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3D PRINTING

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Title: Le dispositif de protection du potentiel scientifique et technique de la nation Author: aa Last modified by: aa Created Date: 11/25/2015 9:46:20 AM – PowerPoint PPT presentation

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Title: 3D PRINTING


1
3D PRINTING
Chief armament engineer Richard
FINCK Direction des affaires
internationales, stratégiques et
technologiques Secrétariat Général de la Défense
et de la Sécurité Nationale
2
3D PRINTING FOR AEROSPACE The THOR UAV
The UAV, dubbed Thor for Test of High-Tech
Objectives in Reality, is a massive 4 m (13 ft)
in length, has a 4-m (13-ft) wingspan and weighs
25 kg (55 lbs) was unveiled this month by
Aibus. Manufacturing drones isnt new for
Airbus, but 3D printing them is. Thor is made up
of about 50 3D-printed parts, two electric
engines and a remote control. The 3D printing
process for Thor lasted roughly one month, and
the production cost was estimated to be around 20
000 .  This short manufacturing period is a key
reason behind Airbus decision to 3D print Thor,
as the flexibility that 3D printing offers could
allow designers and engineers to create new
aircraft on the fly. As Peter Sander, head of
emerging technologies and concepts at Airbus,
explained in his Innovation Days presentation,
"You can 3D print this kind of aircraft in four
weeks. It has low lead times for fast track
developments." 
With Thor acting as a small test bed, Airbus
hopes to demonstrate that the same flexible
design and manufacturing approach could be
applied to full-scale aircraft. Although Airbus
dream of a fully 3D-printed aircraft may not be
realized for some time, this methodology could be
applied to the numerous 3D printing endeavors
already being pursued by the company 3D-printed
fuel nozzles within its A320neo, numerous
components for the A350 XWB, bionic cabin
partitions, 3D-printed fuselage and engine pylon
parts.
3
3D Printing and additive manufacturing
3D printing, rapid prototyping or freeform
fabrication, is the process of joining materials
to make objects from 3D model data, usually layer
upon layer, as opposed to subtractive
manufacturing methodologies such as machining.
The term 3D printing can be defined as the
fabrication of objects through the deposition of
a material using a print head, nozzle, or another
printer technology.
Additive manufacturing with metal powders is a
new and growing industry for industrial
applications. The presentation will focus on this
specific segment only.
Some day
Today
Tomorrow
Ceramics
Organic
Polymers
Metal
ABS
Alumine
Wax
Steel, Inox
Polyamide PA
Mullite
Cells
Ti
Zr
Biological material
PEEK
Ni
Epoxydes
SiC
Co Ch
Cu
PMMA
Au/ Ar
Polycarbonate PC
Silice (sand)
Polyphénylsulfone
Graphite
Polyetherimide
Graphite
  • Industrial applications
  • High quality (mechanical resistance, accuracy)
  • Numerous metals and alloys can be used
  • Whole process must be monitored
  • Higher potential than polymers
  • Simple to use and affordable, low power
    consumption.
  • Easily available and most mature machines, but
    for simple applications with low technical demands
  • At the RD stage
  • Fusion T 2000C gt difficulties
  • High density ceramics hard to process with 3D
    printing
  • Importance of know-how
  • Research
  • Long term applications for health (bones surgery)

4
Summary
  1. Metal additive manufacturing (AM) technologies
  2. Applications
  3. Powders
  4. Market analysis
  5. What to control?

5
1. AM technologies
6
1. AM technologies Powder bed
In beam-based powder bed systems (LBM Laser Beam
Melting or EBM Electron Beam Melting), a powder
layer is first applied on a building
platform. Then a laser or electron beam
selectively melts the upper layer of
powder. After melting, the platform is lowered
and the cycle is repeated until the part is fully
built, embedded in the powder bed.
7
1. AM technologies EBM
Powder metal (steel, titane,
cobalt/chrome) Dimensions ? 350 x H
380 mm Precision /- 200 to 400
µm Cost 600 to 1 000 k
EBM ARCAM
MEDICAL Implant, prosthesis,instrumentation
AERONAUTIC turbine blades, support objects
Fine and homogenous metallographic structure
INDUSTRY heat exchangers, filters, molds
MOTOR RACING crankcases, gas exhaust
Mechanical properties of objects realized with
EBM are highest than standard of forged pieces
(ASTM F136)
Examples of objects realized by EBM
origin 3A S.A.S for TA6V objet
8
1. AM technologies LBM
Powder metal ceramics Dimension 300 x
300 x 300 mm Precision /- 50 à 100
µm Price 150 à 600 k
SLM machine
Good material quality
Maraging steel tools
Examples of objects realized by SLM
Page 8
9
1. AM technologies Blown Powder
In the laser beam melting process, a powder layer
is first applied on a building platform with a
recoater (blade or roller) and a laser beam
selectively melts the layer of powder. Then the
platform is lowered by 20 up to 100 µm and a new
powder layer is applied. The laser beam melting
operation is repeated. After a few thousand
cycles (depending on height of the part), the
built part is removed from the powder bed.
10
1. AM technologies Blown Powder
Dimensions gt 1m Price 800 à 1200 k
coaxial nozzle (Irepa Laser patent)
MANUFACTURING
COATING
REPAIRING
BEAM Magic Machine in a glove box for machining
under in a controlled atmosphere
11
2. Applications
12
2. Applications
13
3. Market Analysis
14
3. Market Analysis
15
4. Powders
16
4. Powders
17
5. What to control?
Wassenaar Groupe Australie MTCR NSG Powders Machines Installed base ()
Canada x x x x Y   2
Chine       x     9
Denmark x x x x   Y  
France x x x x Y Y 3
Germany x x x x Y Y 9
Italy x x x x Y   4
Japan x x x x   Y 10
South Korea x x x x   Y 3
Russian Fed. x x x     1
Spain x x x x     1
Sweden x x x x   Y 1
Turkey x x x x     1
UK x x x x Y Y
USA x x x x Y Y 38
18
5. What to control?
  • NSG Fr proposal Apr. 2016
  • AM can be used for the manufacturing of gas
    centrifuges and nuclear weapon components (open
    literature).
  • 1B8 Additive manufacturing Machines with all the
    following characteristics
  • Having a controlled atmosphere (vacuum or inert
    gas) process environment with one dimension
    greater than 200 mm and
  • Using a selective fusion process with laser or
    electron beams on powder bed.

MTCR Australian proposal feb. 2014
19
5. What to control? WA
  • WA Australian proposal 2014 for the control
    of machines. Rejected but the subject was
    qualified as of interest.
  • WA French proposal 2015 maraging steel
    powders

1.C. 2. Metal alloys, metal alloy powder and alloyed materials, as follows e. Steel alloy powders having all of the following 1. At least 90 of particles having a size between 20 and 100 µm, and 2. Alloying elements, as follows a. Non-stainless steel alloys having all of the following 1. 17 to 19 by weight of nickel, 2. A minimum of 7 by weight of cobalt, 3. 3 to 5 by weight of molybdenum, 4. Less than 0.05 by in weight of carbon, and 5. Hardening elements (e.g. aluminium, titanium, niobium) b. Stainless steel alloys having all of the following 1. 9 to 14 by weight of chromium, 2. 7 to 13 by weight of nickel, 3. Less than 5 by weight of molybdenum, 4. Less than 0.1 by weight of carbon, and 5. Hardening elements (e.g. aluminium, titanium, niobium).

20
Thank you for yourattentionrichard.finck_at_sgds
n.gouv.fr
Direction des affaires internationales,
stratégiques et technologiques Secrétariat
Général de la Défense et de la Sécurité Nationale
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