Metal Additive Manufacturing

Solutions & Services

© confidential 1
 About Wipro Group

S
WORLD’S MOST ETHICAL $ 8.76 BILLION 1,74,000 + 1180 ACTIVE CLIENTS IN USD 21Bn $
COMPANY – 4th YEAR IN A ROW CONSOLIDATED REVENUES WORKFORCE 175+ CITIES, 56 COUNTIRES MAKET CAPITALIZATION
(FY 2015-16) 6 CONTINENTS

IT PRODUCTS & INFRASTRUCTURE ENGINEERING ADDITIVE CONSUMER CARE &

SERVICES MANUFACTURING LIGHTING

Wipro Technologies Wipro Infrastructure Engineering WIPRO3D Wipro Consumer Care & Lighting

• IT • Hydraulic Cylinders • Metal Additive Manufacturing • Personal Care

• Truck Hydraulic Solutions Solutions & Services • Baby Care
• BPO
• Aerospace And Defense • Wellness Products
• R&D Services
• Industrial Hydraulics • Lighting Furniture And Switches
• Consulting Services • Wipro Water

© confidential ‹#›
2
What we do

© confidential ‹#›
 Our AM
Competencies
……………………………….…………………………

Selection to Realization Cycle

2012-13  Capacity
 Build
• 50+ parts (geometries) manufactured

Technology • India’s first Metal AM component in Space

• Stator rings in a 25 KN Turbo Fan
Technology Demonstrator Engine at 100%
2013-14  Capacity
 Build  Design
ground speed

Technology for AM

2014-15  Capacity
 Build  Design
 Post
Technology for AM Processing

2015-17  Capacity
 Build  Design
 Post  Engineering
 Research  Test /
Technology for AM Processing Design Services Validation

© confidential ‹#›
4
 Our AM
Journey
……………………………………………..…………

2012-13  Aerospace
Market Diversification
• Working with clients across 8 sectors
• Sector specific Additive Engineering
solutions

2013-14  Aerospace
 Space
 Healthcare

2014-15  Aerospace
 Space
  
Healthcare Automotive Oil & Gas

2015-17       
Aerospace Space Healthcare Automotive Oil & Gas Defence Industrial /
Tooling

© confidential ‹#›
5
Multiple AM Technologies

SLM EBM LENS EBAM HYBRID

Nozzle Injected Nozzle Injected Nozzle Injected
Feed Delivery Powder bed Powder bed (Powder) (Wire) (Powder)
Laser Electron Beam Laser Electron Beam Upto 2.5 kW
Optics 200 – 1000 W 200 – 1200 W Upto 42 kW

Resolution 50-80 Micron 140 Micron 25 Micron 25 Micron 25 – 140 Micron

Prevalent Build 400 x 400 x 400 350 x 380 mm 1500 x 900 x 900 1778 x 1194 x 1600 660 dia x 1500
Envelope mm mm mm mm

Current Planned

© confidential 6
 Di r e ct ed Ene r gy Deposi tion ( DED)
& El e c t ron Be a m AM ( EBAM )
METAL AM TECH

DED
DED EBAM
Process
Nozzle Injected Nozzle Injected
Feed Delivery (Powder) (Wire)

Laser Electron Beam

Optics
200 – 1200 W Upto 42 kW

Resolution 250 Micron 25 Micron

Prevalent Build 1500 x 900 x 900 1778 x 1194 x 1600

EBAM
Envelope mm mm
Process
Build Speed 0.14 - 0.63 g/s 0.14 - 0.63 g/s

Planned

© confidential ‹#›
 Sel ective L aser M el ting ( SL M )
& El ect ron Beam M el ting ( EBM )
METAL AM TECH

SLM & EBM Energy

Process
SLM EBM

Feed Delivery Powder bed Powder bed

Laser Electron Beam

Optics 200 – 1200 W

Resolution 80 Micron 140 Micron

Prevalent Build 400 x 400 x 400 350 x 380 mm

Envelope mm

Build Speed 0.03 - 0.06 g/s 0.81 - 2.51 g/s

Current Planned

Note: SLM is a proven technology for series production.

© confidential ‹#›
Typical Additive
Value Delivery

Improve Functional Achieve Monolith Design Cost Effective Obsolete/Legacy Parts

Performance Avoid Metal Joining Iterations Out Of Production
Techniques

Better Mechanical Material Workability Maintenance, Repair,

Flexible Production
Properties Issues Overhaul

Achieve Superior Supply Chain Faster Design Customization

Topology Issues Iterations
& Complex Geometry

Weight Reduction Optimized Post Tool-less Production Response Time &

Imperatives Processing (Quick Batch Production) Design To Realize Time

© confidential ‹#›
9
………………………………………………….…………………………….…………….…… AM Metals Offering AM Infrastructure

………………………………………………….………………………………………….…..
 Standard Alloys  AM Technology
Titanium Alloys • EOS M280, M290, M400
(Ti6Al4V, Ti6Al4V ELI, CP Ti) • Automatic powder handling module
• Under evaluation: Direct Energy Deposition,
Nickel Alloys Electron Beam Melting
(IN718, IN625, Hastelloy X)

Aluminium Alloy  Post Processing

(AlSi10Mg)
• Custom Inert Gas furnace
Stainless Steels • Vertical Machining Centre
(17-4 PH, 15-5 PH, 316L, Corax) • Turning Centre
• Surface Grinding & Treatment
Cobalt Chrome Alloys • Special processes capability
(MP1 and SP2)
 Test/Validation & Research
Maraging Steel
• Particle size analyser
• Optical Microscope
•
 Non-Standard Alloys •
7 Axis 3D Scanner
ONH Analyser
Can be Developed • CMM
WIPRO3D has the ability to develop • Part Density Measurement System
custom AM process for non standard • Powder Flowability Measurement
alloys as per business case • Powder Tap Density Measurement © confidential 10
 M e t a l AM Sol ut i ons & Ser vi ces AM Compe t e nc ie s

………………………………………………….…………….………….……………………………
……………………………………………………………….….………………...……………

 AM Consulting  Engineering Design

Aerospace pedigree and understanding of
• Additive Thinking Framework
domain.
• Experience Tours

 Additive Design
 Additive Design & Engineering Build strategy and plan, design & topology
optimization, custom parameters, simulation
• Additive Design
• Simulation & Validation
 AM Build Technology
Existing SLM. EBM & DED upcoming
 AM Services
•
•
Prototyping
Production
 Post Processing
Micro machining, Abrasive Flow Machining
deployed. HIP upcoming
 R&D Services
• Product Development  Research
Custom parameter development, new alloy
• Parameter Optimization/ Customization
adoption, post processing methods.
• New Material Adoption for LPBF/SLM

 Test, Validation, Certifications

 Turnkey Services Part prove out, DOE, functional tests
• Design, Program Manage, Deploy and
operate a Captive AM Center.  Quality
AS9100 D / AS 9100:2016, ISO 9001
confidential
WIPRO3D QMS © 11
INDUSTRY VERTICALS Domains

Space Defence Aerospace Transportation

……………………………………………………………………………………………………………………………………………………………………………………………………

Nuclear Healthcare Industrial Oil & Gas

© confidential 12
Exampl es of W i pr o 3D Addi t i ve Engi neer ing ( No t e x h a u s t i v e )

Client Design Additive Design Client Design Additive Design

Rear Upright
North West Bracket
Feed Cluster 2x2

In Orbit 35% stiffness increase

53.5% weight reduction
Ti6Al4V

RF Leakage eliminated
12 parts redesigned into 1
AlSi10Mg Altimeter

15% weight reduction

1.2 mm wall thickness
4 parts redesigned into 1
AlSi10Mg

PTO Cover

Aero Bracket

73% weight reduction

Laminar Flow Achieved 53% weight reduction
AlSi10Mg 78% deflection reduction
AlSi10Mg

© confidential 13
Component Gal lery ( No t e x h a u s t i v e )

Anti Icing Assembly (Front View) HP Compressor Stator Stage 4

To be tested | Multiple Alloys Validated at 100% ground speed | Ti6Al4V

Anti Icing Assembly

To be tested | Multiple Alloys

Launch Vehicle Gyro Housing UAV Flame Tube

Under testing. | AlSi10Mg Phase 1 testing cleared | IN 718 © confidential 14
 Component Gal lery ( No t e x h a u s t i v e )

Propulsion Nozzle Disc Sensor Housing Ka Band OMT Impeller Cold Finger
Under testing | IN 718 Validated | SS 316L 85% signal efficiency | AlSi10Mg Tech Demonstration | AlSi10Mg Validated | AlSi10Mg

Ka Band Single Body Exhaust Strut (Hollow) HiLov Manifold Integrated Helix Antenna Gas Turbine Nozzle Tip
Delivered | AlSi10Mg Validated | IN 718 Validated | AlSi10Mg Under testing | AlSi10Mg Validated | HX

HP NGV LP NGV Starting Nozzle Tx Antenna

Under testing | IN 718 Under testing | IN 718 To be tested | IN 718 Validated | SS 316 L © confidential 15
Rethink Engineering

Info.wipro3D@wipro.com | www.Wipro-3D.com
+91 73378 94181 | +91 73492 81332

© confidential 16