Additive Manufacturing

AM HADA
HAD200 - AIRCRAFT STRUCTURES - Part 1
Anis HOR, Associate Professor at ISAE- SUPAERO
HAD200 - AIRCRAFT STRUCTURES - Part 1 1
 Plan
I. Additive Manufacturing Environment

II. Definition and concepts of additive manufacturing

III. Additive Manufacturing processes

IV. Conclusions and Prospects

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 I.1. Additive Manufacturing Environment

In the current context (economic crisis, declining budgets, etc.), a

company wishing to maintain and / or acquire new market
shares must:

 Costs mastering

 Improve the quality of products and studies

 Reduce development duration

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 I.1. Additive Manufacturing Environment

• Costs Mmastering

80% of the costs (of development and

industrialization) are incurred in the phases
of the design (10 to 15% of the total time);

Therefore, design choices must be validated

as soon as possible.

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 I.1. Additive Manufacturing Environment

• Improve the quality of products

and studies

The product must respond to

functions of use, exchange but also
productibility. It is necessary to detect
as soon as possible any design errors
that generate costly changes and
delays.

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 I.1. Additive Manufacturing Environment

• Reduce development duration

According to the literature (McKinsey), a delay

of six months in the availability of the product
on the market can lead to a reduction in
profits of 33%, while exceeding the budgets of
a study would lose only 5%; In the face of
market fluctuations, a company that wants to
be competitive must be able to develop its
products more quickly.

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 I.2. Life cycle of a product

Besoin Analyze End of use

identifié
Experience acquired
Utilization
for the new product
Design development
Distribution

Industrialization
Sale

Production

Engineering Techniques bm7017 Rapid Prototyping: P. Dubois; A. Aoussat; R. Duchamp; LCPI-Arts et métiers ParisTech.

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 I.2. Life cycle of a product
Gantt diagram – Life cycle

Design

Industrialization

Production

Sale

Distribution

Utilization

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 I.3. Concurrent Engineering (CE)

4 notions:
 Simultaneity: The simultaneous engagement of activities (and
tasks), services (and trades) helps to reduce wastage and lost time
especially by avoiding too long passage times.

 Competition: by exploring different variants of a product in order to

retain the most suitable solution.

 Project division: cutting the project into sub-projects with well

identified interfaces.

 Integration: Designing a product requires the use of multiple skills

(technology, marketing, sales, IT, ...). These multiple skills require
interaction.

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 I.4. Statement

• One of the solutions to all of these problems is

to use Additive Manufacturing (AM)
techniques.

• What does additive manufacturing bring ?

A real advanced product during the design cycle of
a part (parallel commitment of different activities,
product integration, ...)

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 Example 1

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 Example 2
The Aerodynamics Department that manufactures the
wind tunnel model has grown to 70 employees from 19;
and the ADM Centre has expanded to five from one. As
F1 became more reliant on aerodynamic improvements
for its performance gains, demand for the number of
iterations to be tested rose dramatically. The ability for
these systems to manufacture multiple iterations of the
same part simultaneously has proved invaluable. 3D
Systems’ technologies have become a new and effective
manufacturing process for Renault to reduce both cycle
time and cost. With improved computer-aided design
(CAD), the Department is able to design more quality
complex geometry efficiently incorporating features that
would have previously been impossible. The Digital Age
now allows Renault to manufacture parts directly from
its CAD designs, eliminating the interpretation of
drawings, leading to more accurate components and
testing data. Last year, the Team was able to test 14,000
aerodynamic solutions.

“In Formula 1, aerodynamics is an empirical science,” said Dino Toso, head of aerodynamics. “We
design new ideas, we compare them, we choose directions to follow. The more ideas we can compare
and evaluate, the more successful we will be on the race track.”

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 I.5. Definition of additive manufacturing

The concept of additive manufacturing literally means "rapid manufacturing of

models and prototypes" and designates different processes that allow
physically rendering 3D objects, described by their CAD data, without tools and
in a much shorter time than by conventional processes.

3 essential notions have made the success of additive manufacturing processes:

 Time
The objective of additive manufacturing is to quickly realize models, with the
aim of reducing product development time.
Time to make a piece: ≈ 2h (dragon - slide 11)

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 I.5. Definition of additive manufacturing

 Cost

Additive manufacturing makes it possible to produce prototypes without

the need for expensive tools, while ensuring the performance of the final
product. It is thus possible to explore different variants of the product being
developed in order to retain the most elaborate solution (depends on the
process used)

 Complexity of geometry

The machines proceeding by adding material are capable of elaborating

extremely complex shapes, which can not be achieved by processes such as
machining, for example.

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 I.5. Definition of additive manufacturing

How to make a part in additive manufacturing ?

Must have :
• a material
• localized energy
• conversion software (geometric file  manufacturing file)
CAD
Energy

powder PART

3D part Material CAD

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 I.5. Definition of additive manufacturing

Limitations
 Process devoted only to prototypes.

 Part size.

 Surface defects of parts.

 Cost of parts and machines

(Machines ranging from 1,000 euros to 2,000,000 euros).

…
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 I.6. Types of models and prototypes

Product design requires two major types of physical

representation:
 Representations to visualize the object
 Representations to validate functions (eg in the form of geometric tests)

We find among all these types of models or prototypes:

 The design model/prototype,
 the geometric prototype,
 the functional prototype,
 the technological prototype,
 the pre-production.

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 I.7. Synthesis
• Origin of the development of additive manufacturing
(reduction of the development time of a product).

• 4 notions: Simultaneity, competition, project division and

integration.

• This process improves the time, cost and complexity of

geometries.

• The existence of different models/prototypes: design,

geometrical, functional, technological, pre-production.

Additive manufacturing at the heart of an

industrial evolution
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 Plan
I. Additive Manufacturing Environment

II. Definition and concepts of additive manufacturing

III. Additive Manufacturing processes

IV. Conclusions and Prospects

HAD200 - AIRCRAFT STRUCTURES - Part 1 19

 II.1. History
Prototyping: from the end of the 80's

Rapid tooling: early 1992

Fast manufacturing: now!

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 II.2. Standardization
Standardization AM: where are we in France?
 Vocabulary NF E 67-001 : october 2011
« Ensemble des procédés permettant de fabriquer couche par couche, par ajout de
matière, un objet physique à partir d'un objet numérique »
A set of processes for making layer-by-layer, by adding material, a physical object
from a digital object
 Powders - Technical specifications: technical characteristics of the
powders commonly used in additive manufacturing, to be supplied by the
powder supplier upon delivery
XP E 67-010 : may 2012
 Parts - Specification and acceptance conditions: elements to be
exchanged between the customer and the supplier when ordering,
checking and receiving parts
XP E 67-030 : may 2013
…and in international (ISO17296, ASTMF42)
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 II.3. Concepts

Concept n°1: Material and geometry elaborated at

the same time

Functional piece of laser head

Source : ARCAM Source : Trumph
Camera Support EBM TA6V
Source : Philippe Bauer THALES
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 II.3. Concepts
Concept n°2: reindustrialization

Weight gains on the whole 20%.

Easy assembly.
Decrease in the number of
components.
Source : MBProto / Volume-e
Savings of 15%.
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 II.3. Concepts
 Definitions of mechanical constraints by Flying
Cam Application 2 components
 Specific Re-Design of the Chassis (Topol (Facilitates installation)
Software) by Sirris Topologie 1 material
 Chassis production in Aluminum (MB Proto)

SLM aluminum manufacturing

7 components Re-design via the reduction = 530 g to 438 g
3 materials Topol software.
STL file
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 II.3. Concepts
step 1:
Micro Laser Fusion Manufacturing (SLM)
Machined surfaces

step 2:
machining

68 hours of manufacturing in Aluminum

438g (decrease of 20%)
Source : MBProto
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 II.3. Concepts

Concept n°3: topological optimization

Source : Multistation
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 II.3. Concepts

Source : Roland Berger, Munich, November 2013

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 Plan
I. Additive Manufacturing Environment

II. Definition and concepts of additive manufacturing

III. Additive Manufacturing processes

IV. Conclusions and Prospects

HAD200 - AIRCRAFT STRUCTURES - Part 1 28

 II.4. Additive Manufacturing Technologies
7 additive manufacturing technologies
Powder Liquid Solid

direct
melting / binder rolling / stratification
energy
sintering projection
deposition

Adhesion by Adhesion by
gluing photopolymerization

Extrusion Photopolymerization Direct deposition

inkjet Inkjet /
photopoly.

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 II.5. Stereolithography: SLA

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 II.5. Stereolithography: SLA

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 II.5. Stereolithography: SLA

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 II.6. Binder jetting
Binder delivery by an inkjet
print head on a bed of
powder

Thickness of the layers: 50 μm to 300 μm

Construction speed: 300 - 20,000 cm3 / h @ 150 μm

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 II.6. Binder jetting
Polybricks

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 II.6. Binder jetting
Development of a process to reduce porosity: layer-wise slurry
deposition (LSD)

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 II.6. Binder jetting

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 II.7. Ink jet printing
Principle: Direct deposit of liquid material on a
support

Thickness of the layers:

0.1μm to 10μm
Construction speed: 0.2 -
1 cm3 / h / nozzle

3D printing, direct ink writing, robocasting

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 II.7. Ink jet printing

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 II.7. Ink jet printing
robocasting

P. Miranda, Journal of Biomedical Materials Research Part A, 2008, 219-227

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 II.8. Fused filament fabrication: FFF
Principle: Deposition by extrusion through
a cylindrical nozzle

For ceramics
• Pasta formulation based on
hot melt or aqueous systems
• Piston extruder

Thickness of the layers:

50μm to qq mm
Construction speed:
10 - 200 cm3 / h
Fused deposition modeling (FDM), plastic jet printing (PJP)
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II.9. Electron beam melting: EBM

Arcam
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II.9. Electron beam melting: EBM

Examples of
components

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 II.9. Electron beam melting: EBM
Microstructure and mechanical properties of EBM material
cylinder vertical cylinder horizontal

TA6V

Co-29Cr-6Mo

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 II.9. Electron beam melting: EBM
CE-certified acetabular cups are in series production with EBM since
2007 by two European orthopedic implant manufacturers, Adler
Ortho and Lima Corporate
The U.S. implant manufacturer Exactech has also received FDA
clearance for an acetabular cup manufactured with the EBM
technology

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 II.10. Selective laser sintering/melting:
SLS/SLM
Principle: Localized sintering of a
powder bed by a power laser

Thickness of the layers:

60μm to 150μm
Construction speed: 20 -
5000 cm3 / h @ 150μm

For ceramics :
• Granulometry of the powder (flow)
• Layering systems
• Sensitivity to thermal shock
• Post process (annealing / sintering under load)
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 II.10. Selective laser sintering/melting:
virtual real SLS/SLM
Organic Metal: CoCr, TA6V,…
PMMA
PVA
PEEK
PCL
PHBV (PHA)
PLLA…

Inorganic:
HA
cHA
TCP

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 II.10. Selective laser sintering/melting:
SLS/SLM

Nanotechnology 22 (2011) 285703 (9pp),

Structure and properties of nano-
hydroxypatite scaffolds for bone tissue
engineering with a selective laser sintering
system, Cijun Shuai, Chengde Gao, Yi Nie,
Huanlong Hu, Ying Zhou and Shuping Peng
J Mater Sci: Mater Med (2008) 19:2535–2540Selective laser sintering of porous tissue
engineering scaffolds from poly(L-lactide)/carbonated hydroxyapatite nanocomposite
Microspheres Wen You Zhou, Siu Hang Lee, Min Wang, Wai Lam Cheung, Wing Yuk Ip

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 II.10. Selective laser sintering/melting:
SLS/SLM

Acetabular cup with lattice structures for improved Spinal implant encouraging bone fusion produced with
osseointegration produced with EOS Additive EOS Additive Manufacturing technology. (Source:
Manufacturing technology. (Source: Within) Within)

Additive manufacturing and Windform materials

(polyamide-based material reinforced with glass
https://www.renishaw.com/en/laser-melting-metal-3d-printing-applications--15256
fibers) for the orthosis of new generation
http://www.crp.eu/2427-additive-manufacturing-
and-windform-materials-for-the-orthosis-of-new-
generation.html

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 II.10. Selective laser sintering/melting:
SLS/SLM
SLM Manufacturing defects
lack of material lack of fusion occluded gas oxidation

cracking balling large balls ejection

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 II.8. Selective laser sintering/melting: SLS/SLM
Anisotropy and heat treatment effect of
SLM material

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 II.10. Selective laser sintering/melting:
SLS/SLM
bioprinting

Observation of the slice of 15 layers (a) and

SEM observation of the printed nHA surface: 40 x (a), 690 x 5 layers (b) of nHA printed on glass
(b) and 7000 x (c)
Study of Micro-Printing of Biological Elements by Laser for Bone Tissue Engineering,
Sylvain CATROS, PhD thesis at Bordeaux 1 university, 2010
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II.11. Direct energy deposition

Laser metal deposition, laser cladding

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II.11. Direct energy deposition

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II.11. Direct energy deposition

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 II.9. Direct energy deposition
DED SLM
Large parts / simple geometries Small parts / complex geometries

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 II.9. Direct energy deposition
Schemes of laser-material interaction based power densities
(W/cm2) and interaction time involved

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 II.9. Direct energy deposition
Microstructure of DED material

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 II.9. Direct energy deposition
Mechanical properties of DED material

DED material compared to DED

casted and forged material DED +HT1
DED+ HT2
Casted
forged

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 Plan
I. Additive Manufacturing Environment

II. Definition and concepts of additive manufacturing

III. Additive Manufacturing processes

IV. Conclusions and Prospects

HAD200 - AIRCRAFT STRUCTURES - Part 1 59

 Conclusions
Direct manufacturing

without fusion with fusion

powder bed direct deposition

1st step 2nd step

Main suppliers worldwide

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 Conclusions

Conventional process

Cost by part
Additive Manufacturing

Number of parts

Sources: Wohlers Associates 2013

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 Conclusions
Additive manufactured parts
Additive Manufacturing market growth

Material

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 Prospects
• Rapid development of additive manufacturing
processes.
• Technology faster and more inexpensive.
• Future of manufacturing processes and major advance
of conventional processes. to follow closely ...

Futurs concepts
Towards mass production
Towards an acceleration of the production time
TNO project
Carbon3D – Clip Technology

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 Bibliography
• Engineering Techniques bm7017 Rapid Prototyping: P. Dubois; A. Aoussat; R. Duchamp; LCPI-Arts et
métiers ParisTech.

• Advances in 3D Printing and Additive Manufacturing Technologies: David Ian Wimpenny, Pulak M.
Pandey and L. Jyothish Kumar; Springer 2017

• Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital

Manufacturing: Ian Gibson, David Rosen, and Brent Stucker, Springer 2015

• Laser Additive Manufacturing of High-Performance Materials: Dongdong Gu, Springer 2015

• An Introduction to Rapid Prototyping Tools and Reverse Engineering Methods: S. Thibaud, 2007.

• Rapid prototyping: A. Bernard – G. Taillandier

• O. Kerbrat, PhD thesis, Ecole centrale de Nantes

• http://www.3dsystems.com/
• http://www.stratasys.com/
• http://www.eos.info/
• http://www.stratoconception.com/
• http://formlabs.com/fr/
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