Inspire AG

Zürich, Switzerland

Inspire AG

Zürich, Switzerland
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Bartolo P.,Polytechnic Institute of Leiria | Kruth J.-P.,Catholic University of Leuven | Levy G.,Polytechnic Institute of Leiria | Levy G.,Inspire AG | And 5 more authors.
CIRP Annals - Manufacturing Technology | Year: 2012

Biomanufacturing integrates life science and engineering fundamentals to produce biocompatible products enhancing the quality of life. The state-of-the-art of this rapidly evolving manufacturing sector is presented and discussed, in particular the additive electrical, chemical and physical processes currently being applied to produce synthetic and biological parts. This fabrication strategy is strongly material-dependent, so the main classes of biomaterials are detailed. It is explained the potential to process composite materials combining synthetic and biological materials, such as cells, proteins and growth factors, as well the interdependences between materials and processes. The techniques commonly used to increase the bioactivity of clinical implants and improve the interface characteristics between biological tissues and implants are also presented. © 2012 CIRP.


Eberle G.,ETH Zurich | Chiron V.,ETH Zurich | Wegener K.,ETH Zurich | Wegener K.,Inspire AG
Physics Procedia | Year: 2013

3D laser microprocessing using current market available technologies reveals itself to be a cost intensive and complex undertaking which is mostly due to the control architecture and use of moving components. Recent market appearance of electronically tunable lenses exhibiting NIR transmission, large aperture, high damage threshold and fast response times are available for laser based applications. Hence, enabling usage in the field of laser microprocessing. This paper thus introduces the functional principle of electrically tunable lenses, setup arrangement for 3D laser microprocessing, computational simulation of system parameters and comparison with experimental results. © 2013 The Authors.


Dold C.,Inspire AG | Henerichs M.,ETH Zurich | Gilgen P.,ETH Zurich | Wegener K.,Inspire AG | Wegener K.,ETH Zurich
Physics Procedia | Year: 2013

Manufacturing of cutting edges in PCD cutting tool inserts (CTI) using picosecond pulsewidth laser sources is presented. Cutting edge radii of r edge = 5 to 6 μm are achieved. Validation experiments are carried out on a turning lathe using lasered and ground CTI on machining carbon fibre reinforced plastics (CFRP) which is mainly used for aircraft structures. Experiments are done on fine and coarse grain PCD structures (average grain sizes are 2-4 μm and 25 μm resepectively) which are not economical in the latter case if manufactured conventionally, e.g. using grinding processes. Wear resistance, tool lifetime and process forces can be improved if laser processed coarse grain cutting tools are employed. © 2013 The Authors.


Klahn C.,Inspire AG | Singer D.,ETH Zurich | Meboldt M.,ETH Zurich
Procedia CIRP | Year: 2016

Snap-fit joints are one of the cheapest and fastest connectors available. However, due to geometrical complexity of the joints and the limitations of injection molding, they are used almost exclusively in large-scale manufactured products. Additive manufacturing offers the possibility to create end-user products in small and medium numbers with almost unlimited design complexity. This clears the way for new solutions using snap-fit joints to be explored. In this contribution, the existing design guidelines for snap-fit joints are challenged with the design potentials of additive manufacturing. The general working principles of snap-fit joints prove to be simple, clear, and safe independent of the manufacturing process. While the principles remain unchanged, the advantages of additive manufacturing are utilized to improve the integration in the product and the user handling. By applying the design restrictions of the additive manufacturing processes Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS) the existing guidelines are extended for new manufacturing processes. To demonstrate the new concepts and the capabilities of additive manufactured snap-fit joints a showcase is conceptualized, designed in detail and produced using Fused Deposition Modeling and Selective Laser Sintering. A lid of a container, similar to a jar, is designed as an integrated single component. Aspects of haptics and usability are integrated, resulting in a lid that can easily be assembled and disassembled using one hand only. The design features springs and snap-fit joints adapted to the advantages and limitations of additive manufacturing. © 2016 The Authors.


Leutenecker-Twelsiek B.,ETH Zurich | Klahn C.,Inspire AG | Meboldt M.,ETH Zurich
Procedia CIRP | Year: 2016

Additive Manufacturing (AM) is established not only in prototyping, but also in serial production of end-use products. To use the full potential of the production technology the restrictions of current additive manufacturing processes (like support structures in Selective Laser Melting) must be considered in the design process. Especially the compliance with design rules from early design stages on is important in AM serial production, due to production quantities and the resulting scale effect. The part orientation in the build space has a strong influence on many quality characteristics. In order to use the full potential and to consider the restrictions from the start, a design guideline is necessary to support the whole design process. For this purpose, this paper presents a framework for design guidelines. The framework distinguishes between process characteristics, design principles and design rules; each supporting the designer during different stages of the design process. Furthermore, the paper examines the influence of part orientation in existing design rules and elaborates its importance. Based on this result, the design principle "early determination of part orientation" is presented, which includes a process for determining the part orientation in early stage of the design process. In addition, a design process for additive manufactured parts is demonstrated on an extensive showcase, following the guideline framework and including the principle for early determination of part orientation. The presented framework proved to be helpful in the design process and will be used in the future to collect more process characteristics, design principles and rules.


Tancogne-Dejean T.,Massachusetts Institute of Technology | Spierings A.B.,INSPIRE AG | Mohr D.,ETH Zurich
Acta Materialia | Year: 2016

An octet truss lattice material is designed for energy absorption purposes featuring an exceptionally high specific energy absorption, a constant plateau stress between initial yield and densification, and zero plastic Poisson's ratio. It is demonstrated through detailed finite element simulations that the meso-structural response of metallic lattice materials under compression changes from an unstable twist mode to a stable buckling free mode at a relative density of about 0.3. Furthermore, it is found that the nature of the macroscopic stress-strain curve changes from mildly-oscillating to monotonically-increasing as the meso-structural deformation mode changes, while a stress-plateau is observed at relative densities above 0.3. Since the specific energy absorption is a monotonically increasing function of the relative density, lattice materials of relative densities around 0.3 feature both a plateau stress and a high specific energy absorption capability. Prototype materials are built from stainless steel 316L using Selective Laser Melting. The basic building element of the micro-lattices are 2.2 mm long beams with a 500 μm diameter cross-sections. Detailed micro- and meso-structural analysis including tomography, microscopy and EBSD analysis revealed substantial local material property variations within the lattice structure. Compression experiments are performed under static and dynamic loading conditions confirming the anticipated exceptional energy absorption material characteristics for strain rates of up to 1000/s. © 2016 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.


Klahn C.,Inspire AG | Leutenecker B.,ETH Zurich | Meboldt M.,ETH Zurich
Procedia CIRP | Year: 2015

Additive manufacturing (AM) is a cyclic manufacturing process to create three-dimensional objects layer-by-layer directly from a 3D CAD model. Today AM processes like SLM and SLS are already suitable for direct part production. The processes have little restrictions regarding the shape of the object. The challenge to a designer is to use the unique characteristics of additive manufacturing in the development process to create an added value for the manufacturer and the user of a product. This paper presents two design strategies to use additive manufacturing's benefits in product development. A manufacturing driven design strategy allows a substitution of manufacturing processes at a later stage of the product life cycle, while a function driven design strategy increases the performance of a product. The choice of strategy has great impact on the development process and the design of components. Two cases are presented to explain and illustrate these design strategies. © 2015 The Authors.


Schmid M.,Inspire AG | Wegener K.,ETH Zurich
Procedia Engineering | Year: 2016

Additive Manufacturing (AM) is close to become a production technique changing the way of part fabrication in future. Enhanced complexity and personalized features are aimed. The expectations in AM for the future are enormous and betimes it is considered as kind of the next industrial revolution. Laser Sintering (LS) of polymer powders is one component of the AM production techniques. However materials successfully applicable to Laser Sintering (LS) are very limited today. The presentation picks up this topic and gives a short introduction on the material available today. Important factors of polymer powders, their significance for effective LS processing and analytical approaches to access those values are presented in the main part. Concurrently the exceptional position of polyamide 12 powders is this connection is outlined. © 2016 The Authors. Published by Elsevier Ltd.


Kono D.,Kyoto University | Lorenzer T.,Inspire AG | Weikert S.,ETH Zurich | Wegener K.,ETH Zurich
Precision Engineering | Year: 2010

In order to evaluate the configuration of machine tools, the IWF Axis Construction Kit (ACK) has been developed. This paper describes the evaluation of this approach. The ACK supports rigid body simulations and simple elastic body simulations. The ACK is compared with commercial FEM software to investigate its usability and reliability. Required time was compared in modelling of a machine tool. The ACK needed 30% of the total required time for the FEM because of its modularity in machine modelling. Then, in order to investigate the reliability of the ACK, static and dynamic simulations of both approaches were compared with each other and with analytical calculations on basic beam models. The result showed that the ACK provided equivalent results to the FEM. Static and dynamic simulations were also compared with measurements on an actual machine tool. The ACK obtained almost equivalent results to the FEM. Almost all lower structural mode shapes and their natural frequencies could be reproduced with the ACK when crucial parts were modelled using elastic bodies. © 2009 Elsevier Inc. All rights reserved.


Brinksmeier E.,IWT - Foundation Institute of Materials Engineering | Levy G.,Inspire AG | Meyer D.,IWT - Foundation Institute of Materials Engineering | Spierings A.B.,Inspire AG
CIRP Annals - Manufacturing Technology | Year: 2010

Selective-laser-melting (SLM) is an emerging rapid manufacturing technology allowing the production of components with complex geometries. Though the produced components' dimensions are close to the final dimensions, subsequent machining steps might be necessary. Therefore the resulting surface integrity of SLM-produced and subsequently machined components is crucial. In this study the surface integrity of ground and milled SLM-samples (18 Maraging 300) was analyzed, taking into account the layer orientation. By assessing depth profiles for hardness and residual stresses as well as by measuring the surface roughness, a first time comprehensive view of the correlations between layer orientation, machining process and surface integrity of SLM-samples was obtained. On the basis of these findings, the future potential of SLM can be revealed. The experiments were performed within the framework of the CIRP collaborative working group on "Surface Integrity and the Functional Performance of Components". © 2010 CIRP.

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