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Additive Manufacturing impacting future

Manufacturing systems

Requirements for materials in production & Smart Industry

Cross border Conference

February 15th 2016
Zeughaus Neuss - Germany

Frits Feenstra
TNO - The Netherlands
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Outline

TNO at a glance
AM hype and reality
Towards Hybrid manufacturing
AM and Smart Industry / 4.0
Challenges and solutions
Way forward & high priority products
Technology & materials
Conclusions
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TNO at a glance

Dutch research organization for applied scientific research

Established by law and started in 1932
Independent of public and private interests
Assisting companies to innovate by doing R&D
Supporting government in policy making
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TNO at a glance & Ecosystems
Focus: high speed multi-material and mass-
customization AM
Activities: development of next generation
AM systems, to enable multi-technology
and mass-customization
Expertise: ICT and data path architecture,
system engineering and prototyping of new
equipment concepts, testing equipment,
process modelling and integration.
with industrial partners
Focus: functional AM materials
Activities: development of materials with
improved quality and durability and
incorporating new functionalities
Expertise: new chemical concepts, multi-
scale materials modelling, characterization
methods, process integration
Application-drive R&D supported by basic
academic knowledge
with industrial partners
AM hype and reality
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Implants
Toys/collectables
AM hype and reality
Textiles Jewellery
Dental Surgical
devices & aids
Speciality food

Electronics
Aerospace Prosthesis and orthotics

Armaments

Sports
Automotive Furniture
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Towards hybrid manufacturing

2014

1892

1984 1999
1994
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Towards hybrid manufacturing

Efficiency & yield
Reliability
Durability long term
Combining processes

2014

1892

1984 1999
1994
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Towards hybrid manufacturing

Current Systems
Batch wise
Slow
Monomaterials (or 2)
No composites/inserts

Future Systems
Hybrid Systems
High Speed
Multimaterials & Graded
Combine different technologies
Laser / P&P / sensoring
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From Products a Day, to Products a Minute

AM and Smart Industry / 4.0

From Batch to Continuous production + tact time loops

Allowing industrial integration of AM processes

Industry 4.0 +
an added AM module
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From Products a Day, to Products a Minute

AM and Smart Industry / 4.0

NL: Smart Industry Agenda

1 Capitalising on existing knowledge

2 Accelerating in Field Labs
3 Strengthening the foundation
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AM and Smart Industry / 4.0

Courtesy Siemens, Martin Schaefer, AM-Platform 2014

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AM and Smart Industry / 4.0

The Future & Future Products

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AM and Smart Industry / 4.0

Integrator

Building Blocs
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AM and Smart Industry / 4.0

Products made by
Integrator Hybrid Manufacturing!
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AM and Smart Industry / 4.0

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Challenges and solutions

Concepts for high-throughput, continuous 3D printing

Combining additive & subtractive technologies, pick & place
component integration
In-line inspection and post-processing
Way forward & high priority products
Functional Demonstrator: Embedding electronics
Way forward & high priority products
Functional Demonstrator: Micro bot

3D printed mechanical parts

Way forward & high priority products
3D Printed structural electronics

Pick and place of electrical/mechanical/MEMs components

Integration of relevant additive/subtractive processes

Development of novel hybrid integration tools

Integration of electronics Microfluidics

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Way forward & high priority products

2015 2025 Integration of sensors during build

Self condition & monitoring of parts

- > hostile / far away areas: space, sea, windmills,..

Technology: Multimaterial deposition

Exploring possibilities for high-resolution multimaterial processing

Minimizing post-processing needs

Example applications:
Embedded electronics
Metamaterials
Multicolor prostheses
Technology: high resolution printing

Material & process for high resolution DLP printing

New AM machine concept for large-size, high-resolution (20 m) and high-
speed (scan speed 100 mm/s, 10 s per layer) additive manufacturing
New exposure module based on multiple array of laser sources

Example: microfluidics
500 m mixing channels
200 m bridging channels
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Novel machine development for full 3D

integration
( 3D printing, pick and place of components (3D),
metal interconnection, flash sintering)

Full 3D Direct Integration

( 3D printing, pick and place of components
(3D), metal interconnection, flash sintering)

3D Integration
(3D printing, pick and place of components
(2D), metal interconnection, flash sintering)

2D-3D integration Many

(3D printing, flexible circuit placement, metal
interconnection, flash sintering ) more
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Conclusion

AM / 3D Printing combined with other production technologies in a hybrid

setting is promising for realising integrated products

Industrial implementation of AM can be tackled

AM hybrid enables intelligent products IoT

AM will align with future manufacturing technologies

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Contact information

Frits Feenstra (Projects)

E-mail: Frits.feenstra@tno.nl

Dr. Gregory Hayes

E-mail: greg.hayes@tno.nl
Business Developer

Movie at:
https://www.youtube.com/watch?v=IsSyGph33Hk&feature=player_embedd
ed
 Concept High Speed powder based sintering system

De-powdering

Inline Height adjustment

inspection

Laser
Pre heating sintering

+ Robot P&P Powder

deposition
/ load-unload (new layer)

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 AM has a great future?

Material & Markets Design

Production

Fine Aerospace Complex

controlled (complex, designs
materials JIT, ) Micro/nano
SMART Embedding scales
industry electronics
solutions ..

Affordability
 Companies
electronics for
Its all about collaboration
r
Secto
Metal
customized lighting
electronics for
automotive components
Multimaterial shoe
soles/insoles
Aero
3D Pharma / dispensing

Company Co-Funding
PhD Research
Government support

RVO NRW

RTO
Government