyewear and orthodontics applications rapidly adopt 3D printing technologies. There’s a massive application space around footwear that’s very lucrative for the 3D printing industry.

READ: Bolstering Medical And Dental Applications With 3D Printing

6)     3D Printing Will Power the Electrification of Vehicles

Automakers are increasingly turning to 3D printing and digital manufacturing to help compete in a time of change, as the industry goes through its biggest transformation in more than a 100 years moving away from the internal combustion engine toward electric vehicles. As electric vehicles increase in popularity, automakers will continue to unlock the capabilities of both metal and plastic 3D printing systems to speed up their design and development in order to meet ambitious goals.

READ: 3D Printing The Future Of E-Mobility Tools

7)     3D Printing Will Drive New Supply Chain Efficiencies

The capability to deliver things digitally and produce things locally has not always won out. At the end of the day, manufacturers must analyse where in the supply chain it’s the most efficient to root production – whether that’s near the end users or near the source of material production.

8)     Software Will Push the Boundaries of Digital Manufacturing to New Levels

In 2020 we will close the gap between what 3D printing and digital manufacturing hardware is capable of and what the software ecosystem supports. Advancements in software and data management will drive improved system management and part quality leading to better customer outcomes. Companies within the industry are creating API hooks to build a fluid ecosystem for customers and partners that includes purpose-built individualised products.

READ: How Additive Manufacturing Will Transform Digital Manufacturing 

 

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Powering Additive Manufacturing With Data Analytics

Powering Additive Manufacturing With Data Analytics

In an interview with Asia Pacific Metalworking News, Dr. Mohsen Seifi, Director of Global Additive Manufacturing Programs at ASTM International, discusses the benefits of additive manufacturing (AM) in manufacturing and the role of data analytics in AM.

Dr. Mohsen Seifi, Director of Global Additive Manufacturing Programs, ASTM International

  1. Tell us more about ASTM International, for those who may not be familiar with the organisation.

ASTM International is one of the world’s leading standards development organisations, founded in 1898.  We have 150 technical committees that oversee about 13,000 standards that are widely used around the world.  Several of those committees are in emerging industries, including one for additive manufacturing technology that now has nearly 1,000 members, known as F42.  For over a decade, this group of the world’s top additive manufacturing experts has been meeting and working through ASTM to develop groundbreaking standards that have begun to form the technical foundation for the future of additive manufacturing.  Furthermore, ASTM International has made a dramatic investment in front-end research to develop even more standards through our Additive Manufacturing Center of Excellence, a network of high-profile partners around the globe which includes Singapore’s National Additive Manufacturing Innovation Cluster (NAMIC).  Please visit our website for more detailed information.

  1. In the Industry 4.0 era, greater efficiency and product innovation are key priorities for manufacturers. How can they leverage additive manufacturing/3D printing to achieve both?

A big challenge for manufacturers is the lack of communication between stakeholders at different steps in the process chain. Smart, digital manufacturing could allow manufacturers to effectively transfer the most relevant information across all stages of product development, from designers to end-users. Additive Manufacturing is an integral part of Industry 4.0 and is an excellent technology for product innovation that could significantly reduce the time for product development through iterative design capabilities.

Also, Additive manufacturing can substantially improve the efficiency of the manufacturing process by parts consolidation. This will enhance the effectiveness of a system as a whole in terms of weight reduction, material optimisation, and reduction in fuel consumption.  For AM, digital manufacturing means integrating physical system-oriented manufacturing with digital system-oriented Industry 4.0 technologies (e.g., artificial intelligence (AI), big data, robotics, cybersecurity, and Internet of Things [IoT]). To fully unlock the potential of smart, digital manufacturing, there are still issues to address, which include cybersecurity concerns, data management challenges, and other critical gaps. ASTM uses various roadmaps to develop standards to address these gaps and to meet the industry needs.

  1. Which end-markets do you see increasing adoption of additive manufacturing?

AM has the potential to impact all manufacturing-related sectors—from aerospace, medical and automotive to oil/gas, maritime and other sectors—and we anticipate adoption will increase exponentially across the board in the next 10 years. In particular, AM holds great promise for aerospace/defense and medical applications. Both of these sectors require complex, specialised parts, which AM is capable of producing. More importantly, the demand for AM qualification and certification in these high-tech areas/end-markets is high. This is because successful qualification and certification provide end-market users with increased confidence (i.e., improvements in quality and reduced safety concerns). According to a recent survey, the three most significant challenges to adoption of AM for end-market users over the next ten years are: 1) the certification of finished parts and products, hindering its mainstream commercial uptake in the future; 2) the quality and standardisation of material inputs; and 3) unknown quality of printed components.

  1. What are the biggest challenges when it comes to additive manufacturing?

As an emerging field, the AM industry still needs a shared language and framework for addressing problems. Lack of standards is one of the biggest challenges for additive manufacturing in addition to other challenges such as lack of qualified workforce, limited availability of materials, and the lack of full-fledged certification programs. Standards provide a common reference point to help the industry avoid the time and expense of solving problems by trial and error. For example, there is an ongoing need for a better understanding of feedstock properties, methods for in-process monitoring and control, machine-to-machine variation, and rapid inspection methods for AM parts, among other topics. In addition, standards are a key enabler of the qualification and certification procedures that were mentioned above.

To accelerate the development of standards to address these challenges, we launched the AM Center of Excellence (CoE), a collaborative partnership among industry, academia, and government that integrates research and development (R&D) with standards development. By initiating R&D projects that target specific high-priority standards needs, I believe we can speed the overall advancement and adoption of AM technologies. Detailed information will be available in our upcoming external R&D roadmap, which will be released this spring. In the meantime, our annual report provides an overview of the AM CoE’s activities.

  1. Why is analytics a feasible solution?

One benefit of analytics is that it presents decision-makers with the key information required to make informed decisions. Manufacturers have access to a wealth of data about their products and processes but are not always able to use it. Analytics is a great tool to convert data into actionable knowledge that can be used to optimise product development. In the case of AM, solutions such as data-enabled material screening, build monitoring, and post-build characterisation ensure the product meets its specifications with as few iterations as possible, helping minimise production time and cost.

  1. How will data analytics make additive manufacturing more efficient?

AM generates more data than any other manufacturing field—this data has great value, but there are challenges to extracting useful information. Structuring data in a way that adheres to FAIR principles (findable, accessible, interoperable, and reusable) will be vital to the success of AM. Data analytics holds the key to processing and making sense of vast stores of data, which will ultimately accelerate the AM development timeline. Data analytics is a solution that cuts across all sectors and is already shaping the future of technology as we know it.

Through AI, which encompasses machine learning (ML) and deep learning (DL), the AM industry can quickly decode quantitative structure/process/property/performance relationships, which is a core challenge in the AM field. For example, it is possible to use AI to sift through potential AM materials to find those with optimal properties or functionalities. AI can also enable data-driven in-situ/real-time monitoring for identifying better processes. However, to enable these data-driven advances, the AM community needs an AM data ecosystem that enables the easy and secure generation, storage, analysis, and sharing of data. ASTM and America Makes recently convened a workshop on manufacturing data management and schema to identify and prioritise challenges and potential solutions for strengthening the AM data ecosystem.

  1. What is your outlook for additive manufacturing/3D printing this year?

It is very hard to predict the future of AM because technology is rapidly changing, but I would like to see 2020 as the year of standards. There is an exciting opportunity for more integration between AM and other elements of industry 4.0, in terms of automation, robotics, cybersecurity, and big data—creating these links is a great way to connect the physical world and digital world. I believe that the best way to create synergy between these critical technologies is through standardisation to add trust. The more we can focus on developing standards, the sooner we can see these advances.

 

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MVTec HALCON 19.11: Standard Machine Vision Software With New Functions

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EOS: Additive Manufacturing For The A350 XWB

EOS: Additive Manufacturing For The A350 XWB

Here’s how one company was able to develop a cable mount on the front spar of the vertical stabilizer for a passenger aircraft in record time. Article by EOS GmbH.

Unified design of the additively manufactured tail bracket eliminates 30 parts down to one. (Source: Sogeti)

The moment when a completely new commercial aircraft takes to the skies for the first time is always special—and this was especially true of the Airbus A350 XWB. As a child of the new millennium, it was clear from the very beginning that development work would focus on innovative materials and production processes—the goal was no less than to build the world’s most efficient aircraft.

As a technology of the future, additive manufacturing was another possibility that needed to be considered during development. As part of a pilot project, experts from Sogeti High Tech succeeded in developing a cable mount on the front spar of the vertical stabilizer for the passenger aircraft in record time, taking only two weeks from the initial sketch to the finished part. EOS technology and expertise was a pivotal aspect of this development process.

Challenge

The project specifically involved producing a cable routing mount for the latest Airbus model. The mount was ultimately needed for the power supply and data transportation of a camera located in the vertical stabilizer, providing a view of the outside to passengers and orientation on the ground to the pilots. The product requirements document called for a functionally operational component suitable for series production. This task was entrusted to Sogeti High Tech, a wholly owned subsidiary of Cap Gemini S.A.

The particular challenge in this case was the short lead time of just two weeks. The entire development had to be completed within this time frame: From analysis of the part and of the current installation set-up, a parameter study aimed at optimizing the topology and its interpretation, and the design and production of the finished part. The mount also needed to have as few support structures as possible to avoid post-processing. In addition, the specifications for the component called for integration of the snap-on cable holder, weight reduction, and compliance with the strict requirements for subsequent aviation industry certification.

The conventionally produced component was made up of formed sheet metal parts and numerous rivets—more than 30 individual parts in total. The plug connectors in the upper area were made from plastic, and thus from a different material than the other individual parts of the mount. The aim was to develop an integrated solution consisting of a single part that also included the plug connectors, thereby significantly reducing construction and installation times. The weight reduction target for additive manufacturing was determined by a parameter study based on topology optimization.

Solution

For the new component, Sogeti High Tech followed the tried-and-tested development process for designing additively manufactured parts. The project kicked off with an analysis of the existing, conventionally produced component in terms of the upcoming manufacturing process—with an extremely positive outcome. The component’s functionality, material, and previously complex structure made it an ideal candidate for powder-bed-based 3D printing technology from EOS. The design freedom offered by this technology allows complex structures to be produced in a single piece, meaning that a weight-saving design can be selected without neglecting functional integration.

This analysis then allowed the so-called design space—the space that the cable-routing mount may occupy—to be defined. The aluminium alloy AlSi10Mg, which is ideal for thin-walled, complex structures, was chosen as the material. The interfaces to the external areas remained the same, forming the non-design space, meaning that no changes are needed to be made to them. The defined loads were taken as the boundary conditions for topology optimization in the parameter study, providing the basis for a new design.

As is customary, CAE software was used for the topology optimization calculations; by contrast, a dedicated solution for designing structures with free-form surfaces was used for the re-design. Sogeti High Tech created the design itself. In order to meet the lead time of two weeks, EOS calculated the build time and optimized parameters from the topology optimization results using the EOSPRINT software, which created the CAE implementation for the manufactured part while also taking into account the possibilities and limitations of the manufacturing process and the need to avoid support structures.

“In addition to outstanding hardware, EOS also offers comprehensive expertise in making additively manufactured components reality—something that we rate very highly,” says Carlos Ribeiro Simoes, Additive Manufacturing Offering Leader at Sogeti High Tech.

Results

Thanks to the cooperation between Sogeti and EOS, it was possible to develop a component optimized for additive manufacturing that fully exploits the design freedom afforded by direct metal laser sintering (DMLS) technology, while at the same time taking account of its restrictions. This allowed plug connectors for cable routing to be integrated into the design and local reinforcement to be incorporated in specific critical areas in order to optimize the structure. Self-supporting apertures and struts within the component help to keep the effort, and hence, the post-processing costs to a minimum.

Additionally, the mount can be produced extremely fast, whenever it is needed. Manufacturing—performed on an EOS M 400 with layer thicknesses of 90 μm—only takes 19 hours instead of the 70 days previously required. This corresponds to a reduction in the production time well in excess of 90 percent. This is largely because the many individual steps and formerly 30 parts have been brought together in a central component that can now be produced in a single run. In addition, the individual parts no longer need to be constructed and held in stock, which can be expensive. Storage for the entire component assembly is now also much more straightforward.

Sogeti was not only able to save a huge amount of time in production, but also in development. The entire process from the initial sketch to the finished component took only two weeks. This is a phenomenal lead time. At the same time, the design also means greater weight efficiency. Whereas the conventionally manufactured original part weighed 452 g, the additively manufactured cable mount weighs just 317 g—and it is well known that the aviation industry counts every single gram in the interest of cutting fuel consumption to a minimum. The customer, Airbus, was more than satisfied with the results.

“Getting an existing component ‘AM-ready’ in just two weeks meant that we had to succeed at the first attempt. The excellent, proactive collaboration with EOS made this ambitious undertaking possible—with outstanding results,” says Simoes.

 

Check these articles out:

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HP-NTU Corporate Lab Showcases R&D Innovations And Announces Digital Manufacturing Skills Development Programme

HP-NTU Corporate Lab Showcases R&D Innovations And Announces Digital Manufacturing Skills Development Programme

(Left to right) The HP-NTU Corporate Lab was officially opened today by NRF Singapore Executive Director Lim Tuang Liang, NTU Senior Vice President (Research) Prof Lam Khin Yong; HP Inc CTO Shane Wall; HP Inc Chief Technologist, Print, Glen Hopkins. At the opening, Prof Lam also presented token of appreciation to Mr Wall.

Researchers from global technology leader HP Inc. and Nanyang Technological University, Singapore (NTU Singapore) in the HP-NTU Digital Manufacturing Corporate Lab has showcased digital manufacturing technologies set to make manufacturing and supply chain operations more efficient, cost-effective and sustainable.

Among them are intelligent design software tools that automate advanced customisation, as well as supply chain models that enable faster time to market while lowering carbon footprint.

The lab also unveiled a new skills development programme aimed at helping Singapore train and upskill its talents in additive manufacturing and digital design – from fundamentals of additive manufacturing and digital product designs to data management and automation, under the SkillsFuture programme.

The Corporate Lab aims to train some 120 working professionals per year through the new skills development programme, which includes the fundamentals of Additive Manufacturing, digital product designs, data management, automation, user experience and business models. The new short courses are payable with SkillsFuture credits and are open for registration.

– Examples of 3D printed products from the HP Multi Jet Fusion printer, which allows for flexible designs with both soft and hard plastic in a single print

With the intelligent design software tools being developed by the lab, engineers can customise and optimise their materials’ mechanical properties more effectively. The automated tools let designers achieve designs that have the best combination of properties to achieve the desired strength, flexibility, and weight. Imagine a customised, lightweight 3D-printed plastic cast aimed at giving patients greater comfort and fit.

Another research project is the design and optimisation of end-to-end supply chain operations. Mass customisation requires state-of-the-art supply chain design for digital factories. With advanced business models and analytics to model supply chains, manufacturers will be able to decrease the time required to identify parts suitable for 3D printing production as well as to measure the impact on carbon footprint.

As a result, manufacturers will be able to scale production of customised goods quickly during periods of high demand, reduce time to market while improving sustainability at the same time.

Professor Lam Khin Yong said, “The advanced technologies and automation solutions jointly developed by NTU and HP are expected to impact businesses in Singapore and beyond, as these innovations are geared towards efficiency, productivity and most importantly, sustainability,” said Professor Lam Khin Yong, NTU Senior Vice President (Research).

A workforce equipped with new design, thinking and technical skills is critical to unleashing the potential of digital manufacturing.

“The new SkillsFuture courses developed jointly with HP also bring valuable industrial perspectives to help upskill and train a critical talent pool for Singapore. This will support the country’s drive towards becoming a smart nation as it faces the challenges of the 4th Industrial Revolution,” Professor Lam continued.

 

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With Additive Manufacturing To More Productivity

With Additive Manufacturing To More Productivity

If the weight of PCD tools is reduced, as a rule significantly higher cutting data can be used. Along with design freedom, the possibility of weight optimisation is one of the crucial advantages offered by 3D printing. Due to the specially developed structures inside the tool, which cannot be manufactured conventionally, the weight can be reduced significantly.

New bell tool with low weight, long tool life and best cutting data

An example of how MAPAL uses this advantage of 3D printing in practice is the new bell tools with brazed PCD inserts. Bell tools are used for the external machining of hose connections, among other applications. These connections, for example on turbochargers, must satisfy complex contour requirements. Manufacturing must be correspondingly precise. Existing processes are also subject to continuous improvement so that manufacturing is cost-effective and reliable in series production.

MAPAL has therefore optimised the existing, conventionally manufactured bell tool. Using the selective laser melting process, the inside of the tool has been modified – instead of solid material there is now a specially designed honeycomb structure. As a consequence, the tool is 30 percent lighter and the tool life is increased by approx. 40 percent due to the damping effect. It is therefore possible to machine faster; the machining quality remains at the same high level.

In total the machining time has been reduced by 50 percent. Furthermore, the cooling channel design has also been optimised. The new bell tool is of hybrid design. Using selective laser melting, the new tool geometry is printed on a highly precise tool body with a HSK-63 connection. The additively manufactured part is subsequently machined conventionally. Then the PCD inserts are brazed in place and cut to shape using a laser.

 

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Top 10 Industry 4.0 And Additive Manufacturing Articles For 2019

Top 10 Industry 4.0 And Additive Manufacturing Articles For 2019

As we move into 2020, we take a look back at the most popular Industry 4.0/Automation and Additive Manufacturing articles for 2019. For your enjoyment, here is the list of the top 10 Industry 4.0 and top five most read Additive Manufacturing articles over the past year.

Top 10 Industry 4.0/ Automation articles in 2019

  1. Gripping and Clamping Solutions for Process Automation
  2. The Role of IoT Technology in the Metal Fabricating Industry
  3. Predictive Maintenance for the Metalworking Industry
  4. Smart Data in the Metalworking Industry
  5. Siemens On Data, Digitalisation, And Umati
  6. Putting Automation in the Hands of the People with Collaborative Robots
  7. Smart Sensors Are Bringing About A Paradigm Shift In Production
  8. Updates On The Progress Of Thailand 4.0
  9. Making Use of Big Data
  10. Marvel Of Robotic Arms

Top 5 Additive Manufacturing articles in 2019

  1. Gaining A Competitive Edge With Additive Manufacturing
  2. Venturing Out Into Metal Additive Manufacturing
  3. Creating Predictable, Productive Processes With Industrial AM
  4. Additive Manufacturing: Outlook For 2019
  5. Additive Manufacturing Metals Outlook: Nickel Superalloys

 

 

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Taking metal to the cloud

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Advanced Manufacturing Effort: Partnering Of Singapore & German Firms

Why You Need ERP in the Metalworking Industry

Thailand Sets Sight on Industry 4.0

Bosch Rexroth, Siemens Joins Sodick, PBA Group in JID’s Advanced Manufacturing Ecosystem

Growth Of The Digital Twins Market Is Driven By Industrial Digitalisation

Metalworking Fluid Market To Hit US$14.5 Billion By 2025

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Smart Manufacturing And Industry 4.0 Forum 2019

Flexible Gripping Delivers the Future of Automation Today

Outlook For Indonesia’s Industry 4.0 Roadmap

 

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Easy And Fast 3D Printing: Igus Tribo-Filaments

Easy And Fast 3D Printing: Igus Tribo-Filaments

Due to the co-operation between Ultimaker and igus, the processing of the iglidur tribo-filaments in the Ultimaker 3D printers has become a lot easier. Neither special knowledge nor programming expertise is required to produce lubrication-free, low-wear components. The extensive material tests and the open source software “Cura” make this possible.

The free open source software “Cura” from Ultimaker makes it very easy for users to manufacture their individual components quickly. In just a few minutes, a 3D model is prepared, and after selecting speed and quality, the printing starts.

With pre-configured filament profiles available from the Ultimaker Marketplace, users no longer need to enter specific parameters for their printing material, but still get the best print results at the touch of a button. These profiles are based on extensive tests of the various materials in the Ultimaker printers and include the iglidur tribo-filaments from motion plastics specialist igus, which enable users to print components specifically optimised for friction and wear, such as plain bearings, clamping devices or complex components.

“The collaboration between Ultimaker and igus transforms the processing of iglidur filaments in Ultimaker 3D printers into a ‘plug & play’ solution”, notes Tom Krause, Director of Additive Manufacturing at igus. For this, it is necessary to install the filament profiles in the Cura software, through which the CAD data is transformed into a processable 3D printing file. Experienced users can adapt the provided material profiles to their needs by changing different parameters. The Cura software also allows users to create their own material profiles.

iglidur filaments – friction-optimised polymers for 3D printing

iglidur filaments are suitable for all types of components in motion where wear and friction play a role. Tests in the 3,800 square metre igus test laboratory showed that they have up to 50 times more wear resistance than conventional 3D printing materials. The 3D print with the tribo-filaments from igus is a cost-saving alternative especially in the production of complex moving parts subject to wear in jigs and fixtures, in small batches and special machine construction. For customers who do not have their own 3D printer, igus also offers a 3D printing service for wear-resistant parts, both with iglidur tribo-filaments and with their own laser sintering materials. Customers can upload their data, choose the material, predict the service life, calculate prices and order their individual wear-resistant parts online.

 

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Global Aerospace 3D Printing Market Poised To Surpass $2,857 Million By 2024

Global Aerospace 3D Printing Market Poised To Surpass $2,857 Million By 2024

According to Research and Markets, the Global Aerospace 3D Printing market was valued at around $ 1246 million in 2018 and is poised to grow at CAGR of more than 15 percent to surpass $ 2857 million by 2024 on account of traditional materials getting replaced with new high strength materials and lightweight, which is an effective way of meeting the goal of decreasing emissions, reducing material usage and increasing fuel efficiency.

Additionally, increasing demand for reducing the overall weight of the aircraft to improve fuel consumption is further fueling growth in the market. Moreover, 3D printing can be used to customise components and parts used in the aircraft industry by efficient use of the overall raw material with high accuracy, thereby promoting growth of 3D printing market. Complicated components can be easily made with the 3D printing technology with reduced errors. Growth of lightweight and fuel-efficient components has led to rise in engine application under material application segment, which is further anticipated to increase in the coming years.

Regionally, the market for Aerospace 3D Printing is gaining traction and expanding to various regions including North America, North America, Europe, South America and Middle East & Africa. Among these regions, North America is the largest market of Aerospace 3D Printing. The growth of north America market is attributed to high adoption rate of 3D printing technology in the aerospace industry. Presence of regional and leading players in the region backed by approval from Federal Aviation Administration (FAA) for the use of 3D printed parts in commercial aircraft, the market of North America is anticipated to grow at substantial rate through 2024.

Major companies are developing advanced technologies and launching new products in order to stay competitive in the market. Other competitive strategies include mergers & acquisitions and new product developments.

 

Further reading:

Creaform Expands European Coverage of CUBE-R

Thailand To Establish Committee For Electric Vehicles

Manufacturing Sector Maintains Growth Trajectory Amid Challenging Market Conditions

TRUMPF To Unveil Automated Mass 3D Printing Solution At Formnext 2019

Use Of Durable Consumables In Robotic Welding Torches Reduces Downtime Costs

 

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Sandvik And Renishaw Collaborate To Qualify New AM Materials

Sandvik And Renishaw Collaborate To Qualify New AM Materials

Renishaw is collaborating with Sandvik Additive Manufacturing to qualify new additive manufacturing (AM) materials for production applications. This encompasses a broad range of metal powders, including new alloy compositions that are optimised for the laser powder bed fusion (LPBF) process and which provide superior material properties.

Sandvik has worked with Renishaw AM systems since 2018 at its Additive Manufacturing Centre in Sandviken, Sweden. During this time, the two companies have worked together to develop process parameters for a range of Sandvik metal powders, including stainless and maraging steels, and the latest Osprey nickel-based superalloys. Sandvik has recently inaugurated a state-of-the-art titanium atomiser and powder processing facility and will now turn its focus to qualifying these alloys for industrial and medical applications.

“With our 157-year materials knowledge, our comprehensive range of in-house Osprey steels, duplex and super-duplex stainless steels, as well as nickel-based alloys and our new titanium powders, Sandvik now offers the widest range of AM materials to the market,” said Mikael Schuisky, VP R&D and Operations at Sandvik Additive Manufacturing. “Renishaw’s open machines have enabled us to rapidly optimise process parameters for our alloys for use in many different applications.”

This parameter development work has highlighted opportunities to make small but important changes to the composition of Sandvik alloys, whilst remaining within the relevant ASTM specification, to optimise the mechanical properties of LPBF components. Examples of this include a maraging steel with enhanced strength and hardness, and a crack-free Osprey HX nickel superalloy.

“Much of the innovation in AM in the next few years will come from the pairing of enhanced machine performance with improved alloys,” explained Stephen Crownshaw, AM Business Manager at Renishaw. “Better alloys mean better material properties, enabling the manufacture of AM components that are even more efficient and cost-effective. The consistency of Renishaw’s latest AM systems, combined with Sandvik’s material expertise, provides tremendous opportunities to advance AM processes and to make a stronger business case for AM.”

 

Further reading:

Trains Powered By Hydrogen Will Run In Germany From 2021

Sandvik Coromant To Showcase Digital Solutions For Machining Processes At EMO 2019

Edd China Discusses Vibration-Damping Technology in New Sandvik Coromant Film

Sandvik Acquires Stake In Additive Manufacturing Service Provider Beam IT

Managing Your Data Smartly

 

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E-mobility, Additive Manufacturing Driving Growth In Metrology Sector

E-mobility, Additive Manufacturing Driving Growth in Metrology Sector

Daesuk Chung of ZEISS sat down with Asia Pacific Metalworking Equipment News to talk about the latest technology and manufacturing trends driving the metrology sector. Article by Stephen Las Marias.

Daesuk Chung is the regional sales manager for Asia Pacific, industrial metrology business group, at ZEISS. At the recent EMO Hannover 2019 event in Germany, Asia Pacific Metalworking Equipment News sat down with Chung to talk about the latest technology and manufacturing trends driving the metrology sector.

Tell us some of the technologies you are showcasing at the event.

Daesuk Chung (DC): We are actually celebrating the 100th year anniversary of our business division—IQS (Industrial Quality Solutions)—this year commemorating 100 years of the first measuring technology presented by ZEISS in an industry fair. At this year’s show, we have four different categories in our booth: first is the quality lab with our flexible bridge-type CMM solution PRISMO and new sensors.

Next, we have solutions for productivity, which is getting more and more important. We are presenting some concepts on how customers can reduce their cycle time in order to enhance their productivity. We have new machines designed for measuring—but we now understand that you need flexible solutions on the shop floor. We already have special machines designed for shop floors—but very often they have some limits in terms of measuring volumes, for instance, or there is not enough choice of different models; depending on the tolerance and measuring volume, customers have certain preferences. With our new concept and design, customers will have that flexibility.

Then, we have two sectors where we are showing our new strategic initiatives. In the past, we are only focused on bringing new products—we are a hardware-oriented company. We are now trying to be more of a solutions provider. You will see our offerings related to e-mobility solutions.

And that is a trend. Due to issues like climate change, and the Dieselgate scandal a few years ago, all of the car manufacturers now, especially in Germany, are strongly pursuing the concept of new-energy vehicles. Fuel cell cars, electric vehicles, for instance.

We are now collaborating with a lot of customers already who are manufacturing components for electrical engines, for instance. So far, not many metrology manufacturers have sufficient knowledge or experience about NEV market, but we do have from many reference projects in recent years. So, we are now showing concepts for those customers who are now entering that market; we are showing them examples and strategies in dealing with those special components.

Finally, additive manufacturing is another big trend in our industry, especially in the aerospace and medical sectors, where there is a need to bring customised products or solutions. These sectors are driving the need for additive manufacturing. But again, it’s a totally new process, and many manufacturers who are entering this segment don’t have enough experience. We are now capable of analysing the whole manufacturing processes and can suggest our customers what kind of solutions they need for whatever application they have. We have these solutions because of our wide range of portfolio and knowledge about every single step of manufacturing process.

With the e-mobility trend, how have the market requirements changed?

DC: On the one hand, many manufacturers and customers feel very unsure of the market situation in the coming years. Nobody can really predict how the market will change. Many people know that it will come, except for the real market size of electrical vehicles, for instance, and what will happen to conventional technology.

It does not mean that the number of cars with the combustion engines will not increase, the technology will stay and production will increase, but nobody can really predict.

At the moment, it is difficult to make any kind of forecast or prediction. But it will definitely come, many governments around the world started adapting regulations to put a lot of pressure on the industry, as well as introducing subsidies making the electric vehicles more attractive. Existing car OEMs who are only relying on combustion engines are now starting to enter into the NEV market, and they are all looking for new suppliers and technologies.

How different are the technology requirements?

DC: The way how they use the quality assurance tools, like the CMMS, is not different. But the truth is, we are now dealing with completely different components, so the parts that are built for the assembly of combustion engine and electric engine are completely different. While the machine usage is the same, there are more aspects that you have to consider. For instance, the hairpins inside the stator, which are very significant components of electric engines having a flexible structure and being coated with a sensitive lacquer layer and therefore create challenges for reliable tactile inspection. An automated ZEISS coordinate measuring machine, equipped with confocal light or laser triangulation optical sensor, is one option to accurately measure the shape and lacquer thickness. Another more manual, flexible tool is a standalone ZEISS optical fringe projection sensor or a ZEISS handheld laser scanner

In those kinds of special applications, you need a special sensor, a special software, or a special knowledge to solve those issues. That’s the basic concept of how we approach the customers.

From your perspective, what are the opportunities for growth in asia, and specifically, southeast asia?

DC: We are seeing that the positive economic growth in the past 10 years will now be unachievable, so everybody is a little bit worried about it, considering the trade war between China and the US; and the smaller trade war between Japan and South Korea in terms of the semiconductor segment. But for the Southeast Asian market, I am seeing big opportunities because with the trade war between China and the US, many companies who are producing their products in China are now planning now to move their production to some Southeast Asian countries. Vietnam, for example, is often being mentioned as the best alternative relocation site from China.

There are also other markets who are benefitting from this. That is why I am quite positive now of the business in Southeast Asia.

Are there industry segments that you expect to see high growth potential in the southeast asian market?

DC: The automotive sector, where we are quite strong already. We have countries like Thailand, where the market is still quite big; Vietnam brought its own brand—VinFast—this year, and we are also getting a lot of benefits from that.

In general, the automotive sector is one segment in which I expect a lot of growth in the future. But it is not the only sector that will have that potential; the aerospace sector is also quite growing, especially the MRO, where I see a big growth potential.

Medical is another sector that shouldn’t be neglected; still, maybe it is not as big as of the moment in Southeast Asia, but I expect strong growth in the coming years.

How will the additive manufacturing sector impact the metrology segment?

DC: The aerospace and medical industries—these are the two sectors that will have a big impact on additive manufacturing, because you need individual and flexible parts and manufacturing process to produce them. If we just take an example from the medical technology side, there is a growing demand for artificial implants due to ageing population in many industrial countries. Additive manufacturing can provide cost effective solution for individually customised solutions. In line with that is the growing demand for quality control of those parts produced on 3D printers. Many people only think about dimensional checks or digitise the surface freeform with a 3D scanner. But in reality, you have to start from the material itself—you have to do the internal inspection; you even have to control the quality of the metal powder. You have to use high-quality microscopes to analyse the real sizes of the powders, or the content of the powders, etc.; they all have to be inspected in detail. That is why we see a very big potential for additive manufacturing. I am very confident that we will get a lot of benefits from the developments in this sector.

 

Check out these articles:

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Aluminium Alloy Additive Manufacturing To See 40% CAGR

 

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