Additive Manufacturing’s premiere brands and most innovative minds will gather in Dayton, Ohio on September 20-22, 2016 to accelerate the development and design of manufacturing’s revolution.

The Additive Manufacturing Industry Summit (AMIS) will be held t​his September 20-22nd and offers a 3-day event dedicated to demonstrating the power of this growing technology for real-world applications and the immediate and long term benefits it promises for businesses.

Additive Manufacturing experts will gather to discuss evolving this technology beyond prototyping and modeling and into production-ready applications.

This year’s event focuses on the work being done in Defense, Aerospace, Medical, and Industrial arenas, offering in-depth workshops, targeted case studies, and the best minds in AM.

Taking place in Dayton, the heart of defense, aerospace, aviation, and traditional manufacturing, AMIS offers the unique opportunity to meet the best minds, but also witness t​he work being done first hand.

AMIS includes 25+ presentations on 3D printing and additive manufacturing from companies including Catepillar, Autodesk, Concept Laser, and Cincinnati, Inc.

Speakers Include:

  • John Murray - CEO, Concept Laser
  • Stacey DelVecchio - AM Product Manager, Caterpillar
  • Shannon VanDeren - Senior Product Manager, Layered Manufacturing and Consulting
  • J. Brian Stitt - Senior Program Manager, University of Dayton Research Institute
  • Dr. Larry Dosser - Senior Fellow for Technology Advancement, Wright State University
  • Chris Collins - CTO, Tangible Solutions
  • Adam Clark - Chief Strategy Officer, Tangible Solutions
  • Dr. Josh Deaton - Topology Optimization Engineer, Adjoint Technologies
  • Mike Lander - Senior Scientist, Materials & Manufacturing, UTC
  • Ginger Ruddy - Strategic Account Consultant, 3D Vision Technologies
  • Jeremy Marvin - Applications Manager, 3D Vision Technologies
  • Fred Herman - Manager, Engineering and Technical Services SHEPRA Engineering
  • Greg Loughnune - Adjunct Instructor, Engineering Technology Dept, University of Dayton
  • Marcus Miller - Engineer, Skyward, Ltd.
  • Brian Dow - Executive Director, Investment Banking, Mooreland Partners
  • Charlie Fox - Principal Engineer, Tangible Solutions
  • Rick Neff - BAAM Sales Manager, Cincinnati Inc.
  • Shane Fox - Product Manager Medical, Autodesk
  • Rob Stipek - 3D Printing Marketing Specialist, Fisher Unitech
  • Roger Gilcrest - Partner, Ice Miller LLP
  • James Earle - Advanced Manufacturing Engineer, Local Motors
  • Rachel Muhlbauer - Program Manager: Additive Manufacturing & Aerospace Materials Engineer, Tethers Unlimited, Inc.


Past event attendees have said:

  • "​This event was just the right mix of technical, business, and legal subjects of Additive Manufacturing." - G​erard Nanni, M​anager, Supply Chain, Bell Helicopter Textron
  • "The summit had an interesting mix of individuals attending - people from the medical sciences to equipment suppliers and legal knowledge. A very nice mix of information." - Tim Womer, P​resident, TWWomer & Associates
  • “Intimate gathering of well-informed professionals. Different than other 3D shows I have attended. Will definitely attend again in 2016."  - W​inthrop Sheldon, SLM Solutions NA


For more information or to register, visit: www.amisummit.com/dayton-2016

Published in GSMI

The 11th International Conference on Additive Manufacturing and 3D Printing is all about AM academic and industry experts getting together to share their knowledge and ideas. A setting is provided for both new and experienced users of AM to keep in touch and stay up to date with the latest developments in AM and to enhance commercial success and explore new avenues of research.

Listen to both sides of the story: the successes and challenges of leading technology adopters giving a balanced view of the industry, cutting right through the hype. Find out about current state-of-the-art research and leading industry applications as each carefully selected speaker addresses different issues facing the evolving AM world.

Preceding the main conference on Tuesday July 12th will be the UK AM Research and Innovation day. Throughout this day, highlights of the best of UK Additive Manufacturing Research and Innovation taking place at UK Universities and Innovation Centres will be presented.

UK based research groups with significant AM activity will give technical overview presentations detailing their current and future research work with the intention of showcasing both the breadth and depth of the work that is currently going on in the UK.

The parallel exhibition, to which our conference delegates will have exclusive access, features a select number of organizations whose technology, analysis, expertise and products continue to help drive development in Additive Manufacturing, 3D printing and wider manufacturing industries. It will be open from 12:30 on July 12th until the end of the event.

The event is organized on behalf of the world renowned Additive Manufacturing & 3D Printing Research Group (3DPRG), based at the University of Nottingham, in partnership with Added Scientific Ltd, which provides technical services and training in the areas of materials, process and design to enable business identify and realise the benefits of 3D Printing.

The conference was started in 2006 by Professor Richard Hague, now head of the Additive Manufacturing and 3D Printing Research Group (3DPRG) at Nottingham University. Since 2006 the conference has grown from less than 90 delegates to over 250 delegates, coming from 18 countries. The conference has an excellent reputation, with over 50% of all delegates being repeat visitors. The event attracts delegates from the aerospace, automotive, consumer goods, fashion, retail, materials and defense sectors along with academics involved in materials, lasers, software development and design.

For more information or to register, visit: www.am-conference.com

Speakers at the plenary sessions of the Society of Plastics Engineers (SPE) ANTEC® 2016 conference will focus on the future of the plastics industry, with special emphasis on additive manufacturing, 3D printing, and the promise of automotive light-weighting through use of carbon fiber composites.

ANTEC 2016, the world’s largest plastics technical conference, will take place May 23-25 at the JW Marriott Indianapolis in Indianapolis, Indiana, U.S.A.

Plenary sessions will include the following presentations:

Monday, May 23: Additive Manufacturing and 3D Printing: State of the Industry, by Tim Caffrey, senior consultant at Wohler Associates.
  • Tim Caffrey is a senior consultant at Wohlers Associates Inc., Fort Collins, Colorado. His responsibilities include the execution of consulting projects, speaking, and representing the company at national and international events.  He is a principal author of the Wohlers Report, an in-depth worldwide study of the state of the additive manufacturing and 3D printing industry. He has worked with Wohlers Associates since 2000.

Tuesday, May 24: The State of the Plastics Industry: Outlook for 2016 and Beyond. This will be a discussion by a panel of industry editors, followed by a discussion between the editors and members of SPE’s Next Generation Advisory Board.
  • Plastics Industry Editors Panel will include Jim Callari, associate publisher and editorial director of Plastics Technology; Susan Flynn, managing editor of Composites Manufacturing; Clare Goldsberry, senior contributing editor of Plastics Today; and Don Loepp, editor in chief of Plastics News. Mike Tolinski, managing editor of SPE’s Plastics Engineering, will serve as moderator. Don Rosato, publications chairman for the Plastics Institute of America at the University of Massachusetts—Lowell, will serve as coordinator.

Wednesday, May 25: A Platform for Novel Lightweight Automotive Composite Design, by Antony Dodworth, chief technology and manufacturing officer at Bright Light Structures.
  • Antony Dodworth is chief technology and manufacturing officer at Bright Light Structures, LLC, San Francisco, California. His automotive career began in 1985 with chassis engineering for the Indianapolis 500. He has worked for Bright Lite Structures since 2011. From 2003 until 2011 he was principal research manager at Bentley Motors Ltd. where he led a team investigating the adoption of composite materials. He has designed, worked on, and built chasses for the March Indy 500 car; Leyton House F1; McLaren F1 and F1 road car; Hyundai Coupe concept; Cadillac Cien; Jaguar F Type concept; and Bentley GT concept, road car convertible, Supersport, Mulsanne, and T35. He lectures frequently on composite fibers at universities and serves on the boards of composite fiber industry associations.

 

“The plenary sessions at ‘ANTEC at Indy’ will offer a unique view of the future of plastics,” said Donna S. Davis, technical conference chair of ANTEC 2016. “And with the running of the 100th anniversary Indianapolis 500 race taking place on the following Sunday, we couldn’t miss the opportunity for one of our plenary speakers to look at the future of automotive.”

For more information, visit: www.antec.ws

Published in SPE

3D Platform (3DP) is raising the bar on additive manufacturing solutions, with the launch of the 3DP Workbench, its newest industrial-strength, large-format 3D printer.

“The 3DP Workbench is more than just another 3D printer, it has been designed through a professional user-experience process—with input from engineers, product developers and top creative talent around the world—incorporating tools they need to take our 3D platform to the next level. The result is a comprehensive toolkit that increases capacity, enables them to expand their capabilities and bring their ideas to life,” said John Good, Vice President of Sales & Marketing with 3DP.

The 3DP Workbench comes standard with the large build area of 1m x 1m x 0.5m, and is built on industrial strength mechatronics designed to deliver precision prints down to a 70-micron layer resolution. Additionally, the 3DP Workbench adds versatility with unique production and organizational features including:

  • SurePrint Servo Technology™ - Cut your print time in half with the SurePrint Servo Technology™ motors that have 85% greater torque, allowing for faster acceleration and deceleration and improving print accuracy and quality.
  • Folding Gantry – Even with its large build area, the 3DP Workbench is designed for maximum flexibility and accessibility. A unique two-part configuration will fit through a single width door, make it possible to locate conveniently it where you want – office, factory, etc.
  • Expanded Print Capabilities - The ergonomic height and open print bed enable full access to prints for advanced print techniques, such as core modeling and adding inserts of metal, electronics, and other materials.
  • Industrial Workbench – Solid hardwood work area, 12 industrial built-in storage drawers and cabinets for useful additive manufacturing tools and materials.


The 3DP Workbench will be releasing officially by the end of Q1, 2016. A live, on-going demonstrations of the 3DP Workbench will take place throughout the 28th Annual Additive Manufacturing Users Group (AMUG) Education & Training Conference, April 3 - 7, 2016 At St. Louis, Missouri.

For more information, visit: www.3dplatform.com

Published in 3D Platform

Trade show organizer, Tarsus Group, will run two new B2B events for the additive manufacturing industry (commonly referred to as 3D printing) in 2016. Additive Manufacturing Europe and Additive Manufacturing Americas will focus on the fastest growing vertical sectors – healthcare, aerospace and automotive. Tarsus already runs several shows in these sectors, the most prominent of which are the Dubai Airshow (aerospace), AAITF (automotive) and A4M (medical).

The new events will incorporate 3D Printshow, which Tarsus acquired in 2014. This follows exhibitor requests for larger, consolidated events with an international business-to-business focus.

As part of the new shows, there will also be a 3D Printshow pavilion, focusing on design and prototyping. This will continue to attract the designers and innovators that are driving development and innovation in the industry.

While much of the growing media coverage of additive technologies has focused on abstract concepts or very niche usage, the Additive Manufacturing Shows will focus on the mainstream applications that are revolutionizing these sectors. Additive manufacturing can produce complex, customized solutions that increase functionality, while reducing lead time and waste.

The entire spectrum of 3D printing and additive manufacturing equipment will be on show, with live demonstrations of working machinery a cornerstone of the events. Conferences will run alongside the trade shows, with dedicated streams for the vertical sectors.

Lisa Milburn, Managing Director, commented: “Additive manufacturing is an exciting growth area and recent developments in equipment and software are providing plenty of opportunities for real world applications. 3D Printshow has been the leader in dedicated 3D printing events and, combined with Tarsus’s experience of running large, industrial shows around the world, we look forward to working with our partners to deliver the largest events for this sector.”

For more information, visit: www.amshows.com

Published in Tarsus

Prototype Today announced the launch of a new production 3d printing news website:  AdditiveManufacturingToday.com.  The site offers a trusted information source for the latest news articles and videos about the additive manufacturing industry.  Additive Manufacturing Today officially went online with a beta launch of the website on December, 1st 2015.

Popular topics covered on the new site include the latest additive manufacturing and 3d printing equipment, materials, case studies, acquisitions and industry events. Going forward Prototype Today will cover consumer 3d printing topics such as desktop 3d printers, 3d printing educational initiatives, and consumer prototyping/product development. The new Additive Manufacturing Today website will strictly focus on high-value production applications of additive manufacturing including: aerospace engines and rockets, medical implants & surgical tools, and complex industrial end-use parts. The site will also cover the latest advances in the additive manufacturing field including new industrial 3d printers, new materials and metal powders, and government led research and development.

News and videos are updated at AdditiveManufacturingToday.com on a weekly basis and contain selected content submitted for consideration by verified companies.  The site strives to level the playing field for companies across industries by allowing anyone to submit relevant quality content for inclusion at no charge.

For those who like to network in person the events section lists upcoming industry events on an easy to navigate calendar for quick access.  Networking in person is still a very effective way to meet new people in the industry and see the latest additive manufacturing technology that companies are offering.

Any questions or content submissions can be directed to Brett Johnson, the web manager at:

Brett Johnson
This e-mail address is being protected from spambots. You need JavaScript enabled to view it

Additive Manufacturing Today
http://www.AdditiveManufacturingToday.com

 

Renishaw announced two new metal additive manufacturing (AM) systems: the RenAM 500M and the AM 400.

RenAM 500M industrial metal additive manufacturing system (initially introduced as EVO Project)
Fully designed and engineered in-house to be used for serialised production, the RenAM 500M builds complex metal components directly from CAD using metal powder fusion technology. Highlights of the system include a Renishaw designed and engineered optical system with dynamic focusing; automated powder sieving and recirculation; 500 W ytterbium fibre laser and patented high capacity dual filter SafeChange™ system.

AM 400 metal additive manufacturing system
Renishaw also launched the AM400 flexible metal additive manufacturing system. This new model is a development of the AM250 platform. It includes all the advantages of the latest machine updates with larger SafeChange™ filter, improved control software, revised gas flow and window protection system, and a new 400 W optical system that gives a reduced laser beam diameter of 70 micrometres.

For more information, visit: www.renishaw.com/additive

 

Published in Renishaw

Concept Laser presented a new machine and plant architecture which promises a new level of Additive Manufacturing in terms of quality, flexibility and increase in performance. The modular integration of machine technology into the manufacturing environment is achieved with a new approach in the design of process components. Ultimately, this makes faster and more economic industrial production solutions available. Concept Laser has announced a market launch by as early as the end of 2016.

The previous solutions for machine and plant technology in the market all relied on ideas such as “more laser sources,” “more laser power,” “faster build rates” or “expansion of the build envelope sizes.” The machine technology represented a “standalone” solution without any consistent integration into the manufacturing environment. Build job preparation and build job process proceeded sequentially. Concept Laser is now attempting, with a new machine architecture, to expand the usually quantitative sections with new, qualitative aspects. “In essence,” says Dr. Florian Bechmann, Head of R&D at Concept Laser, “it is about splitting up build job preparation/build job follow-up processing and Additive Manufacturing in any number of combinable modules. With comparatively large build envelopes, build jobs can be carried out with a time delay. The intention is that this should drastically reduce the “downtimes” of previous stand-alone machines. There is plenty of potential here for improving the level of added value in the production chain. In contrast to purely quantitative approaches of previous machine concepts, we see here a fundamentally new approach for advancing industrial series production one step further.”

At present, regional printing centers are being created as service providers all around the globe. This development is characterized by the transition from “prototyping” to a desire for flexible series production at an industrial level. The AM users experience the pressure of traditional manufacturing: demand for space, expansion of the machinery, increasing operating tasks and in particular times. In the new concept from Concept Laser, interesting solutions are offered in this regard: Production is “decoupled in machine terms” from the preparation processes. The time window for AM production is increased to a “24/7 level,” meaning that there is higher availability of all components. An automated flow of materials palpably reduces the workload for the operators. Interfaces integrate the laser melting machine into traditional CNC machine technology, as is important for hybrid parts, for example, but also into downstream processes (post-processing / finishing).

The new plant architecture is characterized essentially by decoupling of “pre-production,” “production” and “post-processing.” This includes among other things flexible machine loading and physical separation of the setting-up and disarming processes. The objective here was to coordinate the process components in a more targeted way with interfaces and increase the flexibility of the process design to create an integrated approach. This becomes possible thanks to a consistent modular structure of “handling stations” and “build and process units” which, in terms of combination and interlinking, promises considerably greater flexibility and availabilities. It will also be possible to handle the present diversity of materials better, and ultimately more economically, through a targeted combination of these modules. For example, in future the machine user will be able to use the modules to very precisely “customize” the production assignment in terms of the part geometry or material. All in all, the level of efficiency and availability of the production system will be markedly increased, along with a significant reduction in the amount of space required. Simulated production scenarios have in fact shown that this space can be reduced by up to 85% compared to the possibilities that exist at present. In addition, the laser power per m2 is increased seven-fold. Dr. Florian Bechmann says: “The build rates have increased enormously thanks to the multilaser technology. The build envelope sizes have also experienced considerable growth. We now want to use an integrated machine concept to highlight the possible ways that the approaches of “Industry 4.0” can change Additive Manufacturing as the manufacturing strategy of the future. There is plenty of potential here to increase industrial added value and enhance suitability for series production.”

The process station shown has a build envelope of 400 x 400 x >400 mm³, laser sources, process gas management and filter technology are integrated in the module, and the layer thicknesses are within the usual range. In addition, the machine solution has a variable focus diameter and will be available optionally with 1, 2 or 4 laser optics with a laser power ranging from 400-1,000 W. An available redundancy of the lasers will ensure that, if one laser fails, the remaining three lasers will still cover the entire build plate – the build job can still be completed. Dr. Florian Bechmann says: “More and more laser sources only increase the expected speeds to a limited extent. But ultimately they also increase the level of complexity and dependencies, which can result in vulnerability, and thus turn the desired positive effect into a negative.”

The new handling station has an integrated sieving station and powder management. There is now no longer any need for containers to be used for transportation between the machine and sieving station. Unpacking, preparations for the next build job and sieving therefore take place in a self-contained system without the operator coming into contact with the powder. But what also makes a modular handling station attractive is the specific configurations: A handling station can be linked to two process stations to create a “manufacturing cell.” The factory building kit also enables several handling stations to be joined together to create a material preparation facility and be physically separated from the process stations.

The new factory building kit boasts three types of modules: process module, dose module and “overflow” module, which are to be offered in different heights. What is remarkable is the direct link between these modules without the use of any pipes or tubes and their identification via RFID interfaces. Accordingly, the result is a reliable flow of materials with high material throughputs along with great flexibility when there is a need to supply different types of materials for the build process and handle them. “In the future,” says Dr. Florian Bechmann, “we think that AM factories will be largely automated. The transport of material or entire modules can be envisaged as being done by driverless transport systems. This could then be the next step in the development. Additive Manufacturing can be automated to the maximum extent.”

The new machine concept has a new type of 2-axis coating system which enables the return of the coater to be performed in parallel with exposure. This results in a considerable time saving during the coating process.
The coater blades, optionally made of rubber, steel or carbon, can be changed automatically during the build job. This results in several advantages according to Dr. Florian Bechmann: “An automated tool changing system, as is the case with CNC machine technology, promises a high level of flexibility, time advantages when setting up the machine, and reduces the level of manual intervention by the operator. We deliberately talk here about ‘robust production’.”

For more information, visit: www.conceptlaser.com

Published in Concept Laser

A proposed ASTM guide will make it easier for businesses to create parts using additive manufacturing, also known as 3D printing. Specifically, the guide will provide overarching principles of design rules in this fast-growing field.

“It is very hard to come up with a single ‘right way’ to create a part using additive manufacturing,” says ASTM member Paul Witherell, a mechanical engineer at the U.S. National Institute of Standards and Technology. “This standard will serve as a foundation that supports the development of design rules for the growing number of additive manufacturing processes and machines.”

Well-formed design rules provide manufacturers – including entrepreneurs and small businesses – with a way to make meaningful changes to parts and production processes without compromising overall manufacturability. The new standard will promote a consistent way to develop and apply these rules, providing key insights into the intricacies of additive processes.

All interested parties, particularly those developing best practices in this field, are welcome to join in the work of ASTM’s additive manufacturing committee (F42) and this proposed standard (WK51841, Guide for Principles of Design Rules in Additive Manufacturing).

For more information, visit: www.astm.org/COMMITTEE/F42.htm

Published in ASTM

GF Machining Solutions has introduced the AgieCharmilles AM S 290 Tooling additive manufacturing system. Representing its collaboration with additive manufacturing leader EOS, the AM S 290 Tooling is based on the proven technology of the EOS M 290 metal laser sintering system.

The new AM S 290 Tooling was created to further extend the scope of solutions provided to mold and die manufacturers, and complements GF Machining Solutions existing lines of AgieCharmilles wire and die-sinking EDMs, Mikron milling centers, Laser texturing centers and System 3R automation systems.

With the additive manufacturing provided by the AM S 290 Tooling, moldmakers can move thermal exchange closer to the surface of a mold, improving temperature homogeneity to reduce throughput times and increase part quality. The incorporation of additive manufacturing also lowers energy consumption and opens the door for programmers to improve part designs through conformal cooling and heating channels.

The ongoing collaboration between GF Machining Solutions and EOS revolves around optimal integration of additive manufacturing for mold and die shops. The AM S 290 Tooling features controls and software that allow for easy and quick integration with existing machine tools and measuring devices.

GF Machining Solutions is the world’s leading provider of machines, automation solutions and services to the tool and mold making industry and to manufacturers of precision components. The products range from electric discharge machines, high-speed and high-performance milling machines, including clamping and palletization systems, and 3D laser surface texturing machines, to services, spare parts and expendable parts, consumables and automation solutions. GF Machining Solutions is a globally acting division of the Georg Fischer Group (Switzerland) and maintains a presence on 50 sites worldwide within its own organization. Its 3,008 employees generated sales of CHF 905 million in 2014.

For more information, visit: www.gfms.com/us

Published in GF Machining Solutions

Following the July announcement of its large scale additive manufacturing (LSAM) program, American Kuhne customer Thermwood Corporation, a US-based manufacturer of CNC routers, announced that its development system performed well during initial additive testing through its entire operating range.

Kevin Slusarz, American Kuhne vice president of process technology, assisted in the start-up effort. ‘It is my pleasure to support Thermwood beyond the design phase. This was a good opportunity to combine our polymer processing know-how with Thermwood’s CNC technology expertise to advise optimizations to melt piping & tooling design for this unique application,’ he said.

Thermwood’s development system is supplied by a 1 ¾ inch American Kuhne extruder custom engineered for this application. ‘Although it’s a demanding application, our extruder performed flawlessly during initial testing,’ said Thermwood chairman & CEO Ken Susnjara. ‘We are quite pleased with our selection of American Kuhne as our development partner in this effort, not only for the quality of the equipment, but also for the service & support,’ he added.

Thermwood expects to fit this initial test machine, which can print parts up to ten foot by ten foot by five foot thick, with a five axis ‘subtractive’ gantry trim system in the next few months. This will enable the system to perform both the ‘additive’ and ‘subtractive’ functions on the same machine. Called ‘near net shape’, this approach uses a high volume thermoplastic printer to quickly create a part that is nearly, but not exactly, the final net shape. The ‘subtractive’ function then machines the part to the exact final net shape.

Testing included initial validation of an all new ‘MeltShape Technology’ for enhanced control of layer shape and improved bonding between layers, a new and promising technique in the advancement of LSAM. This new patent-pending approach uses one or more shaping wheels to shape, form and compress the hot plastic melt as it is being extruded, insuring that each new layer is the proper shape and thickness and that it bonds firmly to previously applied material.

Thermwood plans to continue this development effort with the goal of offering these machines in a variety of large sizes for commercial applications, specifically targeting aerospace patterns and molds. Management cannot yet determine when the technology might be sufficiently refined for commercial rather than purely research and development applications. Thermwood plans to work with material vendors, R&D organizations and potential users in the ongoing development effort.

For more information, visit: www.thermwood.com

Published in Thermwood Corporation

CI will demonstrate the versatility of additive manufacturing at Fabtech with displays featuring a full size Shelby Cobra automobile, a scaled fighter jet, a 12-ft. kayak, and a utility vehicle that were all produced using the new Big Area Additive Manufacturing (BAAM) system. The carbon and glass fiber reinforced ABS plastic materials for these displays were provided by SABIC and Techmer Engineered Solutions. The large-scale additive machine uses a steel fabricated chassis and advanced linear drive motors as the base, and extrudes hot thermoplastic to build parts, layer by layer. The machine, developed as part of a cooperative research and development agreement between CI and Oak Ridge National Laboratory, introduces significant new manufacturing capabilities to a wide range of industries including automotive, aerospace, marine, appliance and many more.

The BAAM machine on display at Fabtech has a work envelope of 65”x140”x34” and extrusion rate of about 38 lbs/hr and will be printing parts made with SABIC’s THERMOCOMP™ compound, an ABS carbon fiber material which provides excellent strength-to-weight ratio and high stiffness.  CI makes a larger size that has a work envelope of 8 x 20 x 6 ft. with an extrusion rate of about 100 lbs/hr. The machine prints polymer components up to 10 times larger than currently producible, at speeds 1,000 times faster than existing additive machines. The machine’s extruder uses a wide variety of thermoplastics and fiber reinforced thermoplastics to meet the needs of a variety of commercial applications, including furniture and tooling.

“All of the displays will show the art of the possible with additive manufacturing,” said Carey Chen, President and CEO of Cincinnati Incorporated. “ The kayak display will be shown as 1/3 raw additive material (ABS carbon fiber), 1/3 filled with gel coat, and 1/3 finished and painted, demonstrating the phases of finishing 3D printed parts. These displays will have a huge ‘wow’ factor at the show because they show how large-part additive manufacturing can be applied in our daily lives.”

In addition to the four displays, the company will have two exhibits. The BAAM machine will be on display in booth N-9000 in the entrance to the North Hall of Chicago’s McCormick Place, while the new electric 40-ton GOFORM press brake will be demonstrated in booth S-2799 in the South Hall. The South Hall booth will include a large video wall with unique footage angles of CI’s laser cutting systems, automation, and press brakes.

For more information, visit: www.e-ci.com

Stratasys will be presenting the role of additive manufacturing as one of the key technologies that will enable the ‘Factory of the Future’ at the annual Oracle OpenWorld conference, October 25 – 29, San Francisco.

Rich Garrity, VP & GM Vertical Solutions, Stratasys, will be a featured speaker at Oracle OpenWorld, discussing additive manufacturing’s role in the ”Factory of the Future” to deliver on the promise of a smart, agile manufacturing workflow. Rich will describe additive manufacturing integration scenarios with adjacent manufacturing software systems and also present specific customer manufacturing stories from strategic industries including aerospace and automotive.

“The inclusion of Industry 4.0 applications at Oracle OpenWorld, this year, make it a natural fit for Stratasys additive manufacturing,” said Danny Weber, VP Strategy and Strategic Alliances, Stratasys. “We invite attendees to come discuss how they can begin integrating additive manufacturing into their supply chain to improve production economics and explore new business models.”

Conference attendees will have the opportunity to experience additive manufacturing first hand at the event as Stratasys will be showcasing its 3D printing solutions, including the Fortus 450mc and uPrint SE Plus 3D printers, as well as its Stratasys Direct Manufacturing parts-on-demand service.

For more information, visit: www.oracle.com/openworld/index.html

Published in Stratasys

The Additive Manufacturing Users Group (AMUG) announced that online registration is now available for its 2016 Education & Training Conference, which will be held in St. Louis, Missouri, at the historic St. Louis Union Station, from April 3 – 7, 2016. The users group conference, now in its 28th year, is open to owners and operators of additive manufacturing (3D printing) technologies.

AMUG brings together engineers, designers, supervisors, plant managers and educators from around the world to share expertise, best practices, challenges, and application developments in additive manufacturing. The AMUG Conference will include technical sessions and hands-on workshops designed to help users get more from, and do more with, their systems. Through its Technical Competition and Awards Banquet, excellence in applying additive manufacturing and contributions to the industry will be recognized. The five-day event also includes the two-night AMUGexpo, networking receptions , student poster session and catered meals.

Mark Barfoot, AMUG president, said, "We are quite excited to be building an agenda that continues to deliver a wealth of hands-on experiences and extremely practical sessions where users gain real insight into techniques or tips that they can take back to the office and start using right away."

The conference agenda is expected to contain over 200 presentations and hands-on workshops. Barfoot said, “To fit it all in, we are condensing our general sessions on two of the four conference days to allow for more concurrent sessions, which means more content and more choice for our attendees.”

Although still in development, several elements of the conference agenda have been confirmed. The event will kick off with keynote presentations on Monday, April 4th by Jason Lopes of Legacy Effects and Todd Grimm, AMUG’s AM industry advisor and president of T. A. Grimm & Associates. On Tuesday, April 5th, the group will host a panel discussion with representatives from its Diamond Sponsors, which are typically manufacturers of additive manufacturing machines and materials.

The conference will also have its second annual Innovators Showcase, which has the feel of a fireside chat, where attendees get to know an innovator in the industry and discover insights from that individual’s experiences. For 2016, the special guest will be Scott Crump, inventor of Fused Deposition Modeling (FDM) and co-founder of Stratasys.

Barfoot noted, "The keynotes, presentations, panel discussions and workshops will keep attendees very busy. But we will still offer plenty of time for networking. That is the one thing that most differentiates the AMUG Conference from all others so we always strive to build the event such that attendees have ample opportunity to meet, converse and share.”

For more information, visit: www.additivemanufacturingusersgroup.com

Published in AMUG

A workshop on the Mechanical Behavior of Additive Manufactured Components will be held May 4, 2016, at the Grand Hyatt San Antonio in San Antonio, Texas.

ASTM International Committee E08 on Fatigue and Fracture is sponsoring the workshop in conjunction with Committees E07 on Nondestructive Testing and F42 on Additive Manufacturing Technologies. The groups are also holding their biannual standards development meetings the same week.

This event will provide a forum for the exchange of ideas regarding the mechanical behavior of components fabricated using additive manufacturing with a focus on fatigue behavior. It is designed for professionals in the aerospace, medical and defense industries.

Topics to be discussed include:

  • Standards for additive manufacturing;
  • Fatigue behavior of components fabricated using additive manufacturing; and
  • Nondestructive evaluation of components fabricated using additive manufacturing.


A technical program will be posted by December 2015. Online registration opens approximately eight weeks before the workshop and closes April 27, 2016.

For more information or to register, visit: www.astm.org/E08WrkshpBehavior5-16

Published in ASTM

At the TCT exhibition in Birmingham, UK, taking place from September 30th to October 1st 2015 Renishaw will announce plans to open a global network of Renishaw Solutions Centers for metal 3D printing, also known as additive manufacturing (AM).

“Additive manufacturing is still mostly used in rapid prototyping applications, where the ability to build metal components direct from CAD, with no special tooling, is especially valuable,” said Clive Martell, Head of Global Additive Manufacturing. “However additive manufacturing has so much more potential than this – it enables us to design and make innovative products with spectacular gains in performance and efficiency. Renishaw's vision is to make additive manufacturing a mainstream manufacturing technology, used in series production of high performance parts for aerospace, medical, automotive, oil & gas, mould & die and consumer products.”

When adopting any disruptive new manufacturing technology, companies will go through a rigorous assessment process to understand the potential benefits, and to prove the reliability and capability of the production process. The investment in time, resources and equipment to achieve this can be significant.

Renishaw Solutions Centers will lower this entry barrier by providing cost-effective access to machinery, facilities and AM expertise. Equipped with the latest additive manufacturing machines and staffed with knowledgeable engineers, the Solutions Centers will provide a confidential development environment in which firms can explore the benefits that additive manufacturing can bring to their products, and quickly build their knowledge and confidence in AM as a production technology.

Each Solutions Center will feature Incubator Cells – private development facilities containing an AM machine, design workstation and all the ancillary equipment needed to design, build and refine a new product design. As the product and process design matures, Renishaw will also provide pre-production capacity where the productivity and capability of the AM process can be established. Renishaw will provide support in the form of operators and applications engineers, as well as access to a range of machining, finishing, treatment and metrology processes.

“Whilst additive manufacturing can create complex geometries in a single process step, some level of finishing is generally required to produce functional products,” said Marc Saunders, Director – Global Solutions Centers. “Renishaw's knowledge of metrology, machining and finishing processes can help customers to develop an integrated manufacturing solution for their innovative new product.”

The network of Renishaw Solutions Centers will open during the final quarter of 2015 and the first half of 2016, and will include facilities in the UK, Europe, USA, Canada, India and China.

For more information, visit: www.renishaw.com

Published in Renishaw

The Association For Manufacturing Technology and VDW – Verein Deutscher Werkzeugmaschinenfabriken (German Machine Tool Builders’ Association) announced that the competition period for the 2016 International Additive Manufacturing Award (IAMA) is now open.

The IAMA recognizes innovations in additive manufacturing for industrial applications. This includes developments in the design of systems or major components, advances in processes or materials, new applications, data generation or measurement.

Those in the industry, such as system producers, users, component suppliers, data modelers, and international academia, are invited to apply. The 2016 award will be presented at METAV 2016 – 19th International Exhibition for Metalworking Technologies – held in Düsseldorf, Germany, from February 23-27, 2016.

The applications will be evaluated by a high-ranking international jury comprised of representatives from industry, academia, trade organizations and the media.

This is the second edition of the IAMA. The inaugural award was presented last March at The MFG Meeting to Hybrid Manufacturing Technologies for its self-contained laser cladding head, which mounts to a machining center's spindle and augments a traditional "subtractive" CNC machine's operations with additive capabilities.

AMT and VDW partnered on the International Additive Manufacturing Award program in response to the rapidly changing landscape in manufacturing created by advances in additive technology. Not only do these advances present myriad opportunities, but also challenges to entry and scalability. This award was created to encourage innovators to accelerate the technology's current availabilities while also creating new solutions to its challenges.

"Additive technology continues to have a significant impact on manufacturing operations and product design," said Douglas K. Woods, President of AMT – The Association For Manufacturing Technology. “With the IAMA, we are aiming to shine a spotlight on innovations and creative solutions in this bourgeoning field. Following a successful inaugural competition, we are looking forward to numerous project entries for the 2016 award.”

VDW – German Machine Tool Builders’ Association - Executive Director Dr. Wilfried Schäfer added, “Additive manufacturing will be one of the technology trends radically transforming the production processes of the future. It has meanwhile evolved into an autonomous technology that opens up new options to the industrial sector for manufacturing complex parts.”

The 2016 IAMA winner will receive a $20,000 cash prize and a media package valued at $80,000 to promote the winning development.

Entries will be accepted through December 7, 2015.

For more information, visit: www.additive-award.com

Published in AMT

The Dynetics and Aerojet Rocketdyne (NYSE:AJRD) team recently performed with its NASA partner, the second successful gas generator test series of the F-1 engine as part of the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) contract. This test series was unique, however, in that a key component of the gas generator was built using additive manufacturing – or 3-D printing – techniques. At 30,000 pounds, the component is among the highest thrust levels ever demonstrated for a 3-D printed part.

NASA awarded the ABEDRR contract in the fall of 2012 to reduce risks for advanced boosters that could help meet SLS's future capability needs. The team has performed a wide-ranging set of full-scale, system-level demonstrations on key advanced booster systems. Dynetics, the prime contractor, designed and fabricated a full-scale cryogenic tank that it tested last month to verify the structural design.

Aerojet Rocketdyne has applied state-of-the-art manufacturing methods to the Apollo-era F-1 rocket engine to demonstrate that a proven design can be built at a competitive cost. Among the new fabrication methods used was Selective Laser Melting (SLM), an additive manufacturing technique that has shown the potential for dramatically reducing cost and schedule for building rocket engine parts. SLM was used to build an F-1-based gas generator injector on the ABEDRR program.

In 2013, an F-1 gas generator made with 1960s-era parts was tested at new conditions to verify its applicability to the NASA SLS requirements. Testing the 3-D printed gas generator provided an opportunity for a one-to-one comparison of a part built with traditional manufacturing to a part built with the SLM process. The two test series were highly successful and the results were nearly identical, giving confidence in the new, lower-cost manufacturing methods.

The F-1 engine gas generator testing, as well as other recent tests with 3-D printed parts, is helping NASA and the aerospace industry gather data on these new manufacturing processes.

Dynetics CEO David King said, "The successful testing of this technology lays the groundwork for future rocket engine development – both for NASA and for others who want the most affordable space solutions."

"Testing of this hardware is just one more step Aerojet Rocketdyne is taking to develop affordable approaches to building complex, advanced rocket engine hardware supporting our current and future engine programs," said Brian Lariviere, F-1B engine program manager at Aerojet Rocketdyne. "The F-1 gas generator fabrication using the SLM process demonstrated part reduction costs by 50 percent and decreased delivery schedules from months to weeks."

Andy Crocker, ABEDRR program manager at Dynetics, said, "This test series is further proof that our team has been able to take successful designs from the past and apply the latest manufacturing methods to create the best of both worlds – a low-cost, proven engine component."

Crocker also said, "I want to compliment the test team from NASA Marshall and Aerojet Rocketdyne on this effort. They were prepared and efficient. They built on previous work in this area to quickly and effectively bring the tests to fruition."

Published in Dynetics

TWeatherford, Inc. (TWI) Team Members will attend the groundbreaking ceremony for the much anticipated Flagship Enterprise Center and Purdue Polytechnic Building at the previous GM Plant 03 facility in Anderson, IN. TWI is currently co housed with Purdue Polytechnic School at the Anderson Innovation Center and will be providing the Additive Manufacturing Equipment for the new Creator Space at the Plant 3 location.

This $15 million, high tech facility will include 28,000 square feet of student innovation and learning space and 40,000 square feet of advanced manufacturing space for local manufacturers and startups. The new building is scheduled to be completed in Fall of 2016. The Flagship Enterprise Center will be the ultimate owner and building manager of the new facility.

“This state of the art facility can truly be looked at as representative of merging the past, the present the future of manufacturing,” said Tim Weatherford, Chief Opportunity Officer of TWI.

“The history of making, doing, and manufacturing in this City are generations deep and we are excited to bring TWI’s Advanced Manufacturing and 3D Printing capabilities to support this collaboration between Higher education and the Private/Public Sector,” Weatherford added.

TWI offers breakthrough technology with a focus on Lean Product Development Methods. TWI meets the product development and support needs of both the Fortune 500 companies and companies in the SMB and emerging small business market. As a leading supplier of product development solutions, TWI is also an experienced leader in PLM implementation. Core Product offerings from PTC (Nasdaq: PTC), ORACLE (NYSE: ORCL) and 3D Systems (NYSE: DDD) complete portfolio of Professional, Production and Direct Metals Printers. TWI, with headquarters in Cicero, IN serves customers in the Midwest Region, including Indiana, Ohio, Michigan, Illinois and Kentucky.

To learn more about this facility please contact Tim Weatherford at (317) 710-9747 or This e-mail address is being protected from spambots. You need JavaScript enabled to view it

Published in TWeatherford, Inc

A cancer diagnosis always comes as a shock. In the case of a boy from Croatia this was particularly true as an aggressive form of bone cancer had destroyed the teenager's hip. The only option for the doctors treating him was a complete reconstruction of the hip bone. The 3D printing experts at Alphaform, a company with extensive experience in the medical sector, successfully produced the implant relying on industrial metal 3D printing from EOS.

The surgeon's challenge: the 15-year-old patient from Croatia had a primary bone tumor, as such not formed by metastasis and lying directly on the bone. The malignancies generally grow destructively, meaning that the original tissue must be removed. A complete arthroplasty of the hip was the fundamental prerequisite for ensuring the cancer cells did not continue to spread in the boy's body. An intervention of this type limits the mobility of the joint, and thus the mobility of the patient. With a precision implant, a patient's motor skills can largely remain unaffected in the future. In the hip area, the precise shaping of the replacement bone is particularly important.

In addition to the pure destructive force of the cancer, time was crucial because the illness was spreading with speed. The new implant also had to meet the doctors' weight specifications. The Croatian surgical team ordered an implant from Alphaform that had to be delivered fast and needed to be lightweight, yet precise. Christoph Erhardt, Director of Additive Manufacturing at Alphaform AG adds: "The design process was a real challenge. We received the complete 3D data including the cavities from Instrumentaria. Based on this we were able to start with the precise manufacture of the implant."

The implant was produced within one week on the EOSINT M 280 using a stable yet light titanium alloy. The process, from the initial computer sketches to the final implant, took only six weeks. This period included the sophisticated finishing of the artificial bone.

The subsequent operation in May 2014 was a great success. First the team of doctors completely removed all of the parts affected by the cancer and then the new artificial hip was inserted, complete with the integrated joint. A part of the young patient's thigh was replaced so that both joint parts fit within one another perfectly. As such, all medical requirements for the implant were fulfilled and laid the foundation for the patient's successful recovery.

For more information, visit: www.eos.info/press/case_study/additive_manufactured_hip_implant

Published in EOS

Additive Industries is proud to announce that Harry Kleijnen, previously responsible for the Philips Healthcare team printing tungsten grids for its X-Ray systems, joined the young Eindhoven technology company on September 1st.

In his role as Manager Process & Application Development, Harry Kleijnen will be responsible for the processes and customer applications for the industrial metal additive manufacturing system MetalFAB1.

""Harry is adding essential and in-depth process knowledge to our team and understands the business cases of our future customers in demanding and regulated markets"", said Daan Kersten, CEO of Additive Industries.

""Since we are preparing the launch of our first system in Q4 of this year, we need to build our sales and support organisation. Harry will play a key role in this next phase of our company", adds Jonas Wintermans, COO.

Additive Industries is dedicated to bringing metal additive manufacturing for functional parts from lab to fab by offering a modular 3D printing system and seamlessly integrated information platform to high-end and demanding industrial markets.

For more information, visit: www.additiveindustries.com

Published in Additive Industries

Cincinnati Incorporated (CI) is ready to make noise at Fabtech promoting the company’s latest technologies, including the Big Area Additive Manufacturing (BAAM) machine that had manufacturers buzzing at IMTS last year when it printed a full-size car at the show. The BAAM machine, with a 6 x 12 x 3 ft work envelope, will be on display in booth N-9000 in the Grand Concourse Lobby of the North Hall of Chicago’s McCormick Place.

The large-scale additive machine uses the chassis, drives and control of CI’s laser cutting system as the base, and extrudes hot thermoplastic to build parts, layer-by-layer. The machine, developed as part of a cooperative research and development agreement between CI and Oak Ridge National Laboratories (ORNL), introduces significant new manufacturing capabilities to a wide range of industries including automotive, aerospace, marine, furniture and much more.

CI is a technology leader in manufacturing press brakes, shears and laser cutting systems for metal fabricating, as well as big area additive manufacturing. In addition, CI powdered metal compacting presses are the most advanced additive process used for high volume production metal parts. PM presses cost-effectively make high volume production parts that make cars lighter and more efficient.

“We developed and pioneered the use of high-speed linear-motor axis drives on laser cutting systems and now the same technology is taking us into the next generation of machine tools,” said Carey Chen, President and CEO of CI. “BAAM is driving a spirit of renewal at CI, as there has been a tremendous response to the machine and the impact it has on manufacturing processes. This sense of rejuvenation also led to a new branding initiative and website, so this is having a positive impact on our entire company.”

The proprietary linear motor drives are capable of reaching accelerations in excess of 2.0G and head positioning speeds of up to 12,000 in./min., to deliver positioning accuracy of ±0.001 in. per axis. Chen added, “This machine platform has been field tested and proven to be virtually trouble free, and the linear motor drive allows fast and precise positioning, required for proper 3D printing.”

A larger version BAAM machine, currently at ORNL, has a work envelope of 8 x 20 x 6 ft. and extrusion rate of about 40 lbs/hr, the machine prints polymer components up to 10 times larger than currently producible, at speeds 200 to 500 times faster than existing additive machines. SABIC Innovative Plastics purchased the first BAAM machine and provided the carbon fiber ABS plastic for the IMTS car and will be providing material for BAAM at the Fabtech show.

The BAAM extruder uses a wide variety of thermoplastics and fiber reinforced thermoplastics and the two companies plan to test a number of materials that will meet the needs of a variety of commercial applications. “We’ve already tested ABS, PPS, PEKK and Ultem, and found that carbon fiber and glass fiber reinforcing improve both the strength and thermal stability of the parts,” added Chen.

For more information, visit: www.e-ci.com

One of the most complex, 3-D printed rocket engine parts ever made, a turbopump, got its “heartbeat” racing at more than 90,000 revolutions per minute (rpms) during a successful series of tests with liquid hydrogen propellant at NASA's Marshall Space Flight Center in Huntsville, Alabama. These tests along with manufacturing and testing of injectors and other rocket engine parts are paving the way for advancements in 3-D printing of complex rocket engines and more efficient production of future spacecraft.

Additive manufacturing, or 3-D printing, is a key technology for enhancing space vehicle designs and enabling affordable missions to Mars. The turbopump is a critical rocket engine component with a turbine that spins and generates more than 2,000 horsepower--twice the horsepower of a NASCAR engine. Over the course of 15 tests, the turbopump reached full power, delivering 1,200 gallons of cryogenic liquid hydrogen per minute--enough to power an upper stage rocket engine capable of generating 35,000 pounds of thrust.

“Designing, building, and testing a 3-D printed rocket part as complex as the fuel pump was crucial to Marshall’s upcoming tests of an additively manufactured demonstrator engine made almost entirely with 3-D printed parts,” said Mary Beth Koelbl, deputy manager of Marshall’s Propulsion Systems Department. “By testing this fuel pump and other rocket parts made with additive manufacturing, NASA aims to drive down the risks and costs associated with using an entirely new process to build rocket engines.”

The 3-D printed turbopump has 45 percent fewer parts than similar pumps made with traditional welding and assembly techniques. Marshall engineers designed the fuel pump and its components and leveraged the expertise of four suppliers to build the parts using 3-D printing processes. To make each part, a design is entered into a 3-D printer's computer. The printer then builds each part by layering metal powder and fusing it together with a laser, using a process known as selective laser melting.

“NASA is making big advances in the additive manufacturing arena with this work," said Marty Calvert, Marshall’s design lead for the turbopump. “Several companies have indicated that the parts for this fuel pump were the most complex they have ever made with 3-D printing.”

During the tests, the 3-D printed turbopump was exposed to extreme environments experienced inside a rocket engine where fuel is burned at greater than 6,000 degrees Fahrenheit (3,315 degrees Celsius) to produce thrust.  The turbopump delivers the fuel in the form of liquid hydrogen cooled below 400 degrees Fahrenheit (-240 degrees Celsius). Testing helps ensure 3-D printed parts operate successfully under these harsh conditions. Test data are available to American companies working to drive down the cost of using this new manufacturing process to build parts that meet aerospace standards. All data on materials characterization and performance are compiled in NASA’s Materials and Processes Technical Information System, called MAPTIS, which is available to approved users.

“Our team designed and tested the fuel pump and other parts, such as injectors and valves, for the additive manufactured demonstrator engine in just two years,” said Nick Case, a propulsion engineer and systems lead for the turbopump work. “If we used traditional manufacturing processes, it would have taken us double that time. Using a completely new manufacturing technique allowed NASA to design components for an additively manufactured demonstration engine in a whole new way.”

In addition to sharing test data with industry, the innovative engine designs can be provided to American companies developing future spaceflight engines. The engine thrust class and propellants were designed within the performance parameters applicable to an advanced configuration of NASA's Space Launch System, referred to as Block II. It will be the most powerful launch vehicle ever built and provide an unprecedented lift capability of 130 metric tons (143 tons) to enable missions even farther into our solar system to places like Mars.

For more information, visit: www.nasa.gov/sls

Published in NASA

Euromold is one of the biggest trade shows devoted to 3D printing and additive manufacturing (AM) technologies worldwide. The organizers have compiled a three-day conference from September 23-25, 2015, where top experts and opinion leaders explain the impact of these technologies in the future. In order to bring added value to every visitor of Euromold, all conference keynotes will be accessible free of charge.

On September 22, Euromold will begin with a sharpened profile and revised concept that will help propel the event into the future. In this context, a powerful three-day international conference has been carefully organized around the exciting future of 3D printing and additive manufacturing. Transitioning the technology into production has problems and challenges, so the conference will address them and other issues related to its future.

Additional topics of the conference include high-end applications in aerospace and medicine, as well as details on the nascent AM ecosystem. The first day of the conference will be under the theme "Global Visions of the Future" and will reveal the status of 3D printing in many regions of the world.

Special highlights of the conference include keynotes by Jeff Kowalski, Senior Vice President and Chief Technology Officer of Autodesk (USA), Professor Dr. Jules Poukens, Cranio-maxillofacial Surgeon at the University of Hasselt and Leuven (Belgium), a pioneer in the use of 3D printing implants, and of Stephen Nigro, Senior Vice President of Hewlett-Packard (USA). These keynotes are available to every visitor at no charge.

Among others that will participate in the conference: Dr. Edward D. Herd Rick (Additive Technologies Leader at GE). He will give an overview of the use of additive manufacturing at GE. William J. Cass Esq. (Partner, Co-Chair Litigation Department, Cantor Colburn LLP) will address the topic of Intellectual Property. Especially interesting for the Euromold - where traditionally classic tool construction and the new method of additive manufacturing are side by side - will be a presentation by Lou Young (New Business Development Director, Tooling & Manufacturing, Linear Mold & Engineering). His subject is the opportunities that arise by conformal cooling channels in injection molds.

Also of special interest is the panel discussion on the first day of the conference. Participants include Ed Davis (Chief Technologist and Senior Strategy Manager, Multi Jet Fusion at HP), Hilde Sevens (Director of Business Development, Autodesk), Emmett Lalish (Senior Mechanical Engineer at Microsoft, USA) and Wilfried Vancraen (CEO of Materialise).

Euromold will take place from September 22-25, 2015 at the exhibition Center in Düsseldorf, Germany.

For more information, visit: www.euromold.com

Published in Euromold

Two separate University of Pittsburgh research projects to improve design development for structures in in additive manufacturing were among nine contracts funded by America Makes, the National Additive Manufacturing Innovation Institute. The two projects, directed by faculty in Pitt's Swanson School of Engineering, will receive more than $1.7 million in America Makes' Project Call #3.

To date, Swanson School faculty have been awarded more than $2.3 million in contracts toward additive manufacturing research from America Makes, the National Science Foundation, and Research for Advanced Manufacturing in Pennsylvania.

Principal investigator for "Integrated Design Tool Development for High Potential AM Applications" is Albert To, PhD , associate professor of mechanical engineering and materials science, in conjunction with Aerotech, ANSYS, EOS of North America, ExOne, Honeywell, Marcus Machinery, Materials Sciences Corporation, RTI International Metals (Alcoa Titanium & Engineered Products), United Technologies Research Center, and the U.S. Army Aviation and Missile Research Development and Engineering Center. This $961,112 contract is in support of an extension of the research previously awarded to Dr. To by America Makes.

"AM technologies are capable of producing very complex geometries and topologies, tremendously expanding the limited design space allowed by traditional manufacturing methods. However, existing CAD/CAE software packages to date have not taken full advantage of this enormous design freedom," Dr. To explained. "We plan to create an integrated design suite that can be rapidly commercialized, thereby helping industry minimize design time, lower manufacturing cost, and reduce time to market for new AM product development."

M. Ravi Shankar, PhD, associate professor of industrial engineering, is principal investigator of "Parametric Design of Functional Support Structures for Metal Alloy Feedstocks." Collaborators on the $805,966 contract include ITAMCO, Johnson & Johnson, and the University of Notre Dame.

"Support structures play two important roles in additive manufacturing - holding a part in place, and dissipating heat during manufacturing. However, these structures are very simple and few rules exist for designing them," Dr. Shankar said. "We want to codify the design rules for support structures used in Direct Metal Laser Sintering (DMLS) to inform and then automatically recommend the optimal part orientation and the designs for optimized supports. Also, by better controlling the design, we can more effectively draw away the heat during manufacturing and minimize distortion."

Led by the National Center for Defense Manufacturing and Machining (NCDMM), America Makes' Project Call #3 for additive manufacturing (AM) applied research and development projects provided up to $8 million in funding toward these projects with $11 million in matching cost share from the awarded project teams for total funding worth $19 million. The Institute's third project call, which was released in February 2015, was focused on five technical additive manufacturing topic areas-design, material, process, value chain, and genome-each with subset focus areas. Proposals could address one or more technical topic areas, but had to address all evaluation criteria.

For more information, visit: www.americamakes.us/engage/projects

The Additive Manufacturing Users Group (AMUG) announced that its 28th annual users group conference will be located in St. Louis, Missouri, from April 3-7, 2016. The five-day event will be held at the St. Louis Union Station, a National Historic Landmark that was built in 1894.

AMUG selected St. Louis because it is centrally located in the United States and it is home to a venue that can accommodate the anticipated growth in attendance. Attendees will be welcomed by a completely renovated facility that retains the grandeur of the golden age of rail travel.

Mark Barfoot, AMUG president, said, “The facility is amazing. It takes you back in time. Everywhere you turn, there is something interesting: artifacts, blueprints, architectural details and historic train cars. And of course, the facility has plenty of space for the conference and networking activities.”

Barfoot continued, “Missouri is the Show Me State, which reflects AMUG’s intent perfectly. Our event is designed to educate users and advance their use of additive manufacturing. We do that by creating an environment where users share information to show others how to achieve success.”

The AMUG Conference draws both novice and expert users seeking insights, assistance and guidance on technologies, applications and processes. The conference also attracts support, in the form of sponsorships, from leading companies in the additive manufacturing industry.

AMUG will have “run of the house” at the St. Louis Union Station property. All hotel guests will be AMUG participants and the entire 100,000 square feet of meeting and exhibit space will be at the group’s disposal. This unique venue consolidates all AMUG activities under one roof so attendee interactions will be continuous over the five days.

The AMUG Conference will include technical sessions and hands-on workshops designed to help users get more from their systems. Through technical competitions and the annual Awards Banquet, excellence in applying additive manufacturing and contributions to the industry will be recognized. The five-day event also includes the two-night AMUGexpo, networking receptions and catered meals.

The users group conference, now in its 28th year, is open to owners and operators of all additive manufacturing (3D printing) technologies.

For more information, visit: www.am-ug.com

Published in AMUG

An SME-designed Additive Manufacturing Contest was a key component of the 51st annual Skills USA National Leadership and Skills Conference, held this summer in Louisville, Kentucky. 6,000 students from across the nation who had already won state-level contests competed and gained enhanced trade, technical and leadership skills during the SkillsUSA Conference.

Providing students with insights into additive manufacturing and hands-on experience using today’s latest 3D printing technology and software, the competition marked the first time an additive manufacturing experience was included in the national event.

SME created the additive manufacturing contest to attract students to the new, exciting, emerging technologies and tools involved. These technologies are already very relevant to industry and companies are looking for a workforce with additive manufacturing/3D printing experience and ability.

In the national competition, student teams were first asked to use three-dimensional CAD software to design a car model meeting contest specifications, including 3D print time, size and material usage. Car models were then printed in ABS material on a Stratasys 3D printer.

Teams were tested on their knowledge of 3D printing with a written exam and participated in a one-hour Quick Challenge: designing an iPhone case for a celebrity client.

Additive manufacturing/3D printing has become a critical component for STEM-related programs and curricula in the education system.

Pam Hurt, workforce development industry manager at SME, suggests educators use 3D printing as a tool to help students visualize their ideas. “It gives the student the ability to design a part, see the printed part, and if they aren’t happy with their results, make the necessary improvements and try again,” she said.

The demand for additive manufacturing engineers and technicians has increased well beyond the supply of qualified entry-level applicants. “SME is working with industry and educators to make sure we’re all working toward the same end-goal: an educated and motivated student,” said Hurt.

For more information, visit: www.sme.org/skillsusa-additive-manufacturing-contest

Published in SME

Praxair, Inc. (NYSE: PX) announced its Praxair Surface Technologies business will begin marketing fine, spherical titanium powder for use in 3-D printing by additive manufacturers serving the aerospace, automotive, industrial and medical markets.

3-D metal printing with titanium, in which components are built up by depositing the material in layers, can lower manufacturing and raw material costs, improve fuel efficiency and enable the design of the most advanced parts, from aerospace brackets to biomedical implants. This enables the benefits of titanium’s strength, light weight and corrosion resistance to be further adopted in advanced applications.

“Until now, there’s been limited availability of fine, titanium powder in the marketplace to create parts,” said Dean Hackett, vice president of advanced materials and equipment for Praxair Surface Technologies. “That won’t be the case for long as we move into full-scale production of aerospace-grade, fine, spherical, titanium powder starting in the third quarter of 2015. In addition to supplying the powder, Praxair also offers the associated industrial gases to the additive manufacturing industry.”

Praxair’s ability to produce large-scale volumes of titanium powders designed for additive manufacturing is rooted in its more than 50 years of experience producing gas atomized powders for the thermal spray coating industry. In recent years, research and development efforts have focused on the production of metal powders, including cobalt, iron and nickel, for 3-D printing purposes. Further development of a proprietary atomization process designed specifically for titanium allows the company to make some of the largest batches of fine, titanium powder in the world.

“What makes our production of titanium powders different from those currently on the market is that we use close-coupled, high-pressure gas atomization to produce fine, spherical titanium powder in large quantities,” said Andy Shives, additive manufacturing marketing manager for Praxair Surface Technologies. “Adding titanium powder to our portfolio enables us to better support the manufacturing needs of aerospace and other industries.”

Praxair is currently working with major aerospace original equipment manufacturers (OEM) by providing limited quantities of its fine titanium powder to further OEM research and development efforts ahead of Praxair’s full commissioning of its gas-atomized titanium powder line.    

Praxair, Inc., a Fortune 250 company with 2014 sales of $12.3 billion, is the largest industrial gases company in North and South America and one of the largest worldwide. The company produces, sells and distributes atmospheric, process and specialty gases, and high-performance surface coatings.

For more information, visit: www.praxairsurfacetechnologies.com/components-materials-and-equipment/materials/additive-manufacturing-powders

Published in Praxair

The Additive Manufacturing Conference (AMC) 2015, presented by Modern Machine Shop, in partnership with Oak Ridge National Laboratory, has announced the complete line-up of technical sessions. The two-day event will offer attendees unique ways to connect with leading suppliers, end-users and researchers of industrial applications of additive manufacturing technologies.

Taking place in Knoxville, TN, October 20-21, 2015, the AMC program includes 20 technical sessions examining design, material, machinery and applications technology used in metal additive manufacturing. Specific topics include 3D geometry measurement, direct metal laser sintering (DMLS), hybrid CNC machines, laser deposition technology, ultrasonic additive manufacturing (UAM) and much more.

Technical presenters include:

  • Thought leaders from global OEMs GE Aviation and Northrup Grumman
  • Leading additive manufacturing job shops Linear Mold & Engineering and DM3D
  • Machinery suppliers Stratasys, EOS and ExOne
  • Cutting-edge research outfits Oak Ridge National Laboratory and Lawrence Livermore National Laboratory
  • Product innovators Local Motors and Noble

“This conference is uniquely focused on metal additive manufacturing. As a result, our presenters represent the leading OEMs, product developers, contract manufacturers and researchers developing metal additive processes and equipment. Whether a company is currently using or considering adopting additive manufacturing, this is the event for learning about the processes, the products and the people, that are leading additive manufacturing,” commented Allison Miller, Event Director.

For more information or to register, visit: www.AdditiveConference.com

Published in Gardner Business Media

Thermwood Corporation, a U.S. based manufacturer of 3 and 5 Axis CNC routers, has announced a program to develop a 3D Additive Manufacturing System, capable of making large carbon graphite reinforced composite thermoplastic components. The systems utilize a “near net shape” approach where a relatively large extruder, mounted to the machine, is used to heat, melt and deposit, or “print”, carbon graphite filled thermoplastic material to quickly create a structure which is almost, but not quite the exact final shape. That structure, when it cools and hardens is then five axis machined to the final net shape.

These new systems will be based on Thermwood’s Model 77, semi-enclosed, high wall gantry machine structures, which are currently offered in sizes up to sixty feet long. For the plastic extruder, Thermwood turned to American Kuhne who developed a custom system, which integrates tightly, both mechanically and electronically, with Thermwood’s CNC machine. This allows not only the machine but also the plastic extruder to be controlled and managed by a central CNC control, insuring smooth integration and increasing both capability and flexibility.

With the addition of a second gantry, both the “Additive” and “Subtractive” processes can be performed on the same machine. The second “Subtractive” gantry will be offered as an option. Companies that already have five axis machining capacity and want to work with Additive Manufacturing may only require “Additive” machine capability as they can use existing equipment for the “Subtractive” part of the process.

The systems will feature full six axis articulated additive deposition head, allowing it to build layered structures on both a horizontal plane as well as planes canted in any direction up to ninety degrees from horizontal. Management believes this capability will be important as technology advances and more complex structures are required.

The initial development machine, which is nearing completion, can make parts up to ten foot by ten foot by five foot high, is equipped with a 20HP, 1 ¾ inch diameter, 24-1 L/D extruder and support equipment capable of processing over 100 pounds of material per hour. Despite the relatively heavy weight of the extrusion system and head, which are both mounted on and move with the machine, the machine generates impressive performance with high acceleration rates and high feed rate capability. This is an ongoing research and development program and it is unknown when commercial systems might be available to the market.

Thermwood is already a major manufacturer of the “Subtractive” machinery part of the equation and this same technology is the basis of the “Additive” equipment. Thermwood also designs, builds and programs its own sophisticated CNC controls which it can tailor to any new requirements and also has experience developing sophisticated design and CAD/CAM software packages which are also an important part of this new technology.

For more information, visit: www.thermwood.com

Published in Thermwood Corporation

The German 3D printing software supplier netfabb has released the new Support Structures add-on to the netfabb 6 suite of software for 3D Printing and Additive Manufacturing. The focus of generation 6 is set upon simplifying and improving 3D printing processes on an industrial scale. In this context, the new add-on is specially designed for the advanced support generation for Selective Laser Melting, Stereolithography, and DLP technology.

The new add-on empowers netfabb Professional 6 to easily add support lattices and structures to parts in additive manufacturing. This happens by creating bar support structures and adjusting the anchor points between the part and the platform as needed. This ensures that the full productive capability of AM machines using Selective Laser Melting, Stereolithography, and DLP technology can be utilized.

The netfabb support structures add-on comes in two variants: netfabb DLP Support Structures is designed specifically for manufacture on Digital Light Processing (DLP) machines, and netfabb Enhanced Support Structures for manufacture on machines using Selective Laser Melting (SLM), Stereolithography (SLA), and FDM (Fused Deposition Modeling).

Three general types of support structures can be chosen as required by the part's geometry: bar support, polyline support, and full volume support. A huge number of features and options grants full flexibility to the designer. For example, different types of support structures can be combined on the same model, to different part areas, and to different angles. If needed, even curved and ramified bars that look like tree branches can be created. Polyline support allows not only to build a simple thin or thick wall support but a structured wall, just by a few clicks. And last but not least, volume support extends the polyline support by an additional dimension, offering 37 different settings in total.

More practical features like a transparent part view and an overview list of all used support entities ready to re-use will help to ease the designer's workload. Very useful is also the automatic downskin analysis of data models to determine which areas do require some support.

Currently, manufacturing is subject to a fundamental paradigm change. Many companies consider introducing additive manufacturing for their business. “In this period of important change, netfabb Professional 6 has the potential to lift additive manufacturing to an unprecedented level of volume manufacturing”, explains Ulf Lindhe, Director of Business Development at netfabb. “Risk reduction, easy maintenance, process reliability, and a whole lot of time savings are the keywords to describe the benefits of using netfabb software.” With the add-on netfabb Selective Space Structures (3S), innovative products using complex structures can be created. Also new is netfabb Enterprise 6 which comes with a cost-saving server licensing model.

For more information, visit: www.netfabb.com/support_structures.php

Published in netfabb

Renishaw plc is pleased to announce the appointment of Clive Martell MSc, CEng, MIET, former President and CEO of Delcam, to a new role as Head of Global Additive Manufacturing.

Clive, age 54, progressed from a graduate recruit to become CEO of Delcam plc, where he successfully managed the company's transition from an AIM (Alternative Investment Market) company to an operating division of Autodesk. After his appointment as Delcam's CEO in 2009 his successful track record of delivering strong revenue and profit growth earned him the CEO of the Year Award at the 2013 Grant Thornton Quoted Company Awards.

In his new role at Renishaw, Clive will report to Geoff McFarland, Group Engineering Director and will be responsible for the strategy and direction of additive manufacturing across the Renishaw Group. He will liaise with development teams in the UK and sales and marketing operations across the world and will be particularly focused on making a global success of Renishaw as an additive manufacturing (AM) solutions provider.

As part of this new role Clive will also guide the company's Additive Manufacturing products line based in Staffordshire, UK, which develops new AM systems and the Medical Dental products line, which delivers AM solutions for the healthcare sector. Clive will also become a member of Renishaw's International Sales and Marketing Board.

Commenting on the appointment, Geoff McFarland, said, “Having worked closely with Clive Martell during my six-year tenure as a non-executive director of Delcam, I am delighted to welcome him to Renishaw. His extensive experience within the global manufacturing industry, including the ability to grow customer service activities, the development of dedicated software solutions and the establishment of Delcam's Healthcare division, will be especially valuable to Renishaw as we develop additive manufacturing as a standard solution for production applications.”

For more information, visit: www.renishaw.com

Published in Renishaw

Stratasys Ltd. (Nasdaq:SSYS) announced that Italian Service Bureau, ZARE, has halved production costs for its direct manufacturing customers in automotive and aerospace since investing in a fleet of Stratasys Fortus 3D Production Systems.

Following the longstanding success of using Stratasys PolyJet and FDM 3D printing for prototyping applications, the company now deploys its Fortus 3D Production Systems to expand its direct manufacturing services to customers. This spans a spectrum of traditional manufacturing applications, including injection molding, tooling and the production of final parts.

“After a steady decline in traditional manufacturing business, the introduction of Stratasys Fortus FDM technology has given us a significant edge over our competition and has enabled us to reduce manufacturing costs for our aerospace and automotive customers by 50 percent,” says Andrea Pasquali, R&D Manager of ZARE. “This has been key to revitalizing our direct manufacturing business, as we can quickly produce durable end-use parts for our customers in the final material. We have seen a substantial reduction in iteration costs and turnaround times, and we have reduced the cost per final part by around 30 percent.”

Pasquali explains: “For one customer, we tested a 3D printed prototype of an aerospace pipe that we produced in high performance ULTEM 9085 thermoplastic material. However, with the material’s high strength-to-weight ratio and FST (flame, smoke and toxicity) rating, we quickly realised that we could go beyond functional prototype testing and actually manufacture final-parts that match the strength of metal.

“By replacing metal-manufactured parts with high performance thermoplastics, our customers can meet a vital requirement of aircraft manufacturing by reducing overall weight, while maintaining production quality and adhering to passenger safety requirements. A great example of this is the use of additive manufacturing to directly manufacture lightweight air conditioning ducts for aircraft.”

The expansion of additive manufacturing services to include both prototyping and direct manufacturing has had a positive impact across the business, not only for aerospace, but also automotive manufacturing. According to Pasquali, applications for these two sectors now account for nearly 50 percent of ZARE’s operations thanks to the advanced 3D printing materials available from Stratasys.

Pasquali explains: “The wide range of materials at our disposal enables us to select characteristics that match those of traditional manufactured parts at a fraction of the weight and cost. For example, leveraging its high UV-stability, we now manufacture car bumpers in ASA and headlights in PC-ABS, which combines both the superior strength and heat resistance of PC and the flexibility of ABS.”

Davide Ferrulli, Stratasys' Italian Territory Manager concludes: “As ZARE demonstrates, the use of additive manufacturing for the production of production parts in key industries such as aerospace and automotive offers a fast and cost-effective way to improve areas of the traditional manufacturing process. With our materials advancing, customers are finding that they can build more parts than ever before with parallel strength and durability to those traditionally manufactured.”

For more information, visit: www.zare.it

Published in Stratasys

Professor Iain Todd, Director of the Mercury Centre, has been appointed The University of Sheffield and GKN Aerospace Royal Academy of Engineering (RAEng) research chair in additive manufacturing.

Supported by GKN Aerospace, the University and the Royal Academy of Engineering, for the next five years Prof Todd will focus on harnessing and developing the extraordinary potential of additive manufacturing (AM) for aerospace and other high value industrial sectors.

The role will have three fundamental aims: to assist in the industrialization of the current state-of-the-art technology as GKN moves towards production; to develop the required technology to enable the integration of materials and processes, extending its application in the short term; to create entirely innovative processes and materials that will carry industry well beyond what is currently possible.

Russ Dunn, Senior Vice President Engineering & Technology, explains: “AM technologies promise a paradigm shift in engineering design and materials. We will be able to create previously impossible or totally uneconomical shapes, with little or no material wastage, and in the longer term we will be able to develop completely new materials and structures fully optimized for the role they perform.  This new chair will build on GKN’s existing developments in additive manufacturing and will sit at the heart of work to ensure UK industry continues to be a pioneering force in this global revolution in engineering.”

Professor Iain Todd says “I’m delighted and honored to be appointed to this prestigious role and look forward to working with GKN Aerospace and the Royal Academy of Engineering in promoting, researching and helping to drive this hugely exciting and disruptive manufacturing technology forwards. This is a very exciting time for advanced manufacturing and materials research in the UK. My role will be to strengthen the link between industry and academia in these fields and to transfer the engineering and scientific breakthroughs at the University level to industrial practice helping to drive productivity and competitiveness.

Professor Ric Parker CBE FREng, Chair of the Royal Academy of Engineering Research and Secondments Committee, says: “We are delighted to support this Chair as part of the University of Sheffield’s ongoing and productive collaboration with GKN. Additive manufacturing is an important area for research and development, which has enormous potential to improve industrial processes and UK productivity in the future.”

Professor Todd is recognized as a leading academic researcher in the fields of novel processing and alloys. He has led research into additive manufacturing at the University of Sheffield since its commencement in 2006 and has been a driving force in the growth of the world-leading manufacturing research facility, The Mercury Centre. The current University of Sheffield AM research portfolio includes work on the Aerospace Technology Institute (ATI) supported, £15M Horizon Programme, led by GKN Aerospace, as well as collaborative research with organizations such as the Culham Centre for Fusion Engineering and CERN.

The University, GKN Aerospace and the Royal Academy of Engineering will make a combined investment worth £1m to support the chair over the five years, with the GKN Aerospace investment including funding for an additional 10 PhD students to support Professor Todd and the team of over 20 senior research staff already operating at the university.

The University has an established relationship with GKN Aerospace, most recently through the Horizon AM programme. They also support PhD and EngD programmes and provide undergraduate student placements.

For more information, visit: www.sheffield.ac.uk/materials/staff/itodd

Published in The Mercury Centre

Proto Labs, Inc. (NYSE: PRLB) has acquired a new facility to expand its 3D printing service into a larger and more efficient additive manufacturing space. The 77,000 sq. ft. facility will allow the digital manufacturing company to house all of its stereolithography (SL), selective laser sintering (SLS) and direct metal laser sintering (DMLS) technology under one roof. The new plant is scheduled to become fully operational in the first half of 2016, and will remain in the North Carolina area where Proto Labs’ current additive facilities are located.

In addition to moving its existing equipment into the larger space, the prototyping and low-volume manufacturer plans to increase its overall 3D printing capacity with new machines. Anchoring the expansion will be SLS and DMLS equipment, which produce durable nylon parts and functional metal parts respectively. As 3D printing continues to grow industry-wide, Proto Labs’ plans to be well-equipped to accommodate the ongoing evolution of additive manufacturing.

“Since the launch of 3D printing at Proto Labs, we’ve increased our material selection and improved our turnaround time to days. We have also introduced additive services in Europe,” explains Rob Connelly, Proto Labs’ VP of Additive Manufacturing. “Our state-of-the-art facility will be a critical driver in advancing 3D printing for many years to come.”

FineLine Prototyping, Inc. was acquired by Proto Labs in April 2014, and over the past year, its additive manufacturing capabilities have been fully integrated into Proto Labs, serving now as one of three flagship services alongside injection molding and CNC machining. Proto Labs’ revenue from additive services totaled $4.5 million in the first quarter of 2015, which is a 79 percent increase compared to FineLine’s first quarter of 2014.

“We could not be more excited about the progress we’ve made in one short year with our additive manufacturing service,” says Vicki Holt, President and CEO at Proto Labs. “With three uniquely different and complementary offerings, we’re now truly able to help designers and engineers take a product from the initial stages of prototyping through low-volume production.”

For more information, visit: www.protolabs.com

Published in Proto Labs

The Additive Manufacturing Users Group (AMUG) announced new appointments of directors and officers. The expansion of the leadership team is in response to the year-over-year growth in the group’s annual conference and the projected growth for coming years.

Mark Barfoot, AMUG president, said, “We are coming off of a very successful AMUG Conference, thanks in part to the tireless efforts of the board and officers. To grow AMUG while maintaining the characteristics that makes it unique, namely being an educational and informative association that emphasizes collaboration and networking, the users group’s leadership needs more additive manufacturing professionals that are passionate about the its success.”

Gary Rabinovitz, manager of the Additive Manufacturing Lab at Reebok International Ltd. and a past president of AMUG, has been appointed as the chairman of the board. Rabinovitz was selected for the position based on his past leadership and contributions that have made AMUG successful. Rabinovitz oversaw the development of the 2015 conference agenda, which had nearly 200 presentations, and led the users group during its transition from a technology focus to an industry-wide organization. Mark Barfoot, president and former chairman, will retain a director position on the board.

The AMUG Board also created four deputy vice president positions, which will be filled by appointment.  Paul Bates, lead additive manufacturing development engineer at UL, and Derek Ellis, senior applications engineer for Computer Aided Technology, Inc.,  have been appointed to fill two of the deputy vice president positions. Both men will assist the elected vice presidents, Steve Deak and Dana Foster, in developing sponsorships, promoting the user group and overseeing the AMUGexpo.

Paul Bates has volunteered his services, in many capacities, to assist AMUG over the past five years. With the support of UL, Bates offered to become more involved in the organization as one of its officers. Derek Ellis, a past AMUG vice president and advisor, will focus his efforts on new AMUG members and first-time conference attendees.

The AMUG Board also reappointed Mark Abshire, an application engineer at Computer Aided Technology, Inc., as an advisor to the organization. Abshire, a past AMUG vice president, has served as an advisor for the past two years, and his primary responsibility will continue to be overseeing registration for the annual AMUG Conference.

Barfoot stated, “With the men and women that we now have as directors and officers, AMUG has a leadership team that I look forward to leading; a team that will ensure continued growth and success.”

AMUG is an organization that educates and advances the uses and applications of additive manufacturing technologies. AMUG members include those with any commercial additive manufacturing/3D printing technologies from companies such as Stratasys, Somos, Concept Laser, SLM Solutions, EOS, ExOne, Renishaw, HP and Prodways. AMUG meets annually to provide education and training through technical presentations on processes and new technologies. This information addresses operation of additive manufacturing equipment and the applications that use the parts they make.

Images: (Left to Right) Gary Rabinovitz, Derek Ellis, Paul Bates, Mark Abshire

For more information, visit: www.am-ug.com

Published in AMUG

SAE International invites aerospace engineering professionals to participate in the initial meeting of the Additive Manufacturing Committee, which will be held July 21-22 at the DoubleTree by Hilton Hotel Atlanta Downtown in Atlanta, Georgia.

Recognizing that additive manufacturing is an emerging technology within the aerospace industry, the SAE Additive Manufacturing Committee (AMS-AM) will develop and maintain Aerospace Material Specifications (AMS) and Aerospace Standards (AS) for additive manufacturing, including precursor material, additive processes, additive materials, post-process heat treatment, dimensional inspection, mechanical testing, non-destructive testing and quality assurance.

Finished parts produced by additive manufacturing processes are subject to unique regulatory requirements.  Stakeholders in the aerospace industry require tailored material and process specifications to support critical aerospace applications.  

David Abbott, Principal Engineer, MPED Additive Technologies, with GE Aviation will serve as committee chair.  According to Abbott, “This committee will be an important and essential part of the process of generating aerospace industry consensus specifications to aid in the certification process as well as develop a supply chain for the industry. Standards will play a crucial role and SAE is well-positioned to lead this effort.  GE Aviation recognizes the tremendous potential of additive manufacturing and is investing heavily in this technology.”

Participation is open to individuals from aircraft manufacturers, engine manufacturers, material suppliers, equipment suppliers, operators, regulatory authorities, and research organizations.  Those interested in participating in the AMS-AM Committee should contact Laura Feix, Aerospace Standards Engineer, SAE International, at This e-mail address is being protected from spambots. You need JavaScript enabled to view it or call +1-724-799-9198 for additional information.

Attendees are requested to register in advance for the meeting.  Pre-registration fee is $185.00; registration after cut-off date of July 10, 2015 is $220.00.

Published in SAE International

On July 15th the Office of Naval Research (ONR) will host an Industry Day with businesses and academia to discuss the organization's interest in a new metal additive manufacturing (AM) program set to begin in 2016.

The Industry Day will be held in advance of a government announcement this September to formally solicit proposals. It will spotlight ONR's requirements and the solicitation process, and encourage participants to think about ways they could improve existing metal additive manufacturing technology.

Additive manufacturing could represent the future of industrial manufacturing, especially for military hardware. Picture a scenario where a maintenance depot on a military base needs a certain part to finish a repair job. Unfortunately, the part is obsolete and no longer available from suppliers.

No problem. The technician on duty simply loads a digital file containing specs about the original part into a specialized 3-D printer, which then lays down ultra-thin layers of metal atop each other until a brand-new part is produced on the spot. This process could dramatically reduce the cost, time and materials needed to manufacture new equipment parts.

Currently, many additive-manufactured parts are largely made from plastics, but lack the required material properties for many demanding military applications. However, high-precision metal is becoming a more attractive option as industry and the military take a closer look at additive manufacturing. During this process, electron beams or lasers are used to melt layers of metallic powder or wire into the desired shape.

One benefit is that manufacturers can tailor a part in ways not possible with traditional metal casting. For example, a turbine blade could be optimized on one end for strength and on the other for heat resistance. A big concern, however, is determining which metal type offers the ideal blend of durability and versatility.

"Additive manufacturing could be a more efficient, cost-effective way of producing parts for equipment such as submarines and other vessels, aircraft or ground vehicles," said Program Manager Billy Short, who works in ONR's Expeditionary Maneuver Warfare and Combating Terrorism Department. "Right now, we're seeking new ideas on how to improve quality and reliability by additively manufacturing parts that are currently metal cast, such as impellers, engine mounts and transmission housings.

"We're developing quality AM metal processes for naval applications with titanium, aluminum and stainless-steel alloys," he continued. "Ideally, we would one day like to see additive manufacturing machines built that could be placed on vessels and perform well even in the toughest sea conditions, but that is another technical leap beyond this current program."

The Department of the Navy's Office of Naval Research provides the science and technology necessary to maintain the Navy and Marine Corps' technological advantage. Through its affiliates, ONR is a leader in science and technology with engagement in 50 states, 55 countries, 634 institutions of higher learning and nonprofit institutions, and more than 960 industry partners. ONR, through its commands, including headquarters, ONR Global and the Naval Research Laboratory in Washington, D.C., employs more than 3,800 people, comprising uniformed, civilian and contract personnel.

The event will start at 9 a.m. and will be held in Chantilly, Virginia. The deadline to register is 5 p.m. EST on Friday, July 10.

For more information, visit: www.onlineregistrationcenter.com/register.asp?m=4269&c=113

Published in Navy

UL, a global safety science organization, and 3DSIM LLC announced a collaboration to advance additive manufacturing (AM) process simulations. Under the terms of the agreement, UL made an investment in 3DSIM and is now a minority shareholder of the company. In recognition of this investment and the companies’ alliance to serve manufacturers, Simin Zhou, vice president of Digital Manufacturing Technologies at UL, will join the 3DSIM Board of Directors.

“UL has partnered with 3DSIM to rapidly advance simulation for additive manufacturing processing,” said Zhou. “The value of 3D printing is to enable design freedom and the ability to manufacture a variety of parts and products. To statistically qualify a design for production using AM, exploring material and process combinations via trial-and-error is not sustainable. Thus, we must invest in simulation technology and new qualification and validation methodologies to advance manufacturing and move the AM industry forward.”

Brent Stucker, PhD., chief executive officer and a co-founder of 3DSIM LLC, added, “UL has an excellent reputation around the world in validation and certification of manufactured parts. We welcome UL as an investor and partner. As a member of our board, Simin will contribute her deep knowledge and perspectives about how simulations can transform the AM industry. Together, we will move the manufacturing industry away from reliance upon costly experimental testing toward predictable, safe and timely production.”

3DSIM is a rapidly growing company focused on creating software tools that enable accurate, physics-based predictions of the outcomes of an additive manufacturing process before building a part.  3DSIM’s vision is to move the additive manufacturing industry from empirically-driven to simulation-driven innovation. 3DSIM’s simulation tools will help machine users, part designers, researchers, machine manufacturers and material providers dramatically increase their rate of innovation, thus enabling rapid qualification of additively manufactured parts and components.

UL 3D Printing is a trusted and reliable partner to 3D printing equipment and material manufacturers, retailers, and commercial and industrial companies. UL, with its 120-year history in safety science, is collaborating with the emerging 3D printing industry to advance education and training, close the knowledge transfer gap, enhance and simplify compliance, and interact with regulators on future issues. UL has a rich history as an independent organization with deep expertise in standards, compliance, testing, certification, manufacturing processes and engineering.

Published in UL

LPW and Metalysis have formed a collaboration to develop an alternative supply chain for clean, spherical Tantalum and Tungsten metal powders for quality critical applications. It will combine Metalysis’s unique metal production technology with LPW’s spherodisation and post-processing capability. LPW will be responsible for selling the optimized powder to the additive manufacturing market. This will result in a supply chain that will be robust, quality driven and deliver high performance powders for the additive manufacturing markets.

LPW leads the way in the development, optimization and supply of metal powders into the AM industry and will be able to spherodise, size and blend high quality, free flowing powders directly from the raw material and alloys.

The Metalysis technology, which produces metal powder directly from oxide using electrolysis, has the potential to significantly increase production volumes, indeed its plant in South Yorkshire that begun producing tantalum powder this year is the first new primary tantalum metal production plant in Europe for more than 30 years. The patented process for producing metals, including refractory materials such as tantalum and tungsten alloys, offers both economic and environmental benefits over traditional metal production methods.

LPW Managing Director, Dr Phil Carroll remarked:
“Metalysis offers a greener and more cost-effective process, add our specialist industry knowledge and we can then supply a range of high quality, specially developed powders for the additive manufacturing industry”

Metalysis Chief Executive, Dion Vaughan said:
“The strategic collaboration between LPW and Metalysis will seek to develop and build the additive manufacturing market for tantalum and its alloys by pooling resources. We believe that LPW’s market expertise will complement Metalysis’s experience in metal powder production to further the development of AM”

Established in 2007, LPW Technology is a market leader in the development and supply of metal powders for additive manufacturing, and provides a comprehensive range of services for the AM industry. These services range from the development of new alloys, through expert application support, to AM machine maintenance. The company has developed a full range of optimized powders specifically for Selective Laser Melting (SLM), Laser Metal Deposition (LMD) and Electron Beam Melting (EBM) with standard powders supplied from stock, and custom and development alloys available on request. LPW Technology invests heavily in cutting edge analytical technology and offers a complete powder analysis service. LPW POWDERSOLVE™, a proprietary software package, supports efficient powder lifecycle management. The company operates to quality control standards: AS 9100 & AS 9120 for aerospace, ISO 9001, and ISO 13485 for medical.

Metalysis is a UK-based company, which owns the global rights to a transformational technology capable of producing a wide range of high value metal powders and innovative alloys at a lower cost and with a smaller environmental footprint than traditional methods. The Metalysis process is a breakthrough, solid-state technology which works by introducing metal oxide into a molten salt bath where it is electrolysed to form metal powders. Metalysis has received investment from a number of private equity, public and private companies and after ten years of investing in research and development has built a prototype industrial facility in the UK to produce metal powders. The company is currently focused on the production of tantalum powders for use in conventional and additive manufacturing for a variety of applications in aerospace, electronics, bio-medical, petro-chemical and automotive.

Published in LPW Technology

H.C. Starck, one of the leading producers of customer-specific powders and components made of technology metals and technical ceramics, has acquired a minority stake in one of Sweden’s most innovative start-ups, Metasphere Technology. The company has developed an innovative, proprietary technology for the production of spherical metal powders, a material in high demand in growth industries such as additive manufacturing.

H.C. Starck and Metasphere Technology plan to build a new production line for spherical metal powders in Lulea (Sweden). The agreement secures H.C. Starck exclusive sales rights of the materials produced. H.C. Starck will also provide customer application technology support. The continued expansion of production capacity is planned as the market develops. Both partners have agreed not to disclose further details of the agreement.

H.C. Starck already produces special atomized metal powders for the additive manufacturing market and wants to expand its business activities there long-term. “With our many years of experience in the processing of technology metals and technical ceramics, we see great growth potential for our company in additive manufacturing,” says Andreas Meier, CEO of the H.C. Starck Group. “Metasphere Technology is known in the market for its proven capacity to innovate and therefore is the right technology partner for us. Thanks to our cooperation, our two companies will not only grow in the additive manufacturing market but will even provide the industry itself with impetus for growth.”

“We identified H.C. Starck as an ideal partner at an early stage. So we are pleased that we were able to win H.C. Starck as a new shareholder,” said Metasphere Technology CEO Jan Wicén. “The company has wide-ranging material expertise and long experience in the field of developing novel alloys that we can now produce in spherical shape using our unique process. The process can restructure all electrical conducting materials on a nano level and spheriodise materials to perfect spheres in a wide range of sizes. Our "meta-stable" compositions will pave the way for high precision alloys and materials in spherical form for breakthroughs in many industrial areas. With H.C. Starck on board we have got a solid validation in the international market as well as secured our long-term supply of powder raw materials for our production.”

With the unique production technology developed by Metasphere Technology, a wide variety of metals and other electrically conductive materials can be processed into spherical powders. By restructuring of the material on a nano level, they can be precisely adjusted to customer-specific requirements relating to material characteristics like particle size and distribution. The powders are characterized by the absolutely perfect spherical shape of their particles and their homogenous structure through the entire powder. This gives them unique physical-mechanical characteristics that could not or only scarcely be achieved with previously known technologies. “Among other things, spherical powders have extremely high flowability, which is a key precondition for the production of high-quality components using additive manufacturing,” Meier said. “Since a multitude of materials can be processed with Metasphere’s new technology, we will be able to offer our additive-manufacturing customers a much-expanded product portfolio with new and highly innovative powders beyond the materials processed to this point.”

Additive Manufacturing is one of the highest-growth sectors because it gives engineers new, cost-effective design options for highly stressed components with complex forms. While the technology has initially been used mostly for prototype development, it is increasingly used in series production today.

Published in H.C. Starck

The leader of the soon-to-open training center on the University of Louisville’s Belknap Campus is a well-recognized educator in the additive manufacturing field.

Ed Tackett is currently director of The RapidTech Center at the Henry Samueli School of Engineering at the University of California, Irvine. He will become director of educational programs at the UL Additive Manufacturing Competency Center and a University of Louisville employee on July 1st.

The UL AMCC, which is scheduled to open this fall, will train engineers and other professionals from around the world on sophisticated 3D printing and other additive manufacturing machinery. The University of Louisville announced in May that it is opening the new training center with UL LLC, the Northbrook, Illinois based global science safety company.

The center will be located on Arthur Street in the J.B. Speed School of Engineering’s Institute for Product Realization. Training initially will focus on metals, with a curriculum covering design set up, machine assembly, and parts production, inspection and testing.

Tackett was selected after a national search. He has led UC Irvine’s RapidTech Center, which helps researchers and entrepreneurs quickly design and build product prototypes, since 2010. He held previous positions with the South Orange County (California) Community College District, San Diego Community College District and the United States Navy.

“I am proud to be joining the elite team at the University of Louisville to assist them in continuing development of their advanced manufacturing ecosystem,” Tackett said. “I have spent 20 years in additive manufacturing training and education around these technologies. With the strong public-private partnerships forged at UofL, we will be unparalleled in our ability to deliver certification of materials, processes, machines, parts, safety, quality control and workforce training.”

“Ed is well known nationally for his additive manufacturing training work,” said Thomas Starr, associate dean for research and a professor of chemical engineering at the Speed School. “He is the perfect person to lead this partnership with UL.”

The U.S. Commerce Department’s United States Patent and Trademark Office (USPTO) will host an Additive Manufacturing Partnership Meeting Wednesday, July 8, 2015 on the Alexandria campus. Additive manufacturing, sometimes called "3D printing," refers to a group of new technologies that create objects from 3D computer models, usually by joining thin materials, layer upon layer. The meeting will serve as a forum for sharing ideas, experiences, and insights between individual users and representatives from the USPTO.

Additive manufacturing is used in the fields of jewelry, footwear, architecture, engineering and construction, automotive, aerospace, dental and medical industries, education, geographic information systems, civil engineering, and many others.

Additive Manufacturing Partnership Meeting
July 8, 2015 from 1 p.m. - 5 p.m. ET

USPTO Campus, Madison North Auditorium
600 Dulany Street
Alexandria, VA 22314


Speaker will include:

  • Peer Munck, CEO and Founder of 3Discovered
  • Marcus Worsley, Lawrence Livermore National Laboratory
  • Blake Johnson, Princeton University
  • Dwight Dart, University of Virginia


Space is limited and registration will be done on a first-come first-served basis. Please RSVP by e-mail to This e-mail address is being protected from spambots. You need JavaScript enabled to view it or by telephone to Jill Warden at (571) 272-1267 or Veronica Ewald at (571) 272-8519 to confirm your attendance.

Published in USPTO

The Youngstown Business Incubator and America Makes, the National Additive Manufacturing Innovation Institute, are preparing to launch a $100k technology startup competition called, “AMPED.” The competition has a focus on additive manufacturing, but contestants are also encouraged to submit business ideas related to business-to-business software and information technology.

Entrepreneurs, students and technology innovators from across the nation will have the opportunity to compete for up to $100,000 of investment funding and up to a $50,000 of in-kind professional services offered though the Youngstown Business Incubator. AMPED is not a traditional business competition in which cash prizes are handed out to the winners. Rather, it’s an investment opportunity for credible entrepreneurs looking to grow their early-stage start-up. Prize money will only be awarded to the team or teams that display strong business and technical acumen and have a viable business idea that can be taken to market. In order for finalists of the competition to be eligible to receive investment prizes, they must live or relocate in northeast Ohio.

From July 1 to August 14, 2015, contestants will be able submit their ideas via the third party business competition website, PitchBurner. Once all submissions have been reviewed, YBI will invite up to seven finalists to advance to the final round in Youngstown to present their ideas in front of a panel of experienced judges on November 2, 2015. The winning team or teams will then join YBI as a Portfolio Company where they will work toward taking their idea from an early stage start-up to a scalable business.

The University Business Incubator Index from Stockholm, Sweden recognized the Youngstown Business Incubator as the No. 1 University Affiliated Business Incubator in the world in September 2015. The UBI index global benchmark of business incubators includes most of the top universities in the world, notably Stanford, UC Berkley, Cornell, etc. In this context, YBI performs much better than its peers at top universities.

Located in Youngstown, Ohio, America Makes is the flagship institute for the National Network for Manufacturing Innovation (NNMI) infrastructure. America Makes houses the research management team, as well as a 3D printing demonstration facility.

For more information, visit: www.ybi.org/amped

Published in America Makes

Additive manufacturing, including emerging “3D printing” technologies, is booming. Last year an astronaut on the International Space Station used a 3D printer to make a socket wrench in space, hinting at a future when digital code will replace the need to launch specialized tools into orbit. Here on Earth, the Navy is considering applications for additive manufacturing aboard ships, and a commercial aircraft engine company recently announced its first FAA-approved 3D-printed part. Despite its revolutionary promise, however, additive manufacturing is still in its infancy when it comes to understanding the impact of subtle differences in manufacturing methods on the properties and capabilities of resulting materials. Overcoming this shortcoming is necessary to enable reliable mass production of additively manufactured structures such as aircraft wings or other complex components of military systems, which must meet demanding specification requirements.

DARPA’s Open Manufacturing program seeks to solve this problem by building and demonstrating rapid qualification technologies that comprehensively capture, analyze and control variability in the manufacturing process to predict the properties of resulting products. Success could help unleash the potential time and cost saving benefits of advanced manufacturing methods for a broad range of defense and national security needs.

“The Open Manufacturing program is fundamentally about capturing and understanding the physics and process parameters of additive and other novel production concepts, so we can rapidly predict with high confidence how the finished part will perform,” said Mick Maher, program manager in DARPA’s Defense Sciences Office. “The reliability and run-to-run variability of new manufacturing techniques are always uncertain at first, and as a result we qualify these materials and processes using a blunt and repetitive ‘test and retest’ approach that is inevitably expensive and time-consuming, ultimately undermining incentives for innovation.”

The challenge with additively manufactured parts is that they are typically composed of countless micron scale weld beads piled on top of each other. Even when well known and trusted alloys are used, the additive process produces a material with a much different microstructure, endowing the manufactured part with different properties and behaviors than would be expected if the same part were made by conventional manufacturing. Moreover, parts made on different machines may be dissimilar enough from each other that current statistical qualification methods won’t work. Accordingly, each new material must be precisely understood and the new process controlled to ensure the required degree of confidence in the manufactured product.

To achieve this enhanced manufacturing control, Open Manufacturing is investigating rapid qualification technologies that could be applied not just to additive manufacturing but to any of a range of potentially new manufacturing methodologies. The program comprises three efforts two focusing on metal additive processes and one on bonded composite structures:

  • The Rapid Low Cost Additive Manufacturing (RLCAM) effort aims to use first-principles and physics-based modeling to predict materials performance for direct metal laser sintering (DMLS) using a nickel-based super alloy powder. In DMLS a laser melts the metal powder to additively build a 3D product.
  • The Titanium Fabrication (tiFAB) effort aims to combine physics and data based informatics models to determine key parameters that affect the quality of large manufactured structures, such as aircraft wings. tiFAB is a method that uses an electron beam instead of a laser to melt spool-fed titanium wire to build up a structure layer by layer.
  • The Transition Reliable Unitized Structure (TRUST) effort aims to develop data informatics approaches for quantification of the composite bonding process to enable adhesives alone to join composite structures. State-of-the-art techniques rely on mechanical fasteners in addition to adhesives. TRUST seeks to eliminate the reliance on these fasteners, thereby enabling bonded composites to take advantage of adhesive joining to streamline assembly and lighten the weight of the structures.


The Open Manufacturing program has established two Manufacturing Demonstration Facilities (MDFs); one at Penn State focused on additive manufacturing and the other at the Army Research Laboratory focused on bonded composites. The goal of these MDFs is to establish permanent reference repositories that endure long after the Open Manufacturing program concludes, where individuals can access various contributed approaches and processes models. The facilities also serve as testing centers to demonstrate applications of the technology being developed for the Department of Defense, its industrial base, and other agencies, and as a catalyst to accelerate adoption of the technology.

Open-Manufacturing also is developing several advanced manufacturing techniques to support defense needs. One of these, MicroFactory for MacroProducts, uses more than 1,000 microbots, each smaller than a penny, that zip around like small insects to efficiently assembly truss structures. Microbots have fabricated 12-inch truss structures with integrated electronics as a proof-of-concept, showing the potential for massive parallelism where thousands of microbots could simultaneously and efficiently build intricate truss structures. This technology could be applied to rapid production of advanced electronics for military systems or constructing wings for very small unmanned aerial systems, for example.

To support warfighters, the program is also demonstrating a framework for affordable, rapid manufacturing of customized orthoses, such as leg supports for injured veterans, in quantities of one. This effort would transform the current “artisan” approach for making customized orthoses—where each device is custom-crafted by a specialist—to an automated process allowing greater patient access, rapid device modifications and improved durability.

Another concept being advanced is seamstress-less sewing, which could enable rapid production of U.S. military uniforms in the United States at lower cost. This demonstrated robotic system uses computer vision to accurately and quickly sew fabrics together with fine thread-count precision. Beyond its potential to support cost-efficient fabrication of U.S. military uniforms in the United States, this technology has the potential to boost the domestic apparel industry in general by, for example, enabling customized apparel production directly from a design.

“Historically, U.S. military advantages were supplied by breakthroughs in materials and manufacturing,” Maher said. “More recently, the risks that come along with new manufacturing have caused a lack of confidence that has stifled adoption. Through the Open Manufacturing program, DARPA is empowering the advanced manufacturing community by providing the knowledge, control, and confidence to use new technology."

For more information, visit: www.darpa.mil/Our_Work/DSO/Programs/Open_Manufacturing_%28OM%29.aspx

Published in DARPA

GPI Prototype, located in Lake Bluff, IL, recently announced the completion of a facility expansion to double office space, accommodating new staff brought in to handle the rapid growth experienced at GPI. In addition, existing warehouse space has been remodeled to accommodate six more direct metal machines.

Historically focused on building metal prototypes, GPI has been growing the portion of its business dedicated to additive manufacturing. In preparation for this strategic commitment, GPI added two key individuals to its production and engineering departments in 2014. The team was strengthened by the addition of a metallurgical engineer as well as a metals applications engineer. This engineering strength is spearheading R&D and production capabilities on all DMLM machines.

To further support the growth of its metal additive manufacturing services, GPI has been adding to its production capacity. In 2014, GPI acquired two new direct metal machines. These machines are dedicated to the production of aluminum parts. GPI is currently one of the few companies offering production parts with AlSi12 aluminum on a ProX300.  Growth continues for GPI, especially with the scheduled delivery of a new EOS M290 in June.

In response to increased opportunities from the aerospace and medical industries, GPI recently went through the rigor of certification for AS9100:2009RevC, ISO 13485:2003, ISO 9001:2008 and is a registered ITAR facility. These certifications provide GPI with the standardized processes used to create quality products and meet regulatory requirements. During the course of certifications, GPI created an Internal Management System, providing assurances in all manufacturing processes. Requirements include internal audits, record keeping, process procedures and monitoring, management reviews and corrective and preventative action plans.

In more recent news, GPI is making a change in upper management. Scott Galloway, Founder and President, will take on the new role of CEO. Adam Galloway, has been promoted from VP Sales and Marketing and has assumed the role as President of GPI. Adam joined the company in 2003 and has been an integral member of the management team at GPI for the past eight years. “It is exciting to be part of a company that is not afraid to take risks and realize when diversification is necessary to sustain strong growth. GPI started out specializing in prototypes. As we’ve continued to make giant steps forward, the production capabilities we offer today continue to allow GPI to reach higher levels within the AM industry,” – Adam Galloway.

For more information, visit: www.gpiprototype.com

Published in GPI Prototype

ASTM International Committee F42 on Additive Manufacturing Technologies is working on a standard that will be used to evaluate mechanical properties for additively manufactured materials.

The standard (WK49229, Guide for Anisotropy Effects in Mechanical Properties of AM Parts) will serve as a guideline for using currently available standards for measuring mechanical properties, such as fracture toughness and fatigue crack growth, specifically within the realm of additive manufacturing.

Many mechanical testing standards are applicable to parts made by additive manufacturing, according to ASTM member Mohsen Seifi, a doctoral researcher at Case Western Reserve University. However, these standards do not provide enough guidance tailored to the emerging technology of additive manufacturing. The focus of the proposed standard will be guiding users to adopt or apply current available standards but with considerations and guidelines unique to additive manufacturing.

Vendors and manufacturers will use the standard to partially qualify parts and components to meet certain load bearing capability, damage tolerance, fracture and fatigue properties. Industries that use such parts will be able to use the standard for certification and qualification purposes as well. Regulatory bodies and testing labs will also benefit from the standard.

In addition to WK49229, Committee F42 is working on other standards that will be used to fully qualify additive manufacturing parts. All interested parties are welcome to join the committee’s work.

For more information, visit: www.astm.org/sn-metals

Published in ASTM

The $6 million center, called Lab 22, provides Australian companies with affordable access to specialist additive manufacturing equipment and expertise and offers huge efficiency and productivity benefits for product development.

By lowering their capital investment risk and allowing companies to ‘try before they buy’, Lab 22 overcomes one of the major barriers facing smaller businesses in adopting 3D printing with metal.

“This advanced equipment is in the range of $1 million per unit, but the vast majority of small and medium-sized businesses (SMEs) don’t have that amount of capital on-hand to take a leap of faith on a new or emerging technology,” CSIRO additive manufacturing research leader, Alex Kingsbury said.

“We’re providing Australian companies with a unique opportunity to access some of the most advanced additive manufacturing equipment with the help of our experienced technical experts, for a comparatively minimal daily fee.”

Australian 3D printing service companies, Made for Me and Keech3D, were the first companies to sign to use Lab 22’s new space with the aim of growing their metal 3D printing services.

“It’s critical for companies to be able to take advantage of new technology and development if they are to remain internationally competitive, but investment can be risky and expensive and the technical aspects are complicated,” Ms Kingsbury said.

“Lab 22 makes it much easier and affordable, so local companies can try out the equipment, use it to design or test new products or up skill their workforce – providing them with the tools to differentiate themselves, grow and get ahead of global competitors.

“We’ve already signed up four industry partners and welcome more companies to get on board.”

CSIRO has partnered with industry on a range of world-firsts using its Arcam 3D printer, including a titanium heel bone implant to treat a cancer patient, a mouthguard for treating sleep apnoea and a customisable ‘orthotic’ for horses suffering laminitis.

Lab 22 experts can help companies tailor design solutions, and have the ability to capture 3D data and simulate both the manufacturing process and in-service part performance.

Cold spray deposition technology, laser heat treatment, surface engineering and advanced machinery are also available to improve efficiencies, performance and profitability.

Lab 22’s additive manufacturing equipment includes: Arcam A1, Concept Laser M2, Optomec LENS MR-7, Voxelject VX1000 and Cold Spray Plasma Giken.

For more information, visit: www.csiro.au/en/Research/MF/Areas/Metals/Lab22

Published in CSIRO

UL (Underwriters Laboratories), a global safety science organization, will open a Global Additive Manufacturing Center of Excellence in Singapore. Additive manufacturing (AM), also commonly known as 3D printing, is defined as the process of joining materials to make objects from three-dimensional model data, usually layer upon layer, as opposed to subtractive manufacturing methods. With an investment of S$8million, this facility will be the first-of-its-kind service offering for both UL and the additive manufacturing (AM) industry.

The new center, supported by the Singapore Economic Development Board (EDB), will focus on advanced training, material and process validation programs, advisory services, and research to support both the local and global AM industry. This project is driven by UL's vision that AM will be the catalyst for global transformation in manufacturing. Through R&D collaborations with local research institutes and industry partners such as the Singapore Centre for 3D Printing and the Advanced Remanufacturing and Technology Centre, UL aims to help create a vibrant AM industry in Singapore and the region.

UL's Global Additive Manufacturing Center of Excellence will address critical gaps in the industry through four key areas. First, it will provide advanced training curriculum to speed up adoption and readiness of a strong AM workforce. Next, the center's validation programs will address AM material and process qualification. Third, the center's advisory services will provide best practices on AM fast to production and AM part acceptance. Lastly, research will be conducted at the center to inform standards development.
"UL's Global Additive Manufacturing Center of Excellence will play a catalytic role in helping our industrial companies strengthen their manufacturing competitiveness. This global center is also aligned with Singapore's vision to be the advanced manufacturing hub of Asia that drives the development of disruptive technologies such as Additive Manufacturing and robotics," said Mr. Lim Kok Kiang, Assistant Managing Director of EDB. "We are confident this new investment will add to the vibrancy of the Testing, Inspection and Certification (TIC) sector in Singapore."

Over the next several years, the facility's four technical service areas will support and expand Singapore's already well-established 3D printing infrastructure. The center is expected to employ 10 additive manufacturing technical experts.

"We are excited to help build the Singapore additive manufacturing ecosystem by contributing advanced training, validation programs, advisory services and research," said Ms. Simin Zhou, vice president of Digital Manufacturing Technologies at UL. "We anticipate this site will be the first step of several as we continue to expand into other 3D printing markets, bringing knowledge and best practices."

For more information, visit: industries.ul.com/additive-manufacturing

Published in UL

The organizers of the 10th International Conference on Additive Manufacturing and 3D Printing, taking place on July 7-9, 2015, in Nottingham, UK, have now opened online registrations for the event.

Additive Manufacturing and 3D Printing are becoming a mainstream topic in the popular press, with great examples of medical implants, aerospace components, toys and consumer goods being reported widely by media channels including the BBC, the Economist and the New Scientist. The International Conference on Additive Manufacturing & 3D Printing has firmly established itself as the one of the world’s leading conferences and networking opportunities dedicated to this exciting manufacturing technology, with outstanding speakers, technology users and vendors all coming together under one roof in July each year.

Hosted by the ‘Internationally leading’ Additive Manufacturing and 3D Printing Research Group (3DPRG) at Nottingham University, the conference attracts over 300 delegates from around the world representing some of the world’s most innovative companies and brands, who assemble for 3-days of knowledge transfer and networking.

The conference is aimed at industrialists, entrepreneurs, academics and researchers with an interest in AM & 3DP technologies, materials, software and business applications. An AM/3DP technology exhibition will run in parallel to the conference, providing a valuable networking opportunity for vendors. The event will also include one full day of presentations focusing on scientific advances in AM on July 7th. This day brings together cutting edge research activity from across UK universities with presentations outlining projects focused on early stage research underpinning the science behind Additive Manufacturing. All projects are funded by the EPSRC Centre for Innovative Manufacturing in Additive Manufacturing.

Speakers Include:

  • Burghardt Klöden - IFAM - Germany
  • Chris Tuck - University of Nottingham - UK
  • Daan Kersten - Additive Industries bv - The Netherlands
  • Horst Exner - University of Applied Sciences - Germany
  • James Gardiner - Laing O'Rourke - AUSTRALIA
  • Jim Zunino - US Army Research Lab - USA
  • Johannes Glasschröder - iwb Anwenderzentrum Augsburg - GERMANY
  • Marcel Slot - Océ-Technologies BV - The Netherlands
  • Richard Leach - University of Nottingham - UK
  • Salomé Galjaard - Arup - The Netherlands
  • Sharona Cohen - Orbotech Ltd - ISRAEL
  • Wayne King - Lawrence Livermore National Laboratory - USA
  • Willemijn Elkhuizen - Delft Uni of Technology - The Netherlands


July 7th Presentations Include:

  • Alicia Kim - University of Bath
  • Andrew Moore - Heriot-Watt University
  • Ezra Feilden-Irving - Imperial College London
  • Graham Martin - University of Cambridge
  • James Dowden - University of Nottingham
  • James Sprittles - The University of Warwick
  • Kate Black - University of Liverpool
  • Matthew Benning - Newcastle University
  • Peter Birkin - University of Southampton
  • Wayne Hayes - University of Reading


The conference was started in 2006 by Professor Richard Hague, now head of the Additive Manufacturing and 3D Printing Research Group (3DPRG) at Nottingham University. Since 2006 the conference has grown from less than 90 delegates to over 300 delegates in 2014, coming from 18 countries. The conference has an excellent reputation, with over 50% of all delegates being repeat visitors. The conference attracts delegates from the aerospace, automotive, consumer goods, fashion, retail, materials and defense sectors along with academics involved in materials, lasers, software development and design.

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of metal 3D printing solutions and advanced welding machines, announced that it has launched a new website that features an expanded lineup of new metal 3D printing systems, based on its Electron Beam Additive Manufacturing (EBAM) technology.

The expanded lineup of EBAM 3D printing systems includes new options for medium, large, and extra-large part applications, making EBAM the most widely scalable metal 3D printing solution on the market (in terms of work envelope) for parts ranging from 12 inches (305 mm) to 19 feet (5791 mm) in length. EBAM is also the fastest deposition process in the metal 3D printing market, based on documented deposition rates ranging from 7 to 20 lbs. (pounds) of metal per hour.

The new website also includes updated information on Sciaky’s industry-leading electron beam welding solutions, as well as a recent video that shows how Sciaky’s EBAM technology is helping Lockheed Martin Space Systems 3D print titanium propellant tanks for satellites.

“Sciaky is proud to launch its new website and unveil its expanded lineup of new EBAM metal 3D printing systems,” said Mike Riesen, general manager of Sciaky, Inc. “We hope the new website enlightens visitors about our innovative, industry-leading solutions and inspires them to contact us.”

Last week, Sciaky revealed the availability of financing and leasing options for U.S. customers who purchase EBAM systems and electron beam welders.

Published in Sciaky

Additive Industries confirmed the launch date and revealed the name of its new industrial additive manufacturing system: MetalFAB1. This comprehensive system embodies the ambition of Additive Industries to take 3D metal printing beyond the current lab and prototyping use, to actual fabrication use on the factory floor.

In the short introductory film, Additive Industries reveals aspects of their fully integrated 3D metal printer. "Our system will bring a substantial improvement in reproducibility, productivity and flexibility as a result of our quest to design an industrial grade metal printing process", said Daan Kersten, CEO of Additive Industries.

The high reproducibility of MetalFAB1 takes its inspiration from the semiconductor industry. Stability is achieved by robust machine design in combination with a continuous calibration strategy. Additive Industries believes in an integrated process flow for industrial additive manufacturing, therefore multiple process steps are incorporated in one machine for the first time. Fully automated handling connects all process steps, reduces manual labour, and improves product consistency and quality, while also increasing operator safety. The modular architecture offers maximum flexibility, allowing the user to start with a basic machine configuration with the possibility to enlarge the scope of the process, enabling substantially increased productivity. Moreover, modules can be added to allow the use of multiple materials in one machine without having to clean the powder system and running the risk of cross-contamination. "We are on schedule to launch the machine in the fourth quarter of this year", adds Mark Vaes, Technology Manager of Additive Industries and the leader of the MetalFab1 development project.

For more information, visit: www.additiveindustries.com

Published in Additive Industries

The Additive Manufacturing Users Group (AMUG) announced the recipients of DINO (Distinguished INnovator Operator) awards for additive manufacturing expertise and service. The awards were presented at the 27th annual users group conference in Jacksonville, Florida.

During the annual Awards Banquet, the association named eight DINOs, an award that recognizes industry veterans for years of experience as well as contributions back to the additive manufacturing industry.

The newly named DINOs are:

  • Vince Anewenter, Milwaukee School of Engineering
  • Derek Ellis, Computer Aided Technology, Inc.
  • Andrew Graves, Stratasys Direct Manufacturing
  • Steven Kossett, Natural Resources Research Institute, University of Minnesota
  • Stephan Ritt, SLM Solutions
  • Harold Sears, Ford Motor Company
  • Ed Tackett, University of California, Irvine
  • Mark Wynn, Yazaki North America


Mark Barfoot, AMUG president, said, “This year’s DINO recipients have an average of nearly 20 years of experience in the additive manufacturing industry, but experience is only part of the criteria for this coveted award. To be a DINO, one must also give back to the industry, and these eight men have done that in a big way.”

The new DINOs have been active within the AMUG community in a variety of roles, including board members, ambassadors, advisors, presenters, technical competition participants, workshop leaders and track leaders. Outside of AMUG, the DINOs are equally active, and they contribute to the advancement of the additive manufacturing industry.

AMUG is an organization that educates and advances the uses and applications of additive manufacturing technologies. AMUG members include those with any commercial additive manufacturing/3D printing technologies from companies such as Stratasys, Somos, Concept Laser, SLM Solutions, EOS, ExOne, Renishaw, HP and Prodways. AMUG meets annually to provide education and training through technical presentations on processes and new technologies. This information addresses operation of additive manufacturing equipment and the applications that use the parts they make.

Photo: (Top from top left) Vince Anewenter, Derek Ellis, Andrew Graves and Steven Kossett. (Bottom from left) Stefan Ritt, Harold Sears, Ed Tackett and Mark Wynn.

For more information, visit: www.additivemanufacturingusersgroup.com/AMUG-DINO-award.htm

Published in AMUG

A patient in Argentina required a particularly large cranial implant after stroke-related surgery, placing stringent requirements on the manufacture of the prosthetic. Naturally it needed to fit precisely, but in this case it also had to be permeable to allow brain fluid to pass through. Minimal heat conduction to the cerebral tissue was important, especially in a sunny climate. Additionally, biocompatibility was needed to allow the bone to grow into the edges of the implant.

A titanium alloy lattice structure secured by screws directly into the skull was deemed to be ideal. It was additively manufactured layer by layer from metal powder in a machine produced by German firm, EOS, whose UK subsidiary is on the Warwick Technology Park.

The one-and-a-half-hour surgical procedure was carried out successfully in May last year (2014). The patient left hospital after two days and the wound healed within three weeks. Since that time there have been no complications and the patient has been able to lead a normal life.

Several stringent mechanical requirements had to be met to ensure a successful result and technological advances in additive manufacturing allowed them to be achieved. The pores in the implant are approximately 1 mm across, while the links are about 0.2 mm thick, resulting in 95 percent porosity. To achieve such a fine mesh in a rigid structure to tight dimensional and profile tolerances would be impracticable using conventional, subtractive production techniques.

Time was of the essence in producing the implant. The process was started by Novax DMA in Buenos Aires, which specialises in developing and supplying medical implants for traumatology, orthopaedics and craniofacial surgery. For the 3D design of the implant, software was employed from UK company, Within, which allowed the basic form and porous structure to be defined quickly.

As soon as the CAD work was completed, Alphaform AG, near Munich, manufactured the implant in a matter of hours in an EOSINT M 280 metal additive manufacturing machine from EOS. The implant was in the operating theatre less than three weeks later, with transportation consuming one-third of that time.

Christoph Erhardt, Director of Additive Manufacturing at Alphaform, commented, “We had already successfully completed many additively manufactured products in the EOS system.

“However, we are particularly proud of this implant, not only because of the precise realisation of the form, but also because we were able to optimise the porous structure and the difficult process of cleaning the small interior spaces.

“We developed a multi-step process of abrasive and mechanical cleaning, rinsing and ultrasonics to arrive at the required level of medical purity, which is vital as particles can dislodge with the slightest movement, leading to the possibility of infections or rejection.”

The level of cleanliness was verified by extensive tests, including particle and cytotoxicity testing. Gas-chromatography analysis was also performed. Other tests confirmed that the implant fulfilled the necessary requirements to stabilise and protect the patient's skull.

Daniel Fiz, CEO of Novax DMA, added, “We have been supplying medical implants since 1995. Additive manufacturing represents a new milestone for patients. It offers optimal biomedical characteristics together with the highest levels of compatibility, thereby having a lasting effect on improved quality of life.

“For these reasons, we have applied the technology with success to other areas of the body. Alphaform has also manufactured jaw implants for us, as well as a hip joint and a spinal implant. For the latter, we are currently considering series production using additive manufacturing.”

Christoph Erhardt concluded, “For us, additive manufacturing and EOS are synonymous. We have already produced an enormous number of parts for many companies. Both we and our customers are continually amazed by the application possibilities and the high-quality production that can be achieved.

“That was once again the case here. We were able to help a person to live a normal life, on an ongoing basis, despite their having suffered a very serious injury.”

Published in EOS

UL LLC, a global safety science organization, and the University of Louisville are launching a 3D printing training facility called the UL Additive Manufacturing Competency Center (UL AMCC). It is set to open in fall 2015 adjacent to the university campus.

Developed for established additive manufacturing technical and business professionals, the end-to-end training center will be a hub for advancing manufacturing knowledge and workforce expertise.

Specifically, the UL AMCC will offer hands-on training in additive manufacturing for metals and curriculum covering design set up, design corrections, machine set up, part production, post-processing and parts inspection, testing and validation. The training will allow professionals to understand how to produce metal parts and emerging materials through additive manufacturing, establish safety systems, identify hazards from materials and machines and manufacture parts with safety built into designs.

“Applying the University of Louisville’s deep and practical research expertise in metals and manufacturing education with UL’s rich history in safety science will bridge the workforce development gap and empower professionals with cutting-edge training in this advanced technology,” said UL CEO Keith Williams. “Through the UL AMCC, UL is committed to meeting ever-evolving safety and quality needs and accelerating knowledge transfers within the 3D printing industry.”

“We’re excited about our partnership with UL,” said University of Louisville President James Ramsey. “This is another collaboration with a world-class company that will help us build our reputation as THE university for advanced manufacturing, training and moving research to the marketplace.”

The UL AMCC will join UofL’s global advanced manufacturing campus, the Institute for Product Realization (IPR), and collaborate and share knowledge with other corporate residents, including GE and Local Motors’ FirstBuild.

“As an integral part of the IPR, the UL AMCC will provide engineers and manufacturers with a melting pot of valuable information and resources and provide a direct connection from our academic research and UL’s certification and safety expertise to practical 3D printing applications,” said Neville Pinto, dean of the J.B. Speed School of Engineering and a professor of chemical engineering at UofL.

As additive manufacturing technologies rapidly evolve, UL AMCC will update course curriculum and introduce new content every six to 12 months. Looking forward, UL will develop a formal workforce additive manufacturing certification program during 2016 to help designers, engineers and operators expand from traditional manufacturing techniques into additive manufacturing techniques.

“We anticipate the UL AMCC will expand over time to take on additional innovations to advance manufacturing,” said Simin Zhou, vice president of Digital Manufacturing Technologies at UL. “As additive manufacturing gets deeper and more integrated into production lines, the training center will evolve real time to arm workforces with the most up-to-date knowledge and best practices.”

For more information, visit: industries.ul.com/additive-manufacturing/3d-printing-training

Published in UL

The UK Government’s Department for Business, Innovation and Skills announced that LPW, a market leader in the development and supply of metal powders for additive manufacturing (AM), has been awarded government funding through the Advanced Manufacturing Supply Chain Initiative (AMSCI).

UK manufacturing supply chain projects will benefit from a total of £67 million of government investment, with £109 million being invested in the same projects by industry. The fund to help ‘rebuild British manufacturing prowess’ will see LPW receive support totalling £3 million, with the total project size approximately £13.2 million. LPW are being supported in the project by The Welding Institute (TWI) and The Manufacturing Technology Centre (MTC). The funds will drive the development of super-clean powders of novel composition made using non-conventional powder production processes, which will enable the sustainable use of AM in a wide range of critical and demanding applications.

Funding through AMSCI is available to support research and development, skills training and capital investment to help UK supply chains achieve world-class standards and improve the global competitiveness of UK advanced manufacturing.

LPW have demonstrated impressive growth and a successful business strategy for sustainable development enabling the investment, which will be focused on developing new technologies in a customer collaboration to create lasting shared value innovative technologies, products and research in the aerospace, automotive, medical, defence, and tooling sectors.

A dedicated facility to accommodate new equipment will be built. It is due to create up to 137 new jobs and safeguard 30+ existing roles.

Established in 2007, LPW Technology is a market leader in the development and supply of metal powders for additive manufacturing, and provides a comprehensive range of services for the AM industry. These services range from the development of new alloys, through expert application support, to AM machine maintenance. The company has developed a full range of optimised powders specifically for Selective Laser Melting (SLM), Laser Metal Deposition (LMD) and Electron Beam Melting (EBM) with standard powders supplied from stock, and custom and development alloys available on request.

LPW Technology invests heavily in cutting edge analytical technology and offers a complete powder analysis service. LPW POWDERSOLVE™, a proprietary software package, supports efficient powder lifecycle management.

LPW Technology has its headquarters in Runcorn, Cheshire, UK. In June 2014 the company formally established a US subsidiary; LPW Technology Inc. situated in Pittsburgh, Pennsylvania, to provide local support and sales to a growing number of customers in the US. From these locations the company supplies high quality, certified powders to a global customer base drawn from the aerospace, biomedical and automotive industries. LPW have global partnerships with official representatives in China, Israel, Italy, Japan, Korea, Singapore and Turkey; committed to supporting adoption of AM technologies globally with combined expertise and local knowledge.

The company operates to quality control standards: AS 9100 & AS 9120 for aerospace, ISO 9001, and ISO 13485 for medical.

For more information, visit: www.lpwtechnology.com

Published in LPW Technology

Optomec announced that the Mike O’Reilly, Director of Aerosol Jet Product Management and Jim Cann, LENS Business Development Manager, will give presentations at the Additive Manufacturing Users Group (AMUG) conference. Mr. Cann’s presentation will highlight several unique aspects of Optomec LENS metal 3D Printers, including its ability to print metal onto existing structures enabling the repair of worn or damaged components. In addition, Mr. Cann will highlight a new hybrid manufacturing capability which enables new or used CNC machine tools to be upgraded with LENS 3D additive manufacturing technology. Mr. O’Reilly’s presentation will provide a comparison of methods to add electronic functionality to 3D plastic parts. The AMUG Conference will be held in Jacksonville, Florida April 19-22.

The Optomec booth will feature videos and functional parts produced with Aerosol Jet and LENS printers. Aerosol Jet printers are used to directly print functional electronic circuitry and components onto low-temperature, non-planar substrates, without the need for masks, screens, or plating. The Aerosol Jet process utilizes an innovative aerodynamic focusing technique to collimate a dense mist of material-laden micro droplets into a tightly controlled beam to print features as small as 10 microns or as large as several millimeters in a single pass. A wide assortment of materials can be printed with the Aerosol Jet system including conductive nano-particle inks and conductive polymers, dielectrics, conductive epoxies, ceramics, and bio-active materials.

Optomec LENS metal 3D Printers are used to cost-effectively repair, rework and manufacture high-performance metal components in materials such as titanium, stainless steel, and superalloys. In addition a new Optomec LENS hybrid manufacturing capability, developed under an America Makes project, enables an evolutionary approach for industry to realize the benefits of metal additive manufacturing technology. Under the project Optomec packaged LENS technology into a modular LENS Print Engine for integration with new or used CNC machine tools. The LENS Print Engine leverages the existing CNC automation platform providing a low cost entry point while also enabling additive manufacturing to co-exist with subtractive manufacturing methods in a single machine.

Mr. Cann’s LENS presentation is titled “A Comparison between Powder Bed and Powder Fed Processes for 3D Printed Metals”.  The presentation will discuss the two primary laser based 3D Printing technologies for processing powdered metals. Mr. Cann will describe how each technology works and the processing capabilities for each method. Application examples will be presented showing where each technology can best be applied. Mr. Cann will also provide an update and sneak preview of the LENS hybrid manufacturing system. The presentation is designed for the system and engineering manager, no formal training in metallurgy is required.

Mr. O’Reilly’s presentation is titled “Comparison of Methods to Add Electronic Functionality to 3D Plastic Parts”.  His presentation will discuss how integrating printed electronic circuitry and components with 3D structures is the next step in producing fully printed functional devices.  Mr. O’Reilly will survey various methods for adding conformal electronics onto   3D polymer parts. Design considerations such as substrate preparation, ink selection, and post processing methods will be reviewed, as well as examples of fully printed functional devices using the Aerosol Jet.

The AMUG conference is open to all owners/operators of additive manufacturing equipment. The annual event features an exhibition as well as a technical conference where industry leaders present fresh ideas and cost-effective solutions for additive manufacturing and 3D printing. The AMUG Conference will be held in Jacksonville, Florida April 19-23, 2015.

For more information, visit: www.additivemanufacturingusersgroup.com/conference_agenda.htm

Published in Optomec

The GE90 engine, which was the first jet engine to utilize composite fiber polymeric material on the front fan blades 20 years ago, achieved another milestone—becoming the first GE engine to incorporate an additive manufactured component for the housing on the T25 sensor.

The U.S Federal Aviation Administration granted certification of the T25 engine sensor for the GE90-94B engine in February. The upgraded T25 sensor, located in the inlet to the high pressure compressor, is being retrofitted into more than 400 GE90-94B engines in service. The T25 sensor provides pressure and temperature measurements for the engine’s control system.

“Additive manufacturing has allowed GE engineers to quickly change the geometry through rapid prototyping and producing production parts, saving months of traditional cycle time for the T25 sensor housing without impacting the sensor’s capabilities,” said Bill Millhaem, general manager of the GE90/GE9X engine program at GE Aviation.

The T25 sensor housing is just the start of additive manufacturing at GE Aviation. Several next-generation engines currently in development will incorporate the advance manufacturing technique. On the LEAP engine for narrowbody aircraft and the GE9X for the Boeing 777X aircraft, GE Aviation will produce part of the fuel nozzles with additive manufacturing.

Additive manufacturing represents a significant technology breakthrough for GE and the aviation industry. Unlike traditional manufacturing methods that mill or cut away from a metal slab to produce a part, additive manufacturing (also called 3D printing) "grows" parts directly from a CAD file using layers of fine metal powder and an electron beam or laser. The result is complex, dense parts without the waste, manufactured in a fraction of the time it would take using other methods.

Additive manufacturing has many advantages. It allows GE to design parts with unique geometries that were impossible to create using traditional machining methods. These additive manufactured components can reduce part count by replacing assemblies with single parts and can be lighter than previous designs, saving weight and increasing an engine’s fuel efficiency.

GE Aviation, an operating unit of GE (NYSE: GE), is a world-leading provider of jet, turboprop and turboshaft engines, components and integrated systems for commercial, military, business and general aviation aircraft. GE Aviation has a global service network to support these offerings.

For more information, visit: www.geaviation.com

Published in GE

Concept Laser announced the installation of the M2 cusing Multilaser metal additive manufacturing system at Faustson Tool of Arvada, Colorado. The high precision, machine shop specializes in the aerospace, aeronautics, defense, energy, medical and semiconductor industries.

“From our inception, Faustson Tool has committed to being a pioneer in the industry by utilizing new leap-frog technology and pushing the bounds of a traditional machine shop,” said Alicia Svaldi, President, Faustson Tool. “While conducting our in-depth research on additive manufacturing processes available on the market, the LaserCUSING® technology from Concept Laser was the best fit.”

“Staying at the forefront of technology is critical, not only to stay competitive, but to provide our customers with the best manufacturing solutions available on the market. Concept Laser’s M2 cusing Multilaser system with 2 x 400 W lasers provides another depth to our manufacturing services,” said Heidi Hostetter, Vice President, Faustson Tool.

“There is a tremendous emphasis on UAV and defense in Colorado,” continued Hostetter. “As new technologies, such as metal additive manufacturing came on to the market, our customers began requesting services that could only be produced on an additive manufacturing system. The technology we found from Concept Laser was stronger then other metal additive manufacturing technology available, offered flexible parameters, and fit into our current process seamlessly. The multilaser technology offers throughput similar to higher-powered systems (e.g. 1kW), while maintaining the high-precision and superior finish available with lower power settings.”

Concept Laser introduced the redesign of the M2 cusing with multilaser option at the end of 2014. With a new look and fully integrated structure, the M2 is equipped with a new filter design and increased surface area of 20 square meters. The M2 cusing Multilaser is available with 2 x 200 W lasers, or alternatively with 2 x 400 W lasers, and makes use of Concept Laser’s improved segmented exposure strategy for laser melting of metals. The dual-laser configuration increases the machine’s throughput by up to 1.8 times over that of its single-laser counterpart. The increase is dependent on the geometry of the corresponding component. These solutions with multilaser technology are interesting to digital service centers with a tendency to industrial mass production.

“Concept Laser is very excited about our partnership with Faustson Tool,” said Zach Murphree, PhD, Regional Manager, Technical Sales Engineer, Concept Laser. “Companies like Faustson Tool represent the next step in the maturation of the additive metals industry, where the technology is gaining acceptance within production facilities, not just OEMs. The M2 cusing Multilaser system is the result of fifteen years of continued metal additive development at Concept Laser and is accelerating the acceptance within the industry, and Faustson is on the leading edge of this wave.”

To begin, Faustson will build with Concept Laser’s recently introduced CL 92PH (also known as 17-4 PH Stainless Steel) and Nickel Alloy 718.

Faustson Tool operates a 16,000-square-foot facility with more than 20 highly skilled employees, and is owned and operated by Alicia Svaldi, President, and Heidi Hostetter, Vice President. Faustson Tool remains in the forefront of the manufacturing industry, continuing a tradition of pioneering the newest technology and pushing its limits. Faustson Tool takes on the most challenging applications only a few U.S. companies can handle, using state-of-the-art precision machining to do things no one else in the industry thinks can be done. Faustson’s reputation for innovation and excellence has earned the company prestigious clientele: Faustson Tool manufactured a key component in NASA’s Kepler space telescope, and has worked with Ball Aerospace to produce parts for the U.S. F-35 Lightning II Joint Strike Fighter jet.

Photo Left: Ralph Sassenhausen, Technial lead for 3D printing
Photo Right: Mike Muessel, Manufacturing Manager

For more information, visit: www.faustson.com

Published in Concept Laser

Wohlers Associates, Inc., recognized widely as the leading consulting firm and foremost authority on additive manufacturing and 3D printing worldwide, announced the publication of the Wohlers Report 2015. This annual publication has served as the industry-leading report on the subject for two decades. Over the 20 years of its publication, many have referred to the report as the "bible" of additive manufacturing (AM) and 3D printing—terms that are used interchangeably.

The market for additive manufacturing, consisting of all AM products and services worldwide, grew at a compound annual growth rate (CAGR) of 35.2% to $4.1 billion in 2014, according to Wohlers Report 2015. The industry expanded by more than $1 billion in 2014, with 49 manufacturers producing and selling industrial-grade AM machines. The CAGR over the past three years (2012–2014) was 33.8%.

Wohlers Report 2015 provides an in-depth review and analysis of the industry worldwide. It includes growth, competitive products and services, and the future outlook for the industry. The comprehensive study covers all aspects of AM and 3D printing, including its history, applications, processes, materials, and equipment manufacturers. It covers developments in R&D, investment and collaborative activities in government, academia, and industry, and summarizes the state of the AM industry around the world.

Wohlers Associates reports that growth occurred in all segments of the diverse industry, including the low-cost “desktop” 3D printer segment. The use of industrial metal AM systems for demanding production applications in the aerospace and medical markets also grew strongly. The report thoroughly documents the increasingly rich range of technologies, markets, and business models that are emerging within the industry.

“The first Wohlers Report was published in April 1996,” said Terry Wohlers, principal consultant and president of Wohlers Associates. “It was 40 pages in length and represented the first-ever published analysis of the industry worldwide. The AM industry represented a mere $295 million in 1995. A lot has changed in 20 years, and we’ve worked hard to document this change. I am proud to say that no other publication comes close to matching the depth and breadth of data and market analysis that is found in our annual report.”

Wohlers Report 2015 is an information-rich 314 pages, and includes 39 charts and graphs, 63 tables, and 279 images and illustrations. The report, which sells for $495, was developed with support from 87 service providers, 40 system manufacturers, and the valuable contributions of 78 co-authors in 31 countries. Wohlers Associates is fortunate to have developed the largest network of friends and contacts in the industry. This access and trust has resulted in a report that offers an unparalleled window into AM and 3D printing.

For more information, visit: www.wohlersassociates.com

Published in Wohlers Associates

When Pratt & Whitney delivers its first production PurePower® PW1500G engines to Bombardier this year, these engines will be the first ever to feature entry-into-service jet engine parts produced using additive manufacturing.

While Pratt & Whitney has produced more than 100,000 prototype parts using additive manufacturing over the past 25 years – and hundreds more to support the PurePower Geared Turbofan™ engine family's development – the company will be the first to use additive manufacturing technology to produce compressor stators and synch ring brackets for the production engines. Pratt & Whitney PurePower PW1500G engines exclusively power the Bombardier CSeries aircraft family.

Additive manufacturing, also called three-dimensional (3D) printing, builds parts and products one layer at a time by printers. In 3D printing, additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source.

"Pratt & Whitney has been working with additive manufacturing since the 1980s, and we are looking forward to our upcoming milestone, when the first production PurePower PW1500G engines with parts produced through additive manufacturing will be delivered," said Tom Prete, Pratt & Whitney's Engineering vice president. "We are a vertically integrated additive manufacturing producer with our own metal powder source and the printers necessary to create parts using this innovative technology. As a technology leader, we are intrigued by the potential of additive manufacturing to support our suite of technologies and benefits to customers and the global aerospace industry."

"Additive manufacturing offers significant benefits to the production of jet engines," said Lynn Gambill, chief engineer, Manufacturing Engineering and Global Services at Pratt & Whitney. "We have engine tested components produced through additive manufacturing in the PW1500G."

In production tests, Pratt & Whitney has realized up to 15 months lead-time savings compared to conventional manufacturing processes and up to 50 percent weight reduction in a single part. The PurePower engine family parts will be the first product produced using 3D printing powder bed additive manufacturing.

Related manufacturing technologies that will be used in the PurePower engine production include Metal Injection Molding, Electron Beam Melting and Laser Powder Bed Fusion (including Direct Metal Laser Sintering).

Pratt & Whitney and the University of Connecticut are also collaborating to advance additive manufacturing research and development. The Pratt & Whitney Additive Manufacturing Innovation Center is the first of its kind in the Northeast region to work with metal powder bed technologies. With more than $4.5 million invested, the center will further advance Pratt & Whitney's additive manufacturing capabilities, while providing educational opportunities for the next generation of manufacturing engineers.



Picture 1: A Pratt & Whitney manufacturing engineer with a rapid prototype of a fitting for the PurePower® engine part made using the additive manufacturing Direct Metal Laser Sintering process using nickel alloy powder. This part is located on the external of the engine where it facilitates the passage of pressurized air into the engine interior.

Picture 2: Fuel Bypass Manifold - The picture represents the conventional design of the fuel bypass manifold from the PurePower® engine family. It was manufactured using the Electron Beam Melting process and titanium powder and is a part located on the external of the engine. An optimized version was designed, utilizing design freedom achieved by the additive manufacturing process, to remove weight & material and show the design potential of additive manufacturing. Photo: courtesy of Pratt & Whitney.

Picture 3: Gearbox Bracket - The PurePower® gearbox bracket was manufactured using Direct Metal Laser Sintering in nickel alloy.  Its purpose is to attach the gearbox to the diffuser case.  The bracket was made to mimic the conventionally machine bill-of-material part and then later optimized to reduce weight and volume using design freedom achieved by additive manufacturing. Photo: courtesy of Pratt & Whitney.

Pictures 4&5: These images are from the Pratt & Whitney additive manufacturing lab at the University of Connecticut. The gentleman in these photo is Pratt & Whitney employee working at the lab.

For more information, visit: www.pratt-whitney.com

Published in Pratt & Whitney

What happens when an advanced-tech startup company works with top tier manufacturers of machine parts and controls? You get metal parts much bigger than a breadbox and an opportunity to stretch your imagination. A patented process developed by +Mfg, LLC headquartered in Greater Cincinnati holds promise for a real paradigm shift in metal additive manufacturing. Along with its development partners Parker Hannifin and Miller Electric Mfg., the company entertained enthusiastic visitors at the Automate 2015 exhibition in Chicago last week.

The company’s machine, now known to early adapters as +1000K, performs a process called Arc Metal Deposition (AMD). The +Mfg team simply combined computer driven additive manufacturing processes with a state of art power supply, and super-sized it. The show display led to impassioned discussions of new production capabilities that might be imagined. That’s why the word “IMAGINE” is so prominently emblazoned on the face of the machine when it is operating.

So, can you imagine producing a new automotive engine block in days; a desk-sized stamping die in a week; or an injection mold for a 500 ton press in less than a month? Traditional manufacturing methods of producing metal parts have been around since the Iron Age. “The benefits of additive manufacturing, particularly our AMD process, over casting, forging, and cutting parts out of billet is a gamechanger” was one of the comments made by Paul Saleba, the company spokesperson in his presentation during the Startup Competition at the show.

Jim Blackwood and Tom Kruer, Co-founders of +Mfg were also fielding questions about their +1000K, from all stripes of automation industry personnel and decision makers at the show. They discussed the implications on industry resulting from faster, cleaner, safer, less expensive, easier to operate, and environment friendly of one-off or mass-produced parts composed of combinations of various metals in one seamless operation. The partners are now shifting their attention to moving out of pilot production and into delivering machines to customers; and the sparks are flying!

For more information, visit: www.plus-mfg.com

Published in Plus MFG

GKN Aerospace has entered a strategic partnership with additive manufacturing specialist, Arcam AB, to develop and industrialise one of the most promising of the new ‘additive’ processes to meet the needs of the expanding future aerospace market.

The joint technology development (JTD) partnership is focused on developing electron beam melting (EBM), a process in which metal components are built up, layer-by-layer, using a metal powder that is melted by a powerful electron beam. EBM is able to produce very precise, complex, small to medium-sized components that require very little finishing.

As part of this agreement, GKN Aerospace has ordered two ARCAM Q20 EBM machines to be installed at GKN Aerospace’s Bristol, UK additive manufacturing (AM) centre. GKN Aerospace and ARCAM engineers will then work together to create the next generation of EBM equipment, able to manufacture complex titanium structures at the high volumes required to meet future demand.

Russ Dunn, Senior Vice President Engineering & Technology, GKN Aerospace explains: “We have been working with Arcam for some time exploring what we believe to be one of the most promising of the additive processes. Our aim has been to fully understand how EBM can be applied to our future aerostructures and aero engines portfolio. Through this new strategic partnership with ARCAM our combined additive manufacturing teams will now take the next steps towards fully industrialising this AM technology.”

He adds: “We believe the array of processes that fall under the ‘additive’ umbrella will revolutionise manufacturing across every industrial sector - particularly in aerospace where cost, weight and performance are critical.  Drawing on GKN Powder Metallurgy’s experience and our own extensive aerospace expertise we aim to develop a roadmap that will industrialise additive manufacturing for this sector.”

Magnus René, CEO, Arcam comments:  “We are now very happy to announce this order and important partnership with GKN Aerospace.  We are convinced that the close collaboration with GKN Aerospace will be key for further industrialization of our EBM technology in the aerospace industry”

The agreement forms part of the GKN group’s major AM research and development initiative.  Within the GKN Aerospace business, four dedicated global AM development centres have been established in North America and Europe each clearly focused on progressing specific additive processes and technologies.

Additive processes have huge potential for the future aerospace sector where there is a growing demand for more, and more efficient, aircraft.  In the coming years the industry  will need to  manufacture at greater speeds and with total consistency - producing components that are lighter and more cost-effective, and that generate less waste during manufacture and lower emissions in operation.

For more information, visit: www.gkn.com

Published in GKN Aerospace

Aerojet Rocketdyne has recently completed a successful series of hot-fire tests of key additively manufactured components for its AR1 booster engine at its Sacramento test facility. The testing of the main injector elements represents another important milestone in the development of the AR1 engine and the company's commitment to having a certified engine in production in 2019.

The AR1 is a 500,000 lbf thrust-class liquid oxygen/kerosene booster engine currently in development as an American-made alternative to engines such as the foreign-supplied RD-180. The 2015 National Defense Authorization Act calls for the Russian-built RD-180 to be replaced by an American-made alternative for national security space launches by 2019. Started in 2014, and building off a strong base of past oxygen-rich, staged combustion experience attained through decades of technology development programs as well as our recent AFRL Hydrocarbon Boost Technology Demonstration and the NASA Advanced Booster Engineering Demonstration/Risk Reduction program, the AR1 program is an aggressive effort aimed at delivering a flight-qualified engine in 2019. A similar development timeline was accomplished by Aerojet Rocketdyne on the commercially-developed RS-68 booster engine.

"We believe the AR1 is the best, most affordable option to eliminate U.S. dependence on foreign sources of propulsion while maintaining assured access to space for our nation's critical national security and civil space assets," said Linda Cova, executive director of Hydrocarbon Engine Programs at Aerojet Rocketdyne. The AR1 is designed to integrate with the Atlas V launch vehicle, as well as provide a versatile propulsion solution for multiple current and future launch vehicle applications. "When you consider the minimal changes to the Atlas V launch vehicle, launch pad and related infrastructure that are required with an AR1 solution, this approach is clearly the best path toward finding a replacement for the RD-180 and meeting the launch needs of our nation," said Cova. "We look forward to working with the U.S. government in a competitive procurement environment to bring this engine to market."

The development of AR1 is currently being funded by Aerojet Rocketdyne with assistance from United Launch Alliance (ULA), with engine certification targeted for 2019. The cooperative development of AR1 represents the continuation of a long-standing relationship the companies have had in supporting U.S. launch requirements. Aerojet Rocketdyne and ULA continue to work to reduce costs of propulsion systems that support the Atlas and Delta launch vehicles such as the RS-68A, RL10 and AJ-60A, while maintaining demonstrated 100 percent mission success.

"Aerojet Rocketdyne is committed to delivering an RD-180 replacement by 2019, which is why the company is investing in the engine and inviting the Air Force, ULA and other key stakeholders to all major reviews so that engine certification can occur in parallel," added Cova.

Work on the AR1 full-scale design has been progressing steadily with the team achieving significant milestones over the past months, including the completion of a System Requirements Review, full-scale single-element main injector hot-fire testing, subscale preburner testing and turbopump inducer testing.

The single-element main injector hot-fire tests were conducted to evaluate various main injector element designs and fabrication methods. Several injectors were fabricated using Selective Laser Melting (SLM), a form of additive manufacturing. Additive manufacturing, also known as 3D printing, enables the rapid production of complex engine components at a fraction of the cost of those produced using traditional manufacturing techniques. Aerojet Rocketdyne has invested heavily in developing SLM capabilities for application to its rocket engines. Tested in excess of 2,000 psi, Aerojet Rocketdyne believes the AR1 single-element hot-fire tests represent the highest pressure hot-fire test of an additively-manufactured part in a rocket engine application. In the main injector alone, additive manufacturing offers the potential for a nine month reduction in part lead times, and a 70 percent reduction in cost.

Completion of a vehicle-level system concept review and a main propulsion system Preliminary Design Review are planned major milestones for 2015.

For more information, visit: www.rocket.com/ar1-booster-engine

Published in Aerojet Rocketdyne

Granta Design announced the release of GRANTA MI:Additive Manufacturing™, a new software solution to overcome the substantial data challenges of developing additively-manufactured parts. Applying experience from Granta’s involvement in a number of leading Additive Manufacturing projects, MI:Additive Manufacturing incorporates industry best practices in managing vital material and process information in this area. It helps engineering enterprises: protect their investment and intellectual property in Additive Manufacturing research; build an in-depth knowledge-base that is a prerequisite for better understanding Additive Manufacturing processes; significantly reduce time-to-market by avoiding wasted effort and gaining valuable insights; and support the qualification and certification of additively-manufactured parts.

Additive Manufacturing (‘3D Printing’) has huge promise as a technique to make geometrically-complex parts with optimal cost and performance in industries including aerospace, automotive, and medical. Significant investment is being made in research and development programs to realise this potential. But this work generates huge amounts of data about the structure, properties, and processing of the materials involved. Until now, there has been no easy-to-implement system to capture this data and ensure that it is used effectively across the many disciplines involved: materials suppliers, R&D, part design, simulation, and production. MI:Additive Manufacturing provides a single system, based on the industry-leading GRANTA MI™ materials information management software, which captures all relevant data, links it, makes it available to any appropriately-authorized user, and ensures full traceability.

A typical MI:Additive Manufacturing workflow begins with the import of ‘logfiles’ directly from Additive Manufacturing machines. The system automatically stores process parameters, extracts logged data for specific builds, links this information to supplier data on the batches of material used to make a part, and captures testing and inspection results. This data can feed into statistical analyses that determine mechanical properties. Properties can be exported to simulation codes and the results can be captured for use in optimizing part design and production. MI:Additive Manufacturing both improves efficiency for many of the individual tasks in Additive Manufacturing research and supports collaboration, sharing knowledge and increasing effectiveness across a whole research program.

At the heart of MI:Additive Manufacturing is the data structure (or ‘schema’) that defines the types of data to be captured in the system, their inter-relationships, and how they might be processed. This technology, embodying industry best practices, is then combined with the GRANTA MI materials information management tools, which have been proven for the complex management of advanced materials data in dozens of implementations by  leading research, design and engineering enterprises worldwide.

One Additive Manufacturing project in which Granta has participated is AMAZE – a multinational collaboration of 28 corporations and research institutions that is developing rapid production of large defect-free additively-manufactured metallic components. Granta technology captures and securely shares knowledge on materials, processes, and properties. This enables efficient comparison of data, improvement of production knowledge, refinement of processes, integration of simulation activities, and improved coordination of the R&D program. Experience such as this has supported development of the new software package.

“MI:Additive Manufacturing combines our core strength in materials information management with practical knowledge of Additive Manufacturing data gained from our collaborative projects, and work with some of our leading customers”, comments Dr Patrick Coulter, chief operating officer at Granta Design. “The great news is that this will allow us to help many other customers who have expressed an interest in Additive Manufacturing, and have been asking us for a solution to manage their data in this area.”

For more information, visit: www.grantadesign.com/products/mi/am.htm

Published in Granta Design

Speakers at the plenary sessions of the Society of Plastics Engineers (SPE) ANTEC® 2015 will discuss two technologies that will be key drivers in the future progress of the plastics industry: nanotechnology and additive manufacturing.

ANTEC 2015 will take place March 23-25, 2015 at the Orange County Convention Center (OCCC) in Orlando, FL, U.S.A. and will be co-located with the NPE2015 international plastics show. The plenary speakers and their topics will be as follows:

Monday, March 23

Michael A. Meador is a NASA specialist in nanotechnology who is currently on loan to serve as the director of the National Nanotechnology Coordination Office (NNCO), National Science and Technology Council, White House Office of Science and Technology Policy. His address will be titled The Role of Nanotechnology in Current and Future Space Missions.

Tuesday, March 24

Heinz Gaub is managing director of technology and engineering for Arburg, Inc. His address will be titled Arburg Plastic Freeforming: Additive Manufacturing of Plastic Parts Using Standard Granulates.

Mr. Gaub’s presentation will be the forerunner of two technical sessions on additive manufacturing / 3D printing scheduled for Tuesday, March 24 and Wednesday, March 25.

For more information, visit: www.antec.ws

Published in SPE

With all the hype out there about additive manufacturing, it's time you entered the hype-free zone and got the real scoop on laser-based industrial additive manufacturing. From powders to process chain, learn from some of the top minds in the arena at our seventh Laser Additive Manufacturing Event in Orlando on March 4-5.

LAM 2015 will give you the big picture: advanced AM systems like laser material deposition and direct metal selective laser melting; automotive, aerospace, medical and energy applications; the latest cladding and corrosion repair methods; global perspectives on AM initiatives; and visions for more radical AM applications.

With representatives from major players like GE Global Research, BMW, Siemens and America Makes, LAM 2015 promises an advanced and realistic look at AM technology and market opportunities.

Chaired by Dr. Ingomar Kelbassa — part of the Fraunhofer ILT team that won an Aviation Week innovation award in 2012 — LAM 2015 is the place to be to network with experts on the cutting edge of this manufacturing revolution. Don't be left behind — register for LAM 2015 today.

Speakers Include:

  • Christoph Leyens - Fraunhofer IWS
  • James Sears - GE Global Research Center
  • Daniel Schraknepper - Fraunhofer IPT
  • John Hunter - LPW Technology Inc.
  • Jannis Kranz - Laser-Zentrum Nord GmbH
  • Satyajeet Sharma - Oerlikon Metco
  • Harald Lemke - NanoSteel Company
  • Thomas Schopphoven - Fraunhofer ILT
  • Stefan Mann - Fraunhofer ILT
  • Max Schniedenharn - Fraunhofer ILT
  • Paul Denney - Lincoln Electric Company
  • Richard Grylls - Optomec
  • Sebastian Kaufmann - Trumpf Laser- & Systemtechnik GmbH
  • Henner Schöneborn - SLM Solutions
  • Wayne Penn - Alabama Laser
  • James McGuffin-Cawley - Case Western Reserve University
  • Milan Brandt - RMIT University
  • Tim Biermann - Fraunhofer ILT
  • Craig Bratt & Aravind Jonnalagadda - Fraunhofer CLA
  • Andre W.M. Jansen - Plating Solutions B.V.
  • Jim Cann - Rofin-Sinar, Inc.
  • Allister James - Siemens Energy Inc.
  • Daniel Hayden - Hayden Corporation
  • Bill Shiner - IPG Photonics, Inc.
  • Wolfgang Thiele - BMW Group
  • Bruce Colter - Linear Mold and Engineering

For more information or to register, visit: www.lia.org/conferences/lam

The Additive Manufacturing Users Group (AMUG) announced that it is accepting applications for two scholarships for additive manufacturing and 3D printing education and professional development at its annual conference. The scholarships have been established in the memory of Guy Bourdeau and Randy Stevens, two longtime supports of the users group that were passionate about knowledge sharing in the additive manufacturing industry.

Mark Barfoot, AMUG president said, “The AMUG Conference is a unique experience where information is freely exchanged to promote education, training and knowledge that helps individuals get the most from additive manufacturing. Through these scholarships, we can offer that experience to a student and an educator that might otherwise be unable to attend.”

Barfoot continued, “These scholarships embody Guy’s and Randy’s spirit and passion for additive manufacturing, and they continue the legacy of two giving gentlemen.” Barfoot noted that the scholarships will be awarded to those that demonstrate the same qualities.

The Guy E. Bourdeau Scholarship, founded by Guy's wife, Renee Bourdeau, is awarded annually to one college student, enrolled in any major, who can demonstrate an emphasis on additive manufacturing and its integration in his/her professional field. This scholarship allows the student to attend the AMUG Conference to absorb the vast amount of shared knowledge and develop industry contacts.

Kaiyi Jiang, the 2014 recipient of the Guy E. Bourdeau Scholarship, said, “AMUG 2014 was an unforgettable experience in my life. I felt that I was plugged into a powerful source and enriched by new knowledge every day. I've never felt more welcomed and invited to join in activities and conversations.”

The Randy Stevens Scholarship, founded by Randy's employer, In'Tech Industries, is awarded annually to one professor/teacher that emphasizes or focuses on additive manufacturing. The scholarship will be awarded to an individual that inspires others to pursue additive manufacturing in their continuing education and professional endeavors.

Both scholarships cover travel, lodging, meals and conference registration fees. Applications are being accepted until February 27, 2015.

For eligibility requirements and applications, visit: www.additivemanufacturingusersgroup.com/scholarships.htm

Published in AMUG

Given the rapid growth of the industrial additive manufacturing (i.e. 3D printing) industry, it has become increasingly difficult to keep track of all of the machines and materials that are on the market. Senvol has solved this problem with the launch of the Senvol Database, where users are able to search by over 30 fields, such as machine build size, material type, and material tensile strength. The sheer quantity and dynamic nature of the search fields enable users to search in powerful ways and to quickly get the information that they need. The database is online and free to access.

Senvol President Zach Simkin commented, “We're very excited by the Senvol Database because it's an extremely useful tool for everyone in the additive manufacturing industry. There has been a growing need for a tool like this and we’re pleased to provide the industry with a solution.”

The Senvol Database is used by a wide range of people - everyone from potential machine buyers who want to see what machines are on the market, to engineers who want to search for materials by specific material properties.

Some example uses of the database are:

  • A service bureau searches to see all of the materials (both OEM and 3rd party) that are compatible with the machines that it owns;
  • A design engineer with a specific application in mind searches for nylon materials that have a flexural modulus of at least 1,800 MPa;
  • An industry financial analyst searches to learn about all of the metal AM machines that are available.

“Senvol very much values input and feedback from its user community,” Senvol President Annie Wang said. Wang continued, “It’s through the power of our user community that we are able to continuously improve the Senvol Database.”

Senvol is a services firm that conducts analytics exclusively for the additive manufacturing industry. Senvol has worked with a variety of Fortune 500 companies and government agencies in industries such as aerospace, oil & gas, consumer products, and automotive. Senvol’s founders have been published in various additive manufacturing industry journals, such as the Wohlers Report, and have been featured speakers at numerous industry trade shows and conferences. Senvol is a Gold Member of America Makes. Senvol is run by Annie Wang and Zach Simkin, both MBA graduates of the Wharton Business School.

For more information, visit: www.senvol.com

Published in Senvol

In 1941, Arthur M Young demonstrated a model helicopter flying on a tether while working for Bell Aircraft Corporation and just five years later, Bell Helicopter received the first-ever certification for a commercial helicopter. The Texas company has now made and sold more than 35,000 of the aircraft worldwide.

For some years, the company has used additive manufacturing (AM), otherwise known as 3D printing, to produce prototype components but wanted to use the technology to build functional parts. It turned to nearby AM bureau, Harvest Technologies, which uses more than 40 AM machines, to provide the expertise.

Before production could begin, Bell Helicopter and Harvest needed to prove out the processing capabilities of the latter’s EOSINT P 730 plastic laser-sintering machine from EOS that would be used to make the helicopter parts and to certify the platform for use in the aerospace industry. Heat distribution, powder degradation, dimensional accuracy, repeatability, component quality and performance, and the economics of manufacture were all examined.

Elliott Schulte, Engineer III at Bell Helicopter said, “We characterised the mechanical properties of each additively manufactured build so that we could confirm that the EOS system met our specification requirements and produced the same quality product each time.

“The systematic testing was done with a number of different materials and across a series of individual builds to establish that EOS technology was robust and highly repeatable.”

Subsequently, Bell Helicopter and Harvest began the meticulous process of manufacturing aerospace hardware, taking advantage of the freedom of design that comes with applying AM.

Christopher Gravelle, head of Bell Helicopter’s rapid prototyping lab commented, “Material characterisation is a critical consideration for us during design. For instance, if we are creating bosses for attachment points in additively manufactured nylon rather than metal, it is a new material and process and you cannot just use the same configuration.”

After a final review of the first component design for producibility, Bell Helicopter sent a 3D CAD model to Harvest to develop a build strategy. Before each batch was produced, rigorous pre-production inspections were carried out by Harvest, including checking that nitrogen leak rate was low, which is important for reducing waste and ensuring part quality.

Caleb Ferrell, quality manager at Harvest added, “After every build, we test for tensile and flexural properties of the components. This is a requirement for process assurance that we continuously monitor.

“The parts that we get have very good feature definition and the mechanical properties have been good as well. We are especially happy with the larger platform size and the nestability we are achieving.”

Currently, the helicopter manufacturer 3D prints parts mainly for its environmental control system (ECS) using EOS technology, but AM production is expanding. Bell Helicopter is interested in employing 3D printed components throughout the aircraft systems of its commercial helicopters.

Schulte added, “The ECS engineers who have gained experience with the material and the process are now communicating with teams involved in other functions, and those teams are starting to incorporate additively manufactured hardware into their assemblies.

"The EOS technology produces a robust and highly repeatable process that complies with our specification. We have done a number of conversions of aircraft parts from previous processes to AM. With the EOSINT P 730, we often discover that the production cost per piece is substantially reduced compared to conventional manufacturing methods.”

Bell Helicopter will also be evaluating AM of high-temperature plastics intended for more demanding roles and environments.

Ferrell explained, “In addition to the design advantages, there are significant manufacturing benefits with EOS technology. Tool-less manufacturing means you do not face certain limitations or up-front costs.

“If you need to change something, you can build new revisions simply by changing the CAD file – no moulds, no new machining tool paths and very little wasted time and money.”

“Because of the large build platform in the EOSINT P 730, we can print bigger components in one piece rather than in sections, eliminating assembly costs.”

Another advantage of the EOS system is the clean surface it produces, according to director of business development at Harvest, Ron Clemons. He explained that the EOSINT P 730 incorporates a software fix that provides crisper detail and smoother surfaces. As a result, there is relatively little peripheral powder melting and adhesion, so the desired quality of finish is achieved. There is consequently a saving in post-processing cost compared with the bureau’s other AM systems and lead-times are shorter.

An important secondary benefit of EOS technology is increased recyclability of the plastic powder. Other AM processes used by Harvest leave behind a significant amount of partially melted and therefore unusable powder, whereas more of the EOSINT P 730’s leftover powder can be reused.

Harvest has since acquired a second EOSINT P 730 and an EOSINT P 760 and is currently working with Bell Helicopter to implement the manufacture of one-off or two-off orders for spares, nested within the build volumes of existing batch production.

For more information, visit: Aerospace Case Study - Bell Helicopter

Published in EOS

Mohawk College has officially opened Ontario’s first Additive Manufacturing Resource Centre in Canada’s manufacturing heartland.

Engineering Technology students and faculty are already working with 43 industry, education and government partners on applied research projects.  Digital images are turned into three-dimensional prototypes and parts made out of titanium, aluminum, nickel, stainless steel, bronze and other metals.

The $2 million centre received $720,000 in funding from both the Canada Foundation for Innovation and the Ontario Research Fund, with additional support from industry partners. Mohawk is one of only three postsecondary education institutions in Canada with the capacity to manufacture metal parts for industry.

Additive manufacturing joins digital health and smart grid technologies as Mohawk’s three areas for applied research.

Additive Manufacturing Resource Centre

  • The Additive Manufacturing Resource Centre serves as a test lab for advanced manufacturers and a living lab for Mohawk’s Engineering Technology students.
  • Only three colleges and universities in Canada have 3D printers that can produce metal parts. Mohawk’s centre is the only one of its kind in Ontario.
  • The $2 million Additive Manufacturing Resource Centre received matching $720,000 grants from both the Canada Foundation for Innovation and the Ontario Research Fund, with additional funding from industry partners and the college.
  • The centre features two advanced printers that turn digital images into three dimensional models, prototypes, tooling and production parts made out of titanium, aluminium, nickel, stainless steel, bronze and other metals. The centre also has plastic printers for creating preliminary designs.
  • Mohawk is already working with 43 advanced manufacturers and government and education partners on applied research projects that:
    • Test the feasibility of making existing products using additive manufacturing.
    • Improve the designs of existing products and reduce costs.
    • Design new products that cannot be manufacturing using conventional processes.
    • Develop and test new materials to manufacture products using additive manufacturing.
  • In addition to the Additive Manufacturing Resource Centre, Mohawk also conducts applied projects with industry, education and government partners at the Mohawk eHealth Development and Innovation Centre (MEDIC) and the Applied Research Centre in Energy.
  • More than 4,500 students are enrolled in Mohawk’s Faculty of Engineering Technology program and the collaborative Bachelor of Technology degree program in partnership with McMaster University. Applied research capstone projects are incorporated into the students’ curriculum and co-op work terms.

For more information, visit: www.mohawkcollege.ca

Published in Mohawk College

World-leading helicopter engine manufacturer Turbomeca (Safran) is setting up new manufacturing capability at its facility in Bordes (France). After years of maturation and prototype testing, Turbomeca has entered serial production of parts using the latest additive manufacturing, or 3D printing process. Bordes facility is one of the first of its kind to serial produce additive components for aerospace propulsion industry in France.

Arrano test and production engines will feature fuel injector nozzles made using Selective Laser Melting (SLM) techniques. This leading-edge manufacturing process will also be used to manufacture Ardiden 3 combustor swirlers. These engines are Turbomeca’s latest models and amongst the most advanced turboshafts ever designed.

Additive manufacturing produces parts to a three-dimensional CAD (computer-aided design) model. Unlike traditional manufacturing processes (forging and machining) which are based on material removal, additive manufacturing builds layers, each between 20 and 100-micrometers thick, of fine metal powder to produce complex-shape parts. In the case of SLM, a computer-controlled laser shoots pinpoint beams onto a bed of nickel-based super-alloy powder, to melt the metal in the desired areas.

Additive Manufacturing also simplifies the manufacturing process. A traditional fuel-injector nozzle is made up from dozens different pieces. Arrano component is made from one single piece of material and features advanced injection and cooling functions. One SLM machine is already in service, and qualified for mass production, with others to be integrated over the coming years.

Additive manufacturing is part of Turbomeca’s ambitious “Future Line” programme designed to improve all its manufacturing capabilities. By introducing new, high-end machine tools and new processes like additive manufacturing and HVOF (High Velocity Oxy-Fuel) coatings, Turbomeca will significantly improve its compressor and turbine blade manufacturing capabilities at Bordes.

Turbomeca (Safran) is the leading helicopter engine manufacturer, and has produced 70,000 turbines based on its own designs since the company was founded. Offering the widest range of engines in the world and dedicated to 2,500 customers in 155 countries, Turbomeca provides a proximity service thanks to its 15 sites, 30 proximity maintenance centers, 18 Repair & Overhaul Centers, and 90 Field representatives and Field technicians. Microturbo, the subsidiary of Turbomeca, is the European leader in turbojet engines for missiles, drones and auxiliary power units.

For more information, visit: www.turbomeca.com

Published in SAFRAN

With a 3-D printed twist on an automotive icon, the Department of Energy’s Oak Ridge National Laboratory is showcasing additive manufacturing research at the 2015 North American International Auto Show in Detroit.

ORNL’s newest 3-D printed vehicle pays homage to the classic Shelby Cobra in celebration of the racing car’s 50th anniversary. The 3-D printed Shelby will be on display January 12-15 as part of the show’s inaugural Technology Showcase.

Researchers printed the Shelby car at DOE’s Manufacturing Demonstration Facility at ORNL using the Big Area Additive Manufacturing (BAAM) machine, which can manufacture strong, lightweight composite parts in sizes greater than one cubic meter. The approximately 1400-pound vehicle contains 500 pounds of printed parts made of 20 percent carbon fiber.

Recent improvements to ORNL’s BAAM machine include a smaller print bead size, resulting in a smoother surface finish on the printed pieces. Subsequent work by Knoxville-based TruDesign produced a Class A automotive finish on the completed Shelby.

“Our goal is to demonstrate the potential of large-scale additive manufacturing as an innovative and viable manufacturing technology,” said Lonnie Love, leader of ORNL’s Manufacturing Systems Research group. “We want to improve digital manufacturing solutions for the automotive industry.”

The team took six weeks to design, manufacture and assemble the Shelby, including 24 hours of print time. The new BAAM system, jointly developed by ORNL and Cincinnati Incorporated, can print components 500 to 1000 times faster than today’s industrial additive machines. ORNL researchers say the speed of next-generation additive manufacturing offers new opportunities for the automotive industry, especially in prototyping vehicles.

“You can print out a working vehicle in a matter of days or weeks,” Love said. “You can test it for form, fit and function. Your ability to innovate quickly has radically changed.  There’s a whole industry that could be built up around rapid innovation in transportation.”

The Shelby project builds on the successful completion of the Strati, a fully 3-D printed vehicle created through a collaboration between Local Motors and ORNL.

The lab’s manufacturing and transportation researchers plan to use the 3-D printed Shelby as a laboratory on wheels. The car is designed to “plug and play” components such as battery and fuel cell technologies, hybrid system designs, power electronics, and wireless charging systems, allowing researchers to easily and quickly test out new ideas.

The ORNL booth at NAIAS highlights additional research and development activities in manufacturing and vehicle technologies including displays on energy absorption, composite tooling, printed power electronics and connected vehicles.

The project was funded by the Advanced Manufacturing Office in DOE’s Office of Energy Efficiency and Renewable Energy and ORNL’s Laboratory Directed Research and Development program.

For more information, visit: web.ornl.gov/sci/manufacturing/media/news/detroit-show

Published in ORNL

The Laser Institute of America (LIA)’s annual workshop on laser additive manufacturing moves to LIA’s hometown of Orlando on March 4-5 at the Embassy Suites – Lake Buena Vista South (Orlando, FL) for the first time in 2015. Held at Florida’s high-tech corridor, LAM promises another no-hype look at the disruptive power of additive processes.

Chaired by Dr. Ingomar Kelbassa, the seventh Laser Additive Manufacturing (LAM®) Workshop will focus heavily not only on traditional laser-based cladding applications to prevent or repair corrosion and wear, but also on the process chains vital to optimizing the additive production of parts.

While rapid prototyping with plastic or metal powders is well-established, Kelbassa is among those on the cutting edge of additively producing functional industrial parts. The adjunct professor at Australia’s RMIT University, vice director at the Chair for Laser Technology LLT, RWTH Aachen University and department head at the Fraunhofer Institute for Laser Technology, Kelbassa was also a member of the Fraunhofer ILT team that won an Aviation Week innovation award in 2012 for producing an additively manufactured BLISK (blade-integrated disk) in about 160 minutes — about two minutes per blade.

“We have developed and improved from 2D cladding to 2.5D cladding to 3D cladding and layer-by-layer buildup of structures as well as all the developments and improvements in the powder-bed processes, (also known as) selective laser melting,” Kelbassa says.

“Primarily, LAM was, is and will be a workshop that is industry driven,” he asserts. “Therefore, the majority of the presentations will be on success stories from OEMs as well as from a service provider's perspective — highlighting industrially implemented additive manufacturing (AM) chains in the aeronautics, power generation, offshore, mining, oil, automotive and tool, die and mold-making fields.”

In keeping with prior LAM education tracks, LAM 2015 will feature an overarching theme each day: process chain and process integration on day one, and real-world success stories on day two.

Day one is scheduled to feature four sessions with three presentations each addressing the paradigm shift in manufacturing – along the horizontal and vertical AM process chain; design and material; process and quality assurance; and systems and process integration. Day two “will feature a more industrially driven telling of success stories in different markets and fields of applications.” He calls the last slate of presentations “visions, because hopefully (we will have a talk) on rapid manufacture of organic materials: not metals or ceramics, but depositing living cells. In the end, the vision is to print out ‘spare parts’ for human beings.”

While industrial additive manufacturing might be confusingly lumped in with the broad spectrum of emerging 3D printing options — particularly vis-à-vis the cheaper personal-style systems for making plastic trinkets — achieving a global perspective on real LAM growth is challenging. That’s where LAM fills a significant need. Kelbassa says:

“At the moment, AM is a niche. But it will be growing. It will not entirely replace subtractive manufacture; it can’t. But in the end there will be a larger divergence (in applications) and also larger technology transfer in different fields of applications. Where we come from now is (using AM for) high-value components (for) aerospace, power generation, automotive, highly complex parts for tool, die and mold making and highly individual parts for mass customization — mainly in medicine such as for (dental) implants etc.”

LIA will ensure a chance to network by scheduling an exhibitor reception starting at 5 p.m. on March 4. Attendees can ask their most pressing questions of some of the most experienced laser-industry professionals, including LAM co-chairs Jim Sears of GE and Paul Denney of Lincoln Electric — both past chairs of LAM. Alabama Laser will once again serve as platinum sponsor of the workshop. Other Sponsors this year include: Cambridge Technology, Inc.; DM3D Technology, LLC; Fraunhofer USA, CCL; IPG Photonics Corporation; Joining Technologies, Inc.; Laserline Inc.; LPW Technology; Optomec and TRUMPF Inc. A complete list of LAM 2015 Exhibitors can be found on the LAM website.

For more information or to register, visit: www.lia.org/lam

Concept Laser is comprehensively upgrading its models in order to improve performance with the new M2 cusing featuring a modern machine design and numerous innovations including multilaser technology.

Concept Laser has in particular improved the process including innovations in the segmented exposure strategy and on a ground-breaking quality assurance module QMmeltpool 3D. Apart from this, two new certified materials are also available.

The new M2 cusing features a new, modern appearance with a fully integrated structure and no longer any external components for the laser and filter system. This self-contained solution provides benefits for the user in terms of the accessibility of the system components as well as greatly reduced space requirements.

The new M2 cusing is equipped with a new filter design which has increased the surface area of the filter from 4 to 20 square meters. The new filter module has been designed with fixed tubing as well as being fully integrated into the system. The frequency with which the filter has to be replaced can be reduced to such an extent that the overall throughput of the system is increased. This enhancement is important when using the multilaser technology which increases formation of smoke particles.

"Significantly faster build rates demand safer filter replacement concepts. Every filter change must be quick and easy. We have incorporated the new enhanced filter technology with safety as our primary consideration", explains Dr. Florian Bechmann. For instance, the M2 cusing is fitted as standard with a water-submersible filter in order to guarantee safety when changing the filter.

"Our product range is now enhanced with multilaser technology and it directly affects the exposure time. Our experience has shown that build rates can be increased by up to 80%. That's a very pleasing result", notes Dr. Florian Bechmann, Head of Development at Concept Laser.

The multilaser technology is initially being incorporated into the medium size segment. For instance, a multilaser version of the new M2 cusing – called the M2 cusing Multilaser – is available right now. It's available with 2 x 200 watt lasers, or alternatively with 2 x 400 watt lasers.

What's more, Concept Laser has also signalled the arrival of multilaser technology in their largest machine, the X line 1000R. In addition to the X line 1000R which is already well established in the market, in the near future the X line 2000R will also be available, and will be fitted with 2 x 1000 watt lasers. The aim is to drive ever faster construction speeds which are required by users in the aerospace and automotive industries.

Concept Laser has likewise raised its game in relation to its exposure strategy. The key term is segmented exposure. It is common that higher laser power produces a rougher surface finish. "Our new systems technology implements the hull-core principle, which enables density and surface quality to be controlled independently”, says Dr. Florian Bechmann. This means that segmented exposure has an influence on the outer parts of the component – including overhangs and high-density areas of components – in a targeted manner. "An optimised exposure strategy improves both the level of quality and build speeds." The end result is that a component's performance characteristics can be significantly improved through the use of segmented exposure strategy.

Concept Laser has demonstrated key enhancements in real-time process monitoring for quality assurance purposes. "Inline process monitoring" is one of Concept Laser's strategic technology fields, and one which we are now expanding with the QMmeltpool 3D", says Dr. Florian Bechmann: "If we can dynamically micro-analyse the construction process, the level of quality increases. Important key industries with their sophisticated applications have enabled us to develop this important innovative step", Dr. Bechmann continues. In a comparable manner to computed tomography (CT), the new QMmeltpool 3D makes it possible to generate 3D data sets that corelate directly to the component and/or it´s structure. According to Concept Laser, this allows local effects that arise during the construction of the component to be clearly identified and analysed. The practical added value of this innovation is not just that it is an original way of providing real time quality assurance, but also that production builds can be optimised through iterative variation of the parameters. Support structures can be adapted, and above all, the construction of the component can be structured in a more efficient and production-friendly manner. And not least, real time monitoring opens new opportunities in the materials research field.

Concept Laser's development center has certified two new materials. For high-temperature applications, Inconel 625 is mainly intended for use in turbine construction where components are exposed to high thermal stress of up to 1000°C. The second material is  stainless steel, 17-4 PH which can be hardened and consequently made highly resistant to abrasion, wear and corrosion. The certification of 17-4 PH stainless steel applies to the Mlab cusing R, M1cusing, and the M2 cusing series.

For more information, visit: www.concept-laser.de/en/home.html

Published in Concept Laser

Renishaw is pleased to unveil the machine that it is developing specifically for production manufacturing. Provisionally named EVO Project, it is the first additive manufacturing system designed and engineered in-house at Renishaw and reflects the company's 40 years of experience in supplying high quality equipment to demanding global manufacturing businesses.

The new machine, which has a strong emphasis on automation, monitoring technologies and reduced operator interaction, is designed for single material industrial production. Powder handling is almost entirely hands off, whilst powder recirculation, recycling and recovery are all carried out within the inert atmosphere of the system, protecting both the user and the integrity of the material.

The EVO Project machine incorporates a high power 500 W laser which will aid productivity whilst still maintaining precision and surface finish. It also boasts a class leading high capacity filtration system, a large 19” HMI user interface and intelligent workflow to further reduce the need for operator interaction.

The new machine, which is planned to be available in the second-half of 2015, is designed to complement and not replace the current Renishaw AM250 system which is better suited for flexible manufacturing and research applications where changes between materials are a requirement. The AM250 has an interchangeable hopper system which allows various materials to be used on the same machine.

Renishaw continues to develop the AM250 system which is also benefitting from some of the developments made for the EVO Project machine. This has led to the recent introduction of the PlusPac™ upgrade pack which offers improvements to Z-axis seals and chamber lighting, plus substantially improved gas recirculation and filtration.

At Euromold 2014, taking place between 25th and 28th November in Frankfurt, the Renishaw stand will feature an EVO Project machine, AM250 system and an AM250 fitted with the PlusPac upgrade.

For more information, visit: www.renishaw.com/evoproject

Published in Renishaw

Australian Research Council (ARC) Chief Executive Officer (CEO), Professor Aidan Byrne, has welcomed the launch of a new ARC Research Hub that will undertake research to establish Australia as a global leader in metal-based additive manufacturing in Australia.

The ARC Research Hub for Transforming Australia’s Manufacturing Industry through High Value Additive Manufacturing was officially opened today at Monash University. The Research Hub has been awarded $4 million over five years from the ARC through the Industrial Transformation Research Program.

Professor Byrne said the new Research Hub would focus on new additive manufacturing technology—also known as 3D printing—that can build components from metal alloy powders or wires by selective laser or electron beam melting.

“This technology makes it possible to produce components from computer design files without the need for tooling. This can lead to components being made more efficiently, cost and time-wise, while achieving equivalent or better performance,” said Professor Byrne.

“Technological advances in additive manufacturing also bring significant environmental benefits, allowing the creation of more light-weight products which require reduced energy to produce, and a significant reduction in material waste.

“This Research Hub will increase the awareness and uptake of metal-based additive manufacturing in Australia. It aims to establish Australia as a global leader in knowledge of additive manufacturing for metal components, with application in industries such as aerospace, automotive, biomedical, space and defence.”

The Research Hub will work collaboratively with partners including: Deakin University; The University of Queensland; Australian Nuclear Science and Technology Organisation; Metallica Minerals Limited; Safran-Microturbo SAS; A.W. Bell; Amaero Engineering Pty Ltd; Chassis Brakes International (Australia) Pty Ltd; International Seal Company Australia Pty Ltd; and Kinetic Engineering Services Pty Ltd.

For more information, visit: www.arc.gov.au/ncgp/itrp/itrp_default.htm

Lawrence Livermore National Laboratory researchers have developed an efficient method to measure residual stress in metal parts produced by powder-bed fusion additive manufacturing.

This 3D printing process produces metal parts layer by layer using a high-energy laser beam to fuse metal powder particles. When each layer is complete, the build platform moves downward by the thickness of one layer, and a new powder layer is spread on the previous layer.

While this process is able to produce quality parts and components, residual stress is a major problem during the fabrication process. That’s because large temperature changes near the last melt spot -- rapid heating and cooling -- and the repetition of this process result in localized expansion and contraction, factors that cause residual stress.

Aside from their potential impact on mechanical performance and structural integrity, residual stress may cause distortions during processing resulting in a loss of net shape, detachment from support structures and, potentially, the failure of additively manufactured (AM) parts and components.

An LLNL research team, led by engineer Amanda Wu, has developed an accurate residual stress measurement method that combines traditional stress-relieving methods (destructive analysis) with modern technology: digital image correlation (DIC). This process is able to provide fast and accurate measurements of surface-level residual stresses in AM parts.

The team used DIC to produce a set of quantified residual stress data for AM, exploring laser parameters. DIC is a cost-effective, image analysis method in which a dual camera setup is used to photograph an AM part once before it’s removed from the build plate for analysis and once after. The part is imaged, removed and then re-imaged to measure the external residual stress.

In a part with no residual stresses, the two sections should fit together perfectly and no surface distortion will occur. In AM parts, residual stresses cause the parts to distort close to the cut interface. The deformation is measured by digitally comparing images of the parts or components before and after removal. A black and white speckle pattern is applied to the AM parts so that the images can be fed into a software program that produces digital illustrations of high to low distortion areas on the part’s surface.

In order to validate their results from DIC, the team collaborated with Los Alamos National Laboratory (LANL) to perform residual stress tests using a method known as neutron diffraction (ND). This technique, performed by LANL researcher Donald Brown, measures residual stresses deep within a material by detecting the diffraction of an incident neutron beam. The diffracted beam of neutrons enables the detection of changes in atomic lattice spacing due to stress.

Although it’s highly accurate, ND is rarely used to measure residual stress because there are only three federal research labs in the U.S. -- LANL being one of them -- that have the high-energy neutron source required for this analysis.

The LLNL team’s DIC results were validated by the ND experiments, showing that DIC is a reliable way to measure residual stress in powder-bed fusion AM parts.

Their findings were the first to provide quantitative data showing internal residual stress distributions in AM parts as a function of laser power and speed. The team demonstrated that reducing the laser scan vector length instead of using a continuous laser scan regulates temperature changes during processing to reduce residual stress. Furthermore, the results show that rotating the laser scan vector relative to the AM part’s largest dimension also helps reduce residual stress. The team’s results confirm qualitative data from other researchers that reached the same conclusion.

By using DIC, the team was able to produce reliable quantitative data that will enable AM researchers to optimally calibrate process parameters to reduce residual stress during fabrication. Laser settings (power and speed) and scanning parameters (pattern, orientation angle and overlaps) can be adjusted to produce more reliable parts. Furthermore, DIC allowed the Lawrence Livermore team to evaluate the coupled effects of laser power and speed, and to observe a potentially beneficial effect of subsurface layer heating on residual stress development.

“We took time to do a systematic study of residual stresses that allowed us to measure things that were not quantified before,” Wu said. “Being able to calibrate our AM parameters for residual stress minimization is critical.”

LLNL’s findings eventually will be used to help qualify properties of metal parts built using the powder-bed fusion AM process. The team’s research helps build on other qualification processes designed at LLNL to improve quality and performance of 3D printed parts and components.

Wu and her colleagues are part of LLNL’s Accelerated Certification of Additively Manufactured Metals (ACAMM) Strategic Initiative. The other members of the Lawrence Livermore team include Wayne King, Gilbert Gallegos and Mukul Kumar.

The team’s results were reported in an article titled “An Experimental Investigation Into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel” that was recently published in the journal, Metallurgical and Materials Transactions.

For more information, visit: acamm.llnl.gov

Published in LLNL

Today’s innovations in science and technology are being driven by new capabilities in additive manufacturing.  Also known as 3-D printing, this approach is changing the speed, cost and flexibility of designing and building future machines for space and earth applications.

NASA’s Game Changing Development Program in the Space Technology and Mission Directorate has been actively funding research in 3-D printing and co-funded a recent groundbreaking test series with Aerojet Rocketdyne (AR) at NASA’s Glenn Research Center. Recently, AR in partnership with NASA, successfully completed the first hot-fire tests on an advanced rocket engine thrust chamber assembly using copper alloy materials.  This was the first time a series of rigorous tests confirmed that 3-D manufactured copper parts could withstand the heat and pressure required of combustion engines used in space launches.

In all, NASA and AR conducted 19 hot-fire tests on four injector and thrust chamber assembly configurations, exploring various mixture ratios and injector operability points and were deemed fully successful against the planned test program.

“The successful hot fire test of subscale engine components provides confidence in the additive manufacturing process and paves the way for full scale development,” says Tyler Hickman, lead engineer for the test at Glenn.

The work is a major milestone in the development and certification of different materials used in this manufacturing process.  According to AR, copper alloys offer unique challenges to the additive manufacturing processes.  The microstructure and material properties can be well below typical copper. So they have worked through a regimented process to optimize and lock down processing characteristics and have performed rigorous materials tests to know how the alloy performs structurally.

“Additively manufactured metal propulsion components are truly a paradigm shift for the aerospace industry,” says Paul Senick, Glenn project manager. “NASA and its commercial partners continue to invest in additive manufacturing technologies, which will improve efficiency and bring down the cost of space launches and other earth applications.”

For more information, visit: www.nasa.gov/centers/glenn/home

Published in NASA

NASA and Aerojet Rocketdyne, a GenCorp (NYSE:GY) company, successfully completed a series of hot-fire tests on an advanced rocket engine Thrust Chamber Assembly (TCA) using copper alloy additive manufacturing technology. This testing, conducted for the first time in the industry, was done with cooperation between Aerojet Rocketdyne, NASA's Space Technology Mission Directorate Game-Changing Development Program and NASA's Glenn Research Center under a Space Act Agreement.

"This work represents another major milestone in the integrated development and certification of the materials characterization, manufacturing processes, analysis and design-tool technologies that are required to successfully implement Selective Laser Melting for critical rocket engine components," said Jay Littles, director of Advanced Launch Programs at Aerojet Rocketdyne. "Aerojet Rocketdyne continues to expand the development of novel material and design solutions made possible through additive manufacturing, which will result in more efficient engines at lower costs. We are working a range of additive manufacturing implementation paths - from affordability and performance enhancement to legacy products such as the RL10 upper stage engine. We also are applying the technology to next-generation propulsion systems, including the Bantam Engine family, as well as our new large, high performance booster engine, the AR1."

The hot-fire tests used Aerojet Rocketdyne's proprietary Selective Laser Melting copper alloy enhanced heat transfer design chamber, which demonstrated a significant increase in performance over traditional combustion chamber designs and material systems. "In all, NASA and Aerojet Rocketdyne conducted 19 hot-fire tests on four injector and TCA configurations, exploring various mixture ratios and injector operability points. At the conclusion of the tests, the injector and chamber hardware were found to be in excellent condition, and test data correlated with performance predictions," said Lee Ryberg, lead project engineer on Aerojet Rocketdyne's Additive Manufacturing development team.

For more information, visit: www.rocket.com

Published in Aerojet Rocketdyne

Researchers at the Department of Energy’s Oak Ridge National Laboratory have demonstrated an additive manufacturing method to control the structure and properties of metal components with precision unmatched by conventional manufacturing processes.

Ryan Dehoff, staff scientist and metal additive manufacturing lead at the Department of Energy’s Manufacturing Demonstration Facility at ORNL, presented the research this week in an invited presentation at the Materials Science & Technology 2014 conference in Pittsburgh.

“We can now control local material properties, which will change the future of how we engineer metallic components,” Dehoff said. “This new manufacturing method takes us from reactive design to proactive design. It will help us make parts that are stronger, lighter and function better for more energy-efficient transportation and energy production applications such as cars and wind turbines.”

The researchers demonstrated the method using an ARCAM electron beam melting system (EBM), in which successive layers of a metal powder are fused together by an electron beam into a three-dimensional product. By manipulating the process to precisely manage the solidification on a microscopic scale, the researchers demonstrated 3-dimensional control of the microstructure, or crystallographic texture, of a nickel-based part during formation.

Crystallographic texture plays an important role in determining a material’s physical and mechanical properties.  Applications from microelectronics to high-temperature jet engine components rely on tailoring of crystallographic texture to achieve desired performance characteristics.

“We’re using well established metallurgical phenomena, but we’ve never been able to control the processes well enough to take advantage of them at this scale and at this level of detail,” said Suresh Babu, the University of Tennessee-ORNL Governor's Chair for Advanced Manufacturing. “As a result of our work, designers can now specify location specific crystal structure orientations in a part.”

Other contributors to the research are ORNL’s Mike Kirka and Hassina Bilheux, University of California Berkeley’s Anton Tremsin, and Texas A&M University’s William Sames.

The research was supported by the Advanced Manufacturing Office in DOE's Office of Energy Efficiency and Renewable Energy.

ORNL is managed by UT-Battelle for the Department of Energy's Office of Science. DOE's Office of Science is the single largest supporter of basic research in the physical sciences in the United States, and is working to address some of the most pressing challenges of our time.

For more information, visit: www.ornl.gov/user-facilities/mdf

Published in ORNL

Returning for its second year, 3D Printing & Additive Manufacturing: Industrial Applications Global Summit will be led by industrial end users of additive manufacturing technology, focusing on high volume production applications from sectors including aerospace, automotive, construction, apparel and medical.

This year’s event being held November 25-26 in London features an entirely new speaker line-up with keynote presentations from TATA, Wipro, Arcelik, Croft Filters, Smit Rontgen, HEAD Sports and many more.

What's New For 2014:

  • BUSINESS CASE ANALYSIS: Assessing the very latest economic factors to determine whether the return on investment justifies the costs of technology adoption
  • MATERIALS FOCUS: Revealing the very latest emerging materials and building unique relationships with suppliers to develop reliable supply chains across metals, plastics and ceramics
  • NEW INDUSTRY SECTOR CASE STUDIES: Identifying the roadmap to AM adoption across aerospace, automotive, medical, construction, apparel and retail industries to deliver personalised business case analysis for each delegate
  • STANDARDISATION: Understanding what work is being done to standardise materials and machines to speed up quality assurance
  • DESIGN & DESIGNERS: Examining the new rules of design for AM and 3D Printing and methods to train a new generation of designers to fully leverage the potential of additive manufacturing

Expert Line-Up Includes:

  • Maltesh Somasekharappa, Head Of Advanced Manufacturing Solutions, Wipro Infrastructure Engineering
  • Ralf Schwenger, R&D Director, HEAD Sports
  • Neil Burns, Director, Croft Filters Ltd
  • Pieter Nuijts, Director OEM Grids, Tubes And Components, Smit Rontgen (Philips Healthcare)
  • Ajau Purohit, Technical Chief Rapid Proto And Craftmanship Tools, TATA Motors
  • Daniel Lau, Technical Specialist In R&D Pre-Development, HEAD Sports
  • Metin Bilgili, Technical Leader Of Production Technologies, Arcelik A.S.
  • Damien Buchbinder, Teamleader (Advanced SLM Systems), Rapid Manufacturing Group, Fraunhofer ILT
  • Harry Kleijnen, Manager Development And Engineering Grids, Smit Rontgen (Philips Healthcare)
  • Lionel T Dean, Founder & Creative Director, FutureFactories
  • Nicola Searle, Economic Advisor, Intellectual Property Office
  • Sam Stacey, Head Of Innovation, Skanska UK
  • Michael Banach, Senior Research Manager, Plastic Logic
  • Richard Beckett, Design Tutor, Bartlett School Of Architecture
  • Moataz Attalah, Professor Of Advanced Materials Processing, University Of Birmingham
  • Rainer Koch, Head Of Department, Mechanical Engineering, University Of Paderborn
  • Steinar Killi, Researcher, Oslo School Of Architecture And Design

For more information, visit: www.3d-printing-additive-manufacturing-2014.com

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of large-scale additive manufacturing solutions, announced that it recently received a purchase order from Lockheed Martin Space Systems to provide a turnkey electron beam additive manufacturing (EBAM) system. The EBAM system will help Lockheed Martin reduce time and cost on the production of titanium propulsion tanks.

On July 10, Sciaky announced the availability of EBAM systems to the marketplace. This is the second multi-million dollar order from a major global manufacturing company since the announcement. In addition, Sciaky is working with over a dozen other companies and entities within the aerospace, defense and manufacturing sectors to provide EBAM systems for their unique needs.

Lockheed Martin Space Systems designs, develops, tests, manufactures and operates a full spectrum of advanced-technology systems for national security, civil and commercial customers. Chief products include human space flight systems; a full range of remote sensing, navigation, meteorological and communications satellites and instruments; space observatories and interplanetary spacecraft; laser radar; fleet ballistic missiles; and missile defense systems.

Sciaky’s EBAM process combines computer-aided design (CAD), electron beam manufacturing technology and layer-additive processing. Starting with a 3D model from a CAD program, Sciaky's fully-articulated, moving electron beam gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining. The 110” x 110” x 110” (L x W x H) build envelope of the EBAM system will allow Lockheed Martin to produce large titanium parts, with virtually no waste.

“Sciaky is proud to partner with a progressive leader like Lockheed Martin Space Systems” said Mike Riesen, general manager of Sciaky, Inc. “Sciaky’s EBAM technology will help Lockheed Martin significantly reduce material costs, lead times, and machining times.”

Besides offering innovative additive manufacturing solutions for metal parts, Sciaky provides state-of-the-art electron beam and advanced arc welding systems, as well as job shop/contract welding services, for manufacturers in the aerospace, defense, automotive, and healthcare industries. Sciaky’s welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

For information, visit: www.sciaky.com

Published in Sciaky

The Association For Manufacturing Technology and VDW – Verein Deutscher Werkzeugmaschinenfabriken (German Machine Tool Builders’ Association) announced at IMTS – The International Manufacturing Technology Show 2014 a partnership to present the International Additive Manufacturing Award annually, beginning in 2015.

The award will recognize innovations in additive manufacturing for industrial applications. This includes developments in the design of systems or major components, advances in processes or materials, new applications, data generation or measurement.

Those in the industry, such as system producers, users, component suppliers, and data modelers, and international academia will be invited to apply. The inaugural winner will be announced at an award dinner at The MFG Meeting, Manufacturing for Growth, taking place March 4-7 in Orlando, Florida.

In 2016, the award will be presented at the METAV, the international fair for manufacturing technology and automation, in February in Düsseldorf, Germany.

The applications will be evaluated by a high-ranking international jury comprised of representatives from industry, academia, the health sector, the media, and trade associations.

AMT and VDW founded the International Additive Manufacturing Award program recognizing that the United States and Germany are the key markets/regions for additive technology in terms of suppliers, users and academia. Both partners have the understanding required to encourage the international community to participate in this initiative and support the exchange of views and knowledge.

AMT – The Association For Manufacturing Technology President – Douglas K. Woods said “It is clear that the advances in additive manufacturing will change forever the landscape of manufacturing, from the innovators of the technology to the users and consumers. Our collaboration with the VDW will spotlight some of the most innovative and impactful players driving this dynamic industry.”

VDW – German Machine Tool Builders’ Association - Executive Director – Dr. Wilfried Schäfer, added “Additive manufacturing has now, following a lengthy phase of development, matured sufficiently to establish itself more firmly as a technology for industrial-scale applications. In conjunction with AMT, the VDW aims to support all interested companies from the relevant sector in technical and market-related issues. With the International Award, moreover, we want to turn the international spotlight on the pioneers and high-performers in the sector, and give them the recognition they deserve. The idea is that the premier players from academia, the business and industrial communities, from the political environment and from societal stakeholders in this multifaceted scene, shall get together regularly at the award ceremonies, so as to put in place a stable international network.”

The winner will receive a $20,000 cash prize and a media package valued at $80,000 to promote the winning development.

Published in AMT

The current generation of satellites includes metal brackets that serve as a link between the body of a satellite and the carbon fibre reflectors and feed array mounted at the upper end. Engineers at the Spanish arm of EADS Group division, Airbus Defence and Space, is using additive manufacturing equipment from EOS to produce the retaining brackets at its competence centre for composite materials in Madrid.

The brackets must fix securely to the satellite body and withstand high thermal stresses caused by extreme temperature fluctuations in space, ranging from -180°C to +150°C. Titanium is the material of choice for such applications due to its thermal conductivity properties and high strength-to-weight ratio. The latter is especially important, as every kilogram carried into space costs many thousands of dollars, often running into six figures depending on the carrier system and the orbit to be reached.

Brackets manufactured by conventional metalcutting did not meet the requirements of Airbus Defence and Space, as design limitations prevented optimisation of the weight of the component and the stresses. Moreover it was very time consuming, so costs needed to be reduced.

Additive manufacturing technology from EOS was selected as an alternative production method. The bracket is built up from successive layers of metal powder that are melted and hardened by a laser beam driven by data that originates from the CAD model of the part. Titanium is still usable as a tried and tested material and the process allows the design of components to be adapted easily.

Otilia Castro Matías, who is responsible for antennae at Airbus Defence and Space in Madrid explained, "Additive manufacture has two main advantages. We are not only able to optimise the design of parts but can also produce them in one piece.

“When the precision workpiece is complete, no excess material remains except for raw titanium powder that can be reused in our EOSINT M 280.”

The new devices meet all expectations of the experts involved. Most important of all is the improved temperature resistance of the entire structure, which now can easily and permanently withstand a 330°C temperature variation under a force of 20 kN. In addition, production time for the three brackets required for each satellite has been reduced by five days to less than one month.

Mr Matías added, "Thanks to additive manufacturing, we were able to redesign the bracket and eliminate the vulnerability caused by thermal stress at the interface with the carbon fibre panel.

"The improvements also significantly reduced thermally induced failure during the qualification test campaign. The cost of space activities is relatively high, so it is especially important to protect any hardware from possible failure.

"Additive manufacturing brought measurable benefits to critical aspects of the project without requiring cuts to be made elsewhere, so there were no compromises – something engineers don’t get to hear very often.

“In addition, cost savings in bracket production amounted to more than 20 per cent and the weight was reduced by about 300 grams, which means a saving of nearly one kilogram per satellite.”

The European Space Agency (ESA) supported this program, the successful completion of which allows further use of this efficient production technology in the field of aerospace.

Airbus Defence and Space, a division of Airbus Group, was formed on 1st January 2014 by combining the business activities of Cassidian, Astrium and Airbus Military. The new division is Europe’s number one defence and space enterprise and the second largest space business worldwide.

One of the titanium brackets, additively manufactured in an EOSINT M 280, that connects the body of a satellite with the carbon fibre panel of the reflectors and feeder facilities at the upper end.

Published in EOS

The Additive Manufacturing Users Group (AMUG) announced that online registration is now available for its 2015 Education & Training Conference, which will be held in Jacksonville, Florida, from April 19 – 23, 2015. The users group conference, now in its 27th year, is open to owners and operators of all additive manufacturing (3D printing) technologies.

Mark Barfoot, AMUG president, said, “I am quite excited to be building an agenda that continues to deliver a wealth of hands-on experiences and extremely practical sessions where users gain real insight into techniques or tips that they can take back to the office and start using right away.”

AMUG brings together engineers, designers, managers, and educators from around the world to share expertise, best practices, challenges, and application developments in additive manufacturing. The AMUG Conference will include technical sessions and hands-on workshops designed to help users get more from, and do more with, their systems. Through technical competitions and the annual Awards Banquet, excellence in applying AM and contributions to the industry will be recognized. The five-day event also includes the two-night AMUGexpo, networking receptions and catered meals.

Barfoot said, “What distinguishes AMUG’s conference from all others are the continuous opportunities provided each day for networking and growing your knowledge base. You can easily justify your trip based on the hands-on sessions, but I guarantee that if you actively participate, you will generate more contacts and learn more from casual conversations than you will in the structured conference activities.”

“For the first time, we will have a business track that will help those that are now involved in the business aspects of overseeing a department. Participants will walk away with a better understanding about financing options, investor inquiries and patent concerns, to name a few of the topics. This will be extremely valuable for career growth, and it will provide key points to bring back to management teams,” Barfoot added.

AMUG is an organization that educates and advances the uses and applications of additive manufacturing technologies. AMUG members include all commercial additive manufacturing/3D printing technologies for companies such as 3D Systems, Stratasys, Concept Laser, ExOne, Renishaw and SLM Solutions. AMUG meets annually to provide education and training through technical presentations on processes and new technologies. This information addresses operation of additive manufacturing equipment and the applications that use the parts they make.

For more information, visit: www.am-ug.com

Published in AMUG

Building on the great success of the inaugural Additive Aerospace Summit last year, Infocast has announced the annual second Additive/Aerospace Summit 2014, scheduled for November 3-6, 2014, taking place in Downtown Los Angeles.

Direct part production in metals (and other advanced materials) is the new frontier of aerospace. Every week a new breakthrough is touted: turbine, injector, fuel vessel, wing span. Air forces, OEMs, MRO players and “New Space” startups are growing their use of additive for a wide range of parts, whether it be for ultimate use in passenger or cargo planes, fighter jets, rockets, helicopters, UAVs, satellites, and perhaps someday, …entire space stations? However, aerospace is exacting in the extreme when it comes to materials, and additively produced materials have new properties. Intensive coordination between all stakeholders must take place before additively made parts can be qualified for flight, and the full market unleashed for these new solutions.

Top Officials, R&D directors, additive program managers and thought leaders including:

AIRBUS ¦ BOEING ¦ LOCKHEED MARTIN ¦ SIKORSKY ¦ GKN AEROSPACE ¦ PRATT & WHITNEY ¦ NASA ¦ AGC AEROSPACE & DEFENSE ¦ BELL HELICOPTER ¦ RAYTHEON ¦ DELTA AIRLINES ¦ SPACE SYSTEMS/LORAL ¦ ORBITAL SCIENCES ¦ MET-L-FLO ASTM F42 COMMITTEE ¦ NLR ¦ TNO ¦ SINTEF RAUFOSS MANUFACTURING AS ¦ NATIONAL RESEARCH COUNCIL CANADA ¦ UNIVERSITY OF LOUISVILLE ¦ 3DSIM LLC ¦ PENN STATE UNIVERSITY ¦ AMERICAN WELDING SOCIETY ¦ NAYANG TECH UNIVERSITY ¦ TETHERS UNLIMITED ¦ AREVO LABS ¦ NORTHERN ILLINIOS UNIVERSITY ¦ WICHITA STATE UNIVERSITY ¦ MISSOURI UNIVERSITY OF SCIENCE & TECHONOLOGY ¦ GEORGIA STATE UNIVERSITY ¦ STRATONICS INC. ¦ HARVEST TECHNOLOGIES ¦ EOS OF N.A. ¦ VARIA 3D ¦ FABRISONIC LLC ¦ I3D MANUFACTURING and many more, will gather to share their plans, programs, requirements and timelines for what they need collectively to drive this emerging industry forward.

The Summit will be preceded by FOUR sessions covering the technical challenges, capabilities, and solutions for this white hot innovation sector.

  • Incodema3D’s Laser Metals for Direct Parts Tutorial | November 3, 2014
  • Additive Manufacturing for Aerospace 101 Workshop | November 4, 2014
  • Qualification Technical Symposium | November 4, 2014
  • Direct Manufacturing Platforms Showcase | November 4, 2014

This will be the premiere networking event of the year for decision-makers to prepare for extreme acceleration in 2015!

For more information or to register, visit: www.infocastinc.com/events/add-aero

Published in Infocast

Aerojet Rocketdyne, a GenCorp (NYSE: GY) company, was recently awarded a contract by Wright-Patterson Air Force Base through the Defense Production Act Title III Office for large-scale additive manufacturing development and demonstration. The contract will secure multiple large selective laser melting machines to develop liquid rocket engine applications for national security space launch services. Aerojet Rocketdyne and its subcontractors will design and develop larger scale parts to be converted from conventional manufacturing to additive manufacturing (3D printing).

“Our liquid rocket engines have been used for half a century and our products are highly efficient and complex with a safety and reliability record that is unparalleled,” said Jeff Haynes, program manager of Additive Manufacturing at Aerojet Rocketdyne. “Incremental manufacturing advances have been applied over the history of these programs with great success. Additive manufacturing shifts these advances into high gear and ultimately transforms how these engines are produced.”

“We have developed and successfully demonstrated additive-manufactured hardware over the last four years but the machines have been limited in size to 10-inch cubes,” said Steve Bouley, vice president of Space Launch Systems at Aerojet Rocketdyne. “These next generation systems are about six times larger, enabling more options for our rocket engine components. We are extremely honored to have received this contract, and foresee the day when additive-manufactured engines are used to boost and place important payloads into orbit. The end result will be a more efficient, cost-effective engine.”

Under the contract, Aerojet Rocketdyne will demonstrate three different alloys with these larger additive manufacturing machines to include nickel, copper and aluminum alloys. Parts ranging from simple, large ducts to complex heat exchangers are planned to be demonstrated in full scale. The program scope is expected to replace the need for castings, forgings, plating, machining, brazing and welding.

Aerojet Rocketdyne is a world-recognized aerospace and defense leader providing propulsion and energetics to the space, missile defense and strategic systems, tactical systems and armaments areas, in support of domestic and international markets. GenCorp is a diversified company that provides innovative solutions that create value for its customers in the aerospace and defense, and real estate markets.

For more information, visit: www.Rocket.com

Published in Aerojet Rocketdyne

Continuing to advance his JOBS 1st PA initiative, Governor Tom Corbett announced the award of a Discovered in PA – Developed in PA grant to Carnegie Mellon University and Lehigh University to support the Research for Advanced Manufacturing in Pennsylvania program, created to engage in specific innovation projects with Pennsylvania manufacturers.

"Pennsylvania is known for making products for the world, and to remain competitive, we must ensure our policies support the technology and innovation of the 21st century," said Corbett. "By supporting this collaborative initiative, we will tap the best and brightest from two of Pennsylvania's many prestigious universities to help our manufacturers remain leaders in the global economy."

The Research for Advanced Manufacturing in Pennsylvania program (RAMP) will operate as a competitive funding program that will provide small incentive grants to faculty-led teams at both Carnegie Mellon University and Lehigh University to engage in specific, short-term innovation projects with a Pennsylvania manufacturing company to rapidly develop and transfer innovative technologies to help Pennsylvania manufacturers to compete in the global marketplace.

Carnegie Mellon University (CMU) will receive a $1 million grant from the Discovered in PA—Developed in PA (D2PA) program to support the partnership between CMU and Lehigh's research on additive manufacturing also knows as 3-D printing. The use and deployment of this technology will support the efficiency and competitiveness of manufacturers within the commonwealth.

The governor was joined for the visit by America Makes, Carnegie Mellon and Lehigh Universities at 3D Systems, one of the largest 3D printing manufacturers and a partner on this project.

"Pennsylvania has taken a clear leadership role by actively advancing additive manufacturing in the commonwealth demonstrated by its investment to America Makes through the states Research for Additive Manufacturing in Pennsylvania (RAMP) initiative," said Jim Williams, VP of Aerospace and Defense, 3D Systems. "These programs, supported by Pennsylvania, Governor Corbett, America Makes, Pennsylvania's universities and 3D Systems, will advance 3D printing manufacturing technology, to become pervasive in industry which will lead to increased jobs assuring our national security."

Today's announcement will support at least 10 projects that include the fabrication of medical instrumentation for knee and hip replacement and complex additive processing parameters with various materials.

RAMP provides technical and economic benefits to the state's small, medium and large-sized manufacturing companies by enabling knowledge transfer, the discovery of new technologies and retention of highly-skilled students.

"Through investments made with our students and manufacturers, we will ensure that our students are provided with high-quality educational programs that will help them secure good paying jobs upon graduation," Corbett said.

A $1 million grant to Lehigh University from America Makes, the National Additive Manufacturing Innovation Institute and private industry contributions, has also been provided in matching dollars to fund the project.

"Additive manufacturing shrinks the distance between what we can imagine and what we can make," said Alan J. Snyder, Ph.D., Vice President and Associate Provost for Research and Graduate Studies, Lehigh University. "The RAMP program provides a proven means of doing what needs to be done to capitalize on the potential of additive manufacturing, in what will be a fast-moving and hotly competitive environment: connecting university research and talent development with Pennsylvania companies that can deliver new products and capabilities to customers."

"The advanced manufacturing R&D enabled by the RAMP 2 program will create a strong collaborative environment to make Pennsylvania companies more competitive in the nation and in the global marketplace," said Burak Ozdoganlar, Ph.D., RAMP Co-Director, Director of the Institute for Complex Engineered Systems, Carnegie Mellon University. "Manufacturing competitiveness is vital to retaining and increasing high-technology jobs in Pennsylvania, as well as retaining our best and brightest students in the state."

Additive technology employs computer design and computer-driven machinery to build complex parts and devices in microscopic layers, using plastics or powdered metals. The technology makes it possible to create shapes and designs previously impossible through traditional manufacturing methods.

D2PA was established by Corbett in 2011 to build capacity to support Pennsylvania businesses and to spur creativity and innovation in the provision of economic development services. Last fiscal year, the D2PA program supported initiatives tied to growing the life sciences, advanced manufacturing, business incubators, and education, workforce and economic opportunity collaborations

For more information, visit: www.ices.cmu.edu/ramp/home.asp

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of large-scale additive manufacturing solutions, announced that it received a purchase order from a major aerospace parts maker to provide an electron beam additive manufacturing (EBAM) system. The EBAM system will help the manufacturer save significant time and cost on the production of large, high-value metal parts.

On July 10, Sciaky announced the availability of EBAM systems to the marketplace. This is the first of two multi-million dollar orders from a major global manufacturing company since the announcement. In addition, Sciaky is working with over a dozen other companies and entities within the aerospace, defense and manufacturing sectors to provide EBAM systems for their unique needs.

Sciaky’s EBAM technology combines computer-aided design (CAD), electron beam welding technology and layer-additive processing. Starting with a 3D model from a CAD program, Sciaky's fully-articulated, moving electron beam welding gun deposits metal, layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining. The 110” x 110” x 110” (L x W x H) build envelope of the EBAM system will allow the manufacturer to produce large parts, with virtually no waste.

“Sciaky is proud to partner with this major aerospace parts manufacturer” said Mike Riesen, general manager of Sciaky, Inc. “The EBAM system will certainly give them a competitive advantage in the marketplace.”

Besides offering innovative additive manufacturing solutions for metal parts, Sciaky provides state-of-the-art electron beam and advanced arc welding systems, as well as job shop/contract welding services, for manufacturers in the aerospace, defense, automotive, and healthcare industries. Sciaky’s welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

Sciaky, Inc., a subsidiary of Phillips Service Industries, is the world leader in large-scale, high-value metal additive manufacturing (AM) solutions. Our exclusive AM process, known as Electron Beam Direct Manufacturing (EBDM), allows manufacturers to save time and money over traditional manufacturing and prototyping processes. Sciaky also provides industry-leading electron beam, advanced arc and resistance welding systems, as well as contract welding services, for the aerospace, defense, automotive, healthcare and other industries. Our welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

Established in 1967, Phillips Service Industries, Inc. (PSI) is a privately-held global manufacturing and services holding company, which oversees a diverse collection of innovative subsidiaries: Beaver Aerospace & Defense, Inc., Evana Automation Specialists, Mountain Secure Systems, POWERTHRU, PSI Repair Services, Inc., PSI Semicon Services, Sciaky, Inc., and Skytronics, Inc. We serve a wide range of high-tech industries like aerospace, defense, automotive, alternative energy, healthcare, security and semiconductor. Our award-winning products and services help reduce costs and maximize efficiency for many Fortune 500 companies around the globe, as well as the U.S. Military. We push the boundaries of technology on critical programs like Homeland Security, Defense research and space exploration, delivering innovative solutions for land, sea, air and space.

For information, visit: www.sciaky.com

Published in Sciaky

High grade biomedical implants, automotive and aerospace parts are among the objects that can be made from metal powders using additive manufacturing processes. The makers and users of metal powders will be among those who will benefit from a new ASTM International standard, ASTM F3049, Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes.

John A. Slotwinski, a physicist at the National Institute of Standards and Technology (NIST) and an ASTM member, notes that the new standard will help those who are faced with the large number of existing standards on metal powder properties.

“ASTM F3049 will point readers to existing metal powder standards that may be appropriate for additive manufacturing powders,” says Slotwinksi. “It will provide guidance for someone who may want to measure the properties of AM powders but doesn’t necessarily know what standard methods exist.”

In addition to ASTM F3049, Slotwinksi says that a companion standard covering the mechanical properties of metal parts, ASTM WK43112, Guide for Evaluating Mechanical Properties of Materials Made Via Additive Manufacturing Processes, is also in the works.

ASTM F3049 was developed by Subcommittee F42.05 on Materials and Processes, while ASTM WK43112 is under the jurisdiction of Subcommittee F42.01 on Test Methods. Both subcommittees are part of ASTM International Committee F42 on Additive Manufacturing Technologies.

ASTM International welcomes participation in the development of its standards.

ASTM Committee F42 Next Meeting: Jan. 26-27, 2015, ASTM International Headquarters, West Conshohocken, PA

For more information, visit www.astm.org/sn-quality

Published in ASTM

CVMR Corporation (“CVMR®”) announced its intention to establish three new divisions in the United States: Metal Powder Manufacturing; Metal Additive Manufacturing (3D Printing) Equipment Design and Development; & Metal Powder Innovation Centre.

The Metal Powder Manufacturing plant and Metal Additive Manufacturing Plant will be housed in Kentucky and the Metal Powder Innovation Centre will be located in Tennessee. Phase 1 of all three Divisions will be operational by December 2015, and will gradually expand over the following 3 years.

CVMR Corporation (“CVMR®”) manufactures pure metal powders, metal nano powders, and metal alloy powders of various morphologies, specifically for the additive manufacturing sector. CVMR® uses its proprietary Carbonyl and other proprietary Vapour Metallurgical processes in manufacturing these powders.

CVMR® has partnered with a number of prominent equipment manufacturers in the Additive Manufacturing and 3D Printing field in order to design and build state of the art equipment, using CVMR®’s metal powders as feed material. “This will create a fully integrated operation, from the mineral sources to the end-user products for CVMR®. We either own most of the mining concessions that supply the raw material for our operations, or we have long-term off take agreements with prominent mining companies who supply us with various metal ores or concentrates, worldwide. We refine those minerals, using our proprietary processes and technologies, and now our clients can actually use our metal powders using our equipment to manufacture state of the art end user products," Dr. Kamran M. Khozan, Chairman and CEO of CVMR®, announced at a press conference in New York, today.

He added, “We are currently negotiating with a number of multinational corporations, in the United States and Europe, that have the technical know-how, to partner with us in developing the next generation of additive manufacturing equipment such that they can be used in as many industries as possible, almost off the shelf.”

CVMR® has also carried out extensive research in new methods of Extrusion molding, using metal powders.

The following metals powders and their various alloys are currently being produced by CVMR®: Nickel, Iron, Chromium, Cobalt, Molybdenum, Tungsten, Vanadium, Titanium, Tantalum, Niobium, and others.

These metals and their various alloys are produced by CVMR® from low cost feed sources, such as CVMR®’s own mineral concessions, low-grade ores, concentrates, and scrap metals. Dr. Khozan added, “Our technology allows us to refine low grade ores, quite efficiently. That has helped us to compete in quality and price, simultaneously, in the additive manufacturing market. The development of our fully integrated systems is yet another step in that direction.”

Besides metal powders, CVMR® produces net shapes, coatings and super alloys for the electronics and other high tech industries.

CVMR Corporation (CVMR®) is a privately held multinational organization with its head office and R&D Centre in Toronto, Canada. It is engaged in manufacturing of high value metal powders, net shapes and super alloys using CVMR®’s proprietary vapour metallurgy processes and providing a range of technologically innovative solutions to the mining, refining and metal powder manufacturing industries. CVMR® employs over 42,000 technicians and engineers in 18 countries.

For more information, visit: www.cvmr.ca

Published in CVMR

Arcam launched a process for Inconel 718® as a qualified material for use in Arcam’s EBM systems. The Inconel process is initially available for the Arcam A2X platform. The machine material parameters and mechanical testing was done in collaboration with the U.S. Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory. Parts made in the new process are exhibited at the Rapid conference in Detroit, MI, June 10-12.

“With the introduction of the Inconel 718 our customers in the aerospace industry can now further expand the range of components that they produce in their EBM machines”, says Magnus René, CEO of Arcam.

The material properties comply with chemical requirements of UNS N07718 and properties of ASTM F3055-14 specification.

INCONEL® is a registered trademark of Special Metals Corporation.

Arcam provides a cost-efficient Additive Manufacturing solution for production of metal components. The technology offers freedom in design combined with excellent material properties and high productivity. Arcam’s market is global with customers mainly in the orthopedic and aerospace industries. The company was founded in 1997 and is listed on NASDAQ OMX Stockholm, Sweden. Head office and production facilities are located in Mölndal, Sweden. Support offices are located in the US, UK, Italy and China.

For more information, visit: www.arcam.com

Published in Arcam

Additive manufacturing is changing the way organizations design and manufacture products around the world. Here, the U.S. Army Aviation and Missile Research Development and Engineering Center, NASA's Marshall Space Flight Center, and the University of Alabama in Huntsville, are leading a collaborative effort to share knowledge and resources to promote this emerging technology.

Additive manufacturing, or AM, refers to a process by which digital 3-D design data is used to build up a component by depositing successive layers of liquid, powder, paper, or sheet material. Many have identified additive manufacturing as a potential game changer with important implications to national security and the federal government.

In May, leaders from AMRDEC and MSFC officially established an Additive Manufacturing Integrated Product Team. The IPT's mission is to engage in research and development efforts that advance the state of the art in AM to ensure that Team Redstone can capitalize on the rapid advancements in this technology.

Members of the IPT include, from AMRDEC, Dr. Amy Grover, Brian Harris, Keith Roberts, William Alvarez, Pete Black, and Patrick Olinger; and from MSFC, Niki Werkheiser, Ken Cooper, and Erin Betts.

"When you come to learn and appreciate the potential of AM, it's hard not to judge this as a true game-changer; one that will ultimately have far reaching, historical impacts onto our society at-large," said acting AMRDEC Director James Lackey.

AMRDEC is looking currently at trade studies investigating AM, to minimize cost and optimized performance of missile structures, using topology optimization routines to enhance design and analysis of AM built structures, and characterizing materials and processes for specific missile applications.

"Teaming with NASA MSFC and other partners, AMRDEC will investigate procurements of AM machines to support our research needs, build a cadre of engineers and scientists savvy on this technology, fabricate and performance test qualify components for ground and flight test," he said.

Dr. Dale Thomas, Marshall Center's associate director, technical, signed the IPT charter for NASA.

"Additive manufacturing is a step toward the future," he said. "It is changing the way organizations design and manufacture products around the world, and space is one of the key places where humanity will see the impact of this technology."

The agreement was facilitated by Phil Farrington, professor of industrial and systems engineering and engineering management at the University of Alabama in Huntsville.

"This effort continues a long tradition of collaboration between the AMRDEC and Marshall. This exciting new technology has the potential to radically change the way we manufacture aerospace and defense systems," said Farrington. "One of the team's goals is to identify additive manufacturing research and development needs of greatest importance to the defense and space community."

AMRDEC is part of the U.S. Army Research, Development and Engineering Command, which has the mission to develop technology and engineering solutions for America's Soldiers.

RDECOM is a major subordinate command of the U.S. Army Materiel Command. AMC is the Army's premier provider of materiel readiness -- technology, acquisition support, materiel development, logistics power projection, and sustainment -- to the total force, across the spectrum of joint military operations. If a Soldier shoots it, drives it, flies it, wears it, eats it or communicates with it, AMC provides it.

For more information, visit: www.amrdec.army.mil/amrdec

Published in Army

Leading additive manufacturing experts are due to speak at Asia’s premier 3D printing summit, an upcoming two-day event dedicated to exploit the growth of additive manufacturing products and services which is worth an estimated $3.7 billion worldwide by 2015.

The meeting, hosted by Technology IQ – a division of global events company IQPC – will be a unique opportunity for commercial additive manufacturing end-users, vendors and service bureaus to discuss if this technology will be a sustainable production approach, as well as strategies for manufacturing lighter weight products with less raw materials and lesser cost penalties, if any.

“It has allowed us the freedom to create. We now have a greater design capability that is more cost effective and we can pass these cost savings on to our customers. Another benefit is that production is less cumbersome compared with traditional methods” cited Harry Kleijnen, Manager Development Grids, Philips Healthcare.

Also noted by Keyur Gupte, Senior Project Manager of Tata Technologies, “We’ve reduced design iterations and this has resulted in a shorter design cycle time. And in turn, it’s a shorter time to market.”

With additive manufacturing taking centre-stage in Asia and especially so in Singapore, over 85 other commercial additive manufacturing experts from industries including medical, defense, industrial to consumer products are expected at the event; all of whom bring expert knowledge of based on hands-on experience – from process development to industrialisation for 3D printed products.

The Additive Manufacturing Asia 2014 summit will take place on July 23-24, 2014 in Singapore and special introductory rates are available for Singapore SMEs.

For more information or to register, visit: www.AdditiveManufacturingAsia.com

Published in IQPC

EOS, the technology and market leader in design-driven, integrated e-manufacturing solutions in the field of Additive Manufacturing (AM), will be exhibiting its products at its stand at this year‘s Rapid.Tech, on May 14-15 in Erfurt. At stand 2-301 in Hall 2, the company will be displaying its brand-new EOS M 290 system, the successor to the established and market-leading EOSINT M 280, designed for the tool-free production of high-quality serial components, spare parts and prototypes. With a build volume of 250 mm x 250 mm x 325 mm, the EOS M 290 permits flexible and economic manufacturing of metal components.

Dr. Adrian Keppler, CMO at EOS stresses, “EOS has incorporated proven elements from the M 280 system generation in the new EOS M 290, but at the same time, the EOS M 290 also allows us to set new standards in Additive Manufacturing while expanding our product portfolio for metal applications and extending our innovation leadership in terms of quality management and monitoring. This new system is designed to serve the requirements of our serial-production customers. At the same time, we have also created new optimisation potential in terms of build quality for customers from the prototyping space.” Despite all the innovations that have been incorporated in the EOS M 290, its central processing elements have been retained: process chamber, gas stream, process parameters, etc. This ensures constant process behaviour and in turn consistent component quality beyond the EOSINT M 280 and EOS M 290.

Extensive quality management, expanded monitoring functions, EOSTATE

The new EOS M 290 offers extensive monitoring functions both for the system itself and for monitoring the build process. This adds even more extensive quality assurance to the field of Additive Manufacturing. In particular, it makes the system attractive for industrial applications in the aerospace industry as well for medical applications. With the aid of EOSTATE PowderBed, a camera built into the process chamber monitors the powder bed, following powder deposition and exposure, by means of still images. EOSTATE Base ensures the consistent monitoring of a range of parameters, including the position of the Z axis or scanner, laser power, air humidity, temperature and pressure. Finally, EOSTATE LaserMonitoring measures the laser power throughout the entire build period.

Flexible components and extensive accessories

The system is equipped with a 400 Watt laser, which is characterised by its high radiation quality and stability of performance. The EOS M 290 can be operated under an inert (nitrogen) atmosphere or under argon, which permits processing of a great breadth of materials. These include light alloys, stainless and tool-grade steels, and superalloys. The EOS parameter sets ensure that parts can be manufactured with standardised property profiles, resulting in a broad spectrum of applications. As with the previous model, EOS also supplies its EOS M 290 customers with the EOS ParameterEditor, to allow them to modify a range of exposure parameters for themselves. The tool enables customers to develop their own parameters for specific applications on the basis of the EOS parameter sets. These include laser power and exposure speed or strategy. A new version of the Parameter Editor is currently under development, which will also allow modification of layer thickness, inert gas stream, build platform temperature, and skip layers.

High level of user friendliness, optimised process gas management, intuitive software

The EOS M 290 has been rendered even more user friendly thanks to the new EOSYSTEM machine software, which allows intuitive and task-oriented operation of the system via a graphic user interface, which was developed especially for production environments. In addition, an operator assistant is included which guides the user through the program. The new EOSPRINT Desktop Software allows jobs to be prepared and computed directly at the workplace, separately from the build process. The job file can then be transferred through the network to the system, which can then concentrate fully on building the part. Thanks to the availability of offline job preparation, complex parts with large job files can be processed quickly. This in turn improves the flexibility of the application development process.

Process gas management has also been optimised. The EOS M 290 is fitted with an air circulation filter which itself is equipped with an automatic self-cleaning function. This considerably increases the filters operating life, with the result that they require less frequent replacement. It also reduces filter costs.

The solution portfolio for the EOS M 290 also includes data preparation software, component handling devices, and extensive services.

Founded in 1989 and headquartered in Germany, EOS is the technology and market leader for design-driven, integrated e-Manufacturing solutions for Additive Manufacturing (AM), an industrial 3D printing process. EOS offers a modular solution portfolio including systems, software, materials and material development as well as services (maintenance, training, specific application consulting and support). As an industrial manufacturing process it allows the fast and flexible production of high-end parts based on 3D CAD data at a repeatable industry level of quality. As a disruptive technology it paves the way for a paradigm shift in product design and manufacturing. It accelerates product development, offers freedom of design, optimizes part structures, and enables lattice structures as well as functional integration. As such, it creates significant competitive advantages for its customers.

For more information, visit: www.eos.info/eos_m_290_metal_additive_manufacturing_system

Published in EOS

TRUMPF has agreed on a joint venture in the additive manufacturing sector. The partner is Italy's biggest laser manufacturer SISMA S.p.A., which has a 45-percent stake in the new enterprise while TRUMPF has a 55-percent interest. Both partners are bringing expertise, human resources and capital to the joint venture. TRUMPF SISMA S.r.l. is based in Piovene Rocchette near Vicenza, Italy. There, TRUMPF and SISMA plan to co-develop latest-generation production systems for the 3D printing of metal components.

The technology known as 'additive manufacturing' enables any component to be built up directly from a 3D design program. The parts are created layer by layer from metallic powder, using the power of the laser. The technology has the potential of partially replacing methods such as milling or casting. The components are just as durable and long-lasting as their conventionally produced counterparts.

Today, companies from the most diverse sectors are qualifying components and products suited to additive manufacturing rather than the conventional methods utilized until now. To offer solutions here, TRUMPF is working on rapid entry into this market - at its headquarters in Ditzingen as well as together with SISMA. The two joint venture partners, with their high level of expertise in laser and mechanical engineering, want to provide robust and productive machines for mass production. "Many machines on the market today are aimed more at prototype construction," explains Dr. Peter Leibinger, head of TRUMPF Laser Technology. "In the future, however, the most important criterion where additive manufacturing lines are concerned will be their suitability for industrial applications."

Several years ago SISMA did begin work on developing an additive manufacturing machine for the production of small metallic components - and the Italian company is bringing this expertise to the joint venture. With annual sales of 33 million Euro and around 1000 laser devices sold each year, SISMA is the biggest laser manufacturer in Italy. The company has around 130 employees and can look back on over 50 years of experience in precision mechanics and industrial automation. The target markets of the innovative laser and systems supplier are primarily jewelry, fashion, dental and industry.

TRUMPF entered the additive manufacturing sector as a pioneer back in the year 2000. The "TrumaForm" - a universal tool for the generative manufacturing of metallic materials - was, however, years ahead of its time because the market for serial production of components had not yet developed. At the start of this year TRUMPF entered the additive manufacturing business once again, and is now benefiting from the results of earlier development work as well as from its ever increasing expertise in the related process of laser deposition welding, which is already being used today in all kinds of sectors for repair and coating applications.

For more information, visit: www.trumpf.com

Published in TRUMPF

MIT Professional Education has added Additive Manufacturing: From 3D Printing to the Factory Floor to their Short Programs offerings. Designed for US and international manufacturing and design engineers, science, and architect professionals who seek the MIT experience in a condensed timeframe, the course will focus on a comprehensive overview of additive manufacturing spanning from fundamentals to applications and technology trends.

Enrollment is now open to qualifying professionals from the U.S. and abroad through the MIT Professional Education website.

The course will be held July 21 – 25 on MIT’s campus in Cambridge, Mass. and will be taught by John Hart, Associate Professor of Mechanical Engineering and Mitsui Career Development Chair at MIT.

“Additive manufacturing covers many application areas including aerospace components, electronics, medical devices, architectural designs, and consumer products,” said Hart. “Participants will take part in lab sessions that will provide a hands-on experience with a variety of state-of-the-art desktop 3D printers.”

“Our Short Programs courses give professionals from around the world the opportunity to learn from MIT faculty who are leaders in their field,” said Anna M. Mahr, director of Short Programs at MIT Professional Education. “They then take home valuable skills and working knowledge that can be applied directly to their work.”

MIT Professional Education provides a variety of education and professional training programs for science, engineering, and technology professionals worldwide. MIT Short Programs offer professionals more than 40 industry focused two to five-day sessions, taking place primarily in the summer on their campus in Cambridge, Mass. Participants learn from leading MIT faculty and gain crucial knowledge to help fuel their careers or enhance their companies in a collaborative academic setting. Upon completion, participants receive an MIT Professional Education certificate of completion, continuing education units, and access to MIT Professional Education’s expansive professional alumni network.

In addition to Additive Manufacturing: From 3D Printing to the Factory Floor, new Short Programs for summer 2014 include Beyond Smart Cities; Engineering Leadership for Mid-Career Professionals; and Understanding and Predicting Technological Innovation: New Data and Theory.

MIT Professional Education also offers national and international professionals the capability to take Short Programs courses abroad, regular MIT academic courses offered through the Advanced Study Program, online courses, or customize an educational experience for a group of employees at a company site. Students are drawn from across the U.S. and around the world, and about 30 percent are international.

For 65 years MIT Professional Education has been providing those professionals engaged in engineering, science and technology worldwide, a gateway to renowned MIT research, knowledge and expertise through advanced education programs designed specifically for working professionals.

For more information, visit: web.mit.edu/professional

GSMI recently opened delegate registration and sponsorship sales for the 3D Printing & Additive Manufacturing Summit + Expo, the first-ever 3DP/AM conference designed exclusively for business innovation strategies.  The summit will be held September 16-18th 2014, in Pittsburgh, PA.  A discount of $600 is available for summit attendees who register on or before June 6, 2014.

The summit will host more than 40 distinguished panelists and speakers, including business leaders, professors, scientists, lawyers, designers, policymakers, entrepreneurs, and investors. The purpose of the Summit is to discuss business strategies that incorporate 3D Printing/AM. Multiple sessions and workshops are offered to help attendees understand the economic impact of 3D printing and the long term trends, identify how to gain the competitive advantage by using 3D printing, learn practical applications for 3D printing, and gain practical knowledge from leading case studies.

Distinguished speakers include Jim Williams, Vice President Aerospace & Defense, AM R&D Program/Business Development at 3D Systems Corporation; David Bourell, Temple Foundation Professor, and Director at Laboratory for Freeform Fabrication at The University of Texas at Austin; Bill Macy, Deputy Director at America Makes; Tom Kurfess, HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion Control and Professor at Georgia Institute of Technology as well as many more.

“We are thrilled with the warm reception that this Summit has received, not only from the speakers but the public in general,” said Crystal Everson, Director, Conference Production at GSMI.

GSMI is a leader in the industry of executive education, global conferences, summits, and training sessions that combine rich learning environments with the opportunity to network with today’s most relevant thought leaders, speakers and practitioners. GSMI’s annual events have reached 80% of the Fortune 500 companies, in over 30 countries, and cover topics that today’s leaders find most challenging and inspiring.

For more information, visit: www.the3dprintingsummit.com

Published in GSMI

The manufacturing of final parts, rather than prototyping is where the manufacturing money is, and it is the most significant part of additive manufacturing’s future. This fast growing industry is gaining more and more interest and investment potential, because companies start to understand that these disruptive technologies are going to revolutionise manufacturing and traditional business models.

This exclusive marcus evans conference provides you with best-in-class case studies providing the most efficient ways of implementing additive manufacturing within existing business models. From top industry experts representing leading companies you will learn how to build a financially viable business case for additive manufacturing, how to establish effective processes quality controls and how to gain competitive advantage by leveraging new technological capabilities.

Industrial Additive Manufacturing & 3D Printing, Progressing from Prototyping to Digital Manufacturing and Moving Closer to Mass Production, will be held June 4-6, 2014 at the Mövenpick Hotel in Berlin, Germany.

Why You Should Attend

  • The manufacturing of final parts, rather than prototyping is where the manufacturing money is, and it is the most significant part of additive manufacturing’s future. This fast growing industry is gaining more and more interest and investment potential, because companies start to understand that these disruptive technologies are going to revolutionise manufacturing and traditional business models.
  • This exclusive marcus evans conference provides you with best-in-class case studies providing the most efficient ways of implementing additive manufacturing within existing business models. From top industry experts representing leading companies you will learn how to build a financially viable business case for additive manufacturing, how to establish effective processes quality controls and how to gain competitive advantage by leveraging new technological capabilities.

Key Topics

  • Incorporate additive manufacturing into the existing business structure
  • Apply effective cost modelling techniques to evaluate the most convenient production strategies
  • Make a smooth shift from prototyping to digital manufacturing
  • Optimise investments in manufacturing technologies and advanced materials
  • Innovate production through new and more flexible design capabilities

For more information, visit: www.marcusevans-conferences-paneuropean.com

Published in Marcus Evans
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