With simple changes such as automated transfers and print run layout, an additive manufacturing production process can be optimized to maximize output. Hear how ExOne takes “3D printing” into the realm of manufacturing production. Tom Pasterik, Manager of Application Engineering for The ExOne Company, will discuss what it takes to shift from 3D printing/prototyping to additive manufacturing production, using an example of a traditionally manufactured control arm from a domestic super car and making it using additive manufacturing processes. Learn how to shift from 3D printing/prototyping to additive manufacturing Understand the pros and cons of additive manufacturing Tips on finding the right internal structures for your designs Learn about the various direct metal printing processes

1. Tips for Additive Manufacturing
in Metal

2. Before We Start
 This webinar will be available afterwards at
designworldonline.com & email
 Q&A at the end of the presentation
 Hashtag for this webinar: #DWwebinar

3. Moderator
Presenter
Leslie Langnau
Tom Pasterik
Design World
ExOne

5. About ExOne
•
ExOne is a leading additive manufacturing
company dedicated to the industrial manufacturing
sector.
•
ExOne is a global supplier of industrial 3D printing
systems and offers design and manufacturing
services of 3D printed products.
•
ExOne Production Service Centers are located
throughout the United States, Germany and Japan.
•
ExOne systems are able to print in a variety of
industrial materials with the largest available build
sizes.

6. ExOne Global Facility Locations

7. Products Produced

8. ExOne Overview

9. Distinctive Technology Features
•
Largest build envelopes available
•
Finely detailed complex shapes
•
Print Speed
•
Final Product Accuracy
•
Industrial Grade Materials

10. Direct Metal Process
-
ExOne offers digital part materialization in several metals and metal
alloys, including:
•
316 Stainless Steel Infiltrated with Bronze
•
420 Stainless Steel Infiltrated with Bronze
•
Iron Infiltrated with Bronze
•
Bonded Tungsten
-
Additional material systems are currently in development, and
partnership opportunities are available for specific materials.
-
The 3D printing process in metal includes printing, curing, depowdering,
sintering, infiltrating and annealing.
-
Build Volume (WxDxH): 780 x 400 x 400 mm (30.7 x 15.75 x 15.75 in.)
-
Build Speed: 6 mm/hr (.24 in/hr)

11. In Direct Metal - Sand Process
-
ExOne offers digital part materialization in various
combinations of sand casting media and chemical binders,
depending on the desired strength and level of detail:
•
Silica Sand
•
Synthetic Sand
•
Other casting media
-
Digital production of sand molds and cores eliminates the
need for hard tooling and drastically reduces lead times.
-
Standard foundry industry materials are used, enabling easy
integration of the molds and cores into existing manufacturing
and foundry procedures.
-
This digital process offers design freedoms not possible in
molds and cores produced using the traditional pattern
approach.
-
Build Volume (WxDxH): 1800 x 1000 x 700 mm (70 x 39 x 27 in.)

12. ExOne Systems
M-Lab
M-Flex
M-Print
S-Print
S-Max

13. ExOne’s Process

14. ExOne’s Process

15. ExOne’s Process

16. Optimizing for Manufacturing
•
With simple changes such as automated transfers and print run
layout, an additive manufacturing production process can be
optimized to maximize output.

17. ExOne in a Factory Environment

18. Advantages of Additive Manufacturing
•
The digital process offers design freedoms not possible in
traditional molds, cores and machining approaches
•
Endless patterns and part geometry
•
Functional working prototypes for real life applications
•
Prototyping can turn directly into low or high volume
production runs
•
Draft angles can now be eliminated
•
No tool paths or tooling required
•
Advanced venting schemes and integrated rigging
features are also possible
•
Different parts can be built in a single print bed
•
Parts can be modified on the CAD file in seconds, and
reprinted without complicated tooling changes.

19. Project Overview
•
Advance optimization of a traditionally manufactured control arm from a domestic super car by using additive
manufacturing processes.
•
Push the boundaries of 3D metal printing and design inside a real and applied production workflow with
practical outcomes.
•
Examine existing and heavily optimized designs made using traditional methods and see if they can be
optimized even further using new modeling approaches.
•
Develop new workflows and processes that can directly capitalize on the many benefits that 3DP offers.
•
Reduce weight while still retaining the same structural properties of the what is said to be “already optimized”
traditional control arm.

20. The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part for three different 3DP
workflows:
•
Printed sand mold package for traditional
foundry casting
•
Conservative/constrained direct metal
printing
•
Unlimited direct metal printing

21. The Idea
Take existing production part and provide further
optimization and modeling in pre-constrained
areas of the part for three different 3DP
workflows:
•
Printed sand mold package for traditional
foundry casting
•
Conservative/constrained direct metal
printing
•
Unlimited direct metal printing

22. Unlimited Variable Geometry

23. Finding the Best Internal Structures

24. Initial Reference for Cellular Structure

25. Base Model Control Arm

26. Indirect Metal Printing Process and Cast

27. Advanced Control Arm Is Modeled with Free Constraints

28. Advanced Model Passes Simulation: Export

29. Direct Metal Printing Process

30. Direct Metal Printing – Final Product

31. Direct Fabrication

32. Project Specifications

33. Next Steps – Advanced Designs w/ Automatic Closed Loop Simulation Feedback

34. Services

36. Questions?
Design World
Leslie Langnau
llangnau@wtwhmedia.com
Phone: 440.234.4531
Twitter: @DW_3DPrinting
ExOne
Tom Pasterik
tom.pasterik@exone.com
Phone: 724.765.1361
www.exone.com

37. Thank You
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