Inspire AG fur Mechatronische Produktionssysteme und Fertigungstechnik

Switzerland

Inspire AG fur Mechatronische Produktionssysteme und Fertigungstechnik

Switzerland

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Grant
Agency: European Commission | Branch: FP7 | Program: CP-SICA | Phase: NMP.2012.2.2-3 | Award Amount: 5.68M | Year: 2013

OXIGEN will combine leading-edge European expertise in the manufacture of specialist powder alloys (Mechanical Alloying), knowledge of niche high-temperature materials and capabilities in additive manufacturing. This will produce an integrated, world-leading capability to directly manufacture from powder to part custom-designed, best-in-class high temperature alloys for power generation component applications. OXIGEN will develop different (Oxide Dispersion Strengthened (ODS)) alloys individually designed to address specific high temperature materials performance challenges currently limiting power generation component capabilities. This will lead to the prospect of higher efficiency power generation turbine systems. Working within OXIGEN, and with end users (Alstom, Siemens and Ivchenko Progress) with a combined significant global reach and capabilities, it is expected that holistic exploitation of project results can contribute significantly towards achieving sustained high temperature turbine operation (>620 Degrees C) leading towards power plant efficiency gains greater than 30%. To achieve these key objectives, the consortium consists of 11 organisations who are recognised leaders in various industrial sectors, in the Development of ODS materials and powder production technologies and in the development of LMD and SLM processes.


Grant
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: NMP-2007-3.3-1 | Award Amount: 5.44M | Year: 2008

Shoe Manufacturing in Europe faces an intense and growing competitive pressure brought forth by low-wage countries.To maintain competitiveness DOROTHY promotes a response based on the transformation of shoe industry and related business model meant to strengthen Europes ability to compete in terms of high added value for the customer (as cost-based competition is not compatible with the goal of maintaining the Communitys social and sustainability standards). This transformation relies, on one hand, on the development of tools for the design of customer driven adding value shoes and, on the other hand, on the realization of tools for the design, configuration and reconfiguration of flexible multi-site multi-nation production plants, meant to manufacture those customer driven shoes. DOROTHY mission is to design customer driven shoes everywhere, manufacture them intelligently anywhere as a crucial challenge for shoe industry to gain competitiveness in the global markets, also through better cooperation (and not only to compete) with low-wage countries. In order to address this challenge and to support the proposed new paradigm, DOROTHY fosters three main scientific and technological objectives and their corresponding research clusters: 1- Design tools for the intelligent customer driven and customer fit shoe, as added-value product/service; 2- Tools for advanced industrial engineering design of multi-site and multi-nation production systems and factories, based on the customer driven shoe; 3- New business models associated with the above mentioned paradigm, meant to support it; Given the global challenge addresses, the proposal is coupled with an IMS initiative


Grant
Agency: European Commission | Branch: FP7 | Program: CP-TP | Phase: NMP-2007-3.4-1 | Award Amount: 4.44M | Year: 2009

An innovative mechano-chemical approach (based on the high energy ball milling) will be used for the development of innovative nanopolymers to be used in Rapid Manufacturing (RM) based on Selective Laser Sintering (SLS),by: 1.Structural modification (up nanopolymers stage) using a currently widely used polymer like Polyammide PA (a nanoPA will be produced); 2.Alloying (at nanoscale) with different polymers to tune mechanical properties; 3.Nanocharging of polymers (development of nanocomposites). Moving from this background, the project will make a real, LARGE, step up in polymers and composites properties by including nano features into the base materials and the final products. The final products will benefit from radically extended performances (i.e. operating temperatures, increased strength). In this way it will be possible, using existing prototyping machines, to realize freeform manufacturing technologies for the direct automated and customised production of parts and products from small to medium size batches for a wide range of possible applications (from vehicle applications to biomedical devices). The following are the project S/T objectives of SLS materials and parts produced using the modified PA -New nanostructured materials based on Poliammides (PA) -Agglomerated (scale of 20-50 micron) nanophased (scale of 10-20 nm) particles suited for RM via SLS -Properties improvements in materials and RM/SLS parts properties (referred to conventional PA) of more than 200%. -Parts having improved properties and wider application window for automotive sector, consumer goods and medical instrumentation. For these reasons STEPUP responds quite well to the call topics by: introducing new concepts for the micro/nano fabrication (usage of nanoplymers); enabling transition of RM to customised solutions integrating materials design and simulations.


Grant
Agency: European Commission | Branch: H2020 | Program: RIA | Phase: NMBP-08-2016 | Award Amount: 9.02M | Year: 2016

6 of the European carmakers (DAIMLER, VW, TME, CRF, VOLVO, Opel), under the coordination of EUCAR, have joined forces to commonly address the high cost issue of innovations in vehicle lightweighting, having identified it as the major bottleneck towards their implementation in vehicle series and mass production. The AffordabLe LIghtweight Automobiles AlliaNCE (ALLIANCE) has the ambition to develop novel advanced materials (steel, aluminium, hybrid) and production technologies, aiming at an average 25% weight reduction over 100k units/year, at costs of <3 /kg. Additionally, ALLIANCE will develop a mass-optimizer software tool and a multi-parameter design optimisation methodology and process, aiming at an accelerated pre-assessment of technologies over existing designs in a holistic framework. ALLIANCE will work on 8 different demonstrators of real vehicle models, 6 of which will be physically tested, aiming at market application by OEMs within 6 years from project end (in 2025). A transferability and scalability methodology will also be developed for results replication across other vehicle components and models in other segments. ALLIANCE aims at becoming a central hub for innovation in lightweight design in Europe. To do so, it will establish an open inclusive framework towards external centres and clusters in this field, involving them in ALLIANCE development through an open lightweight design contest and dedicated workshops.


Grant
Agency: European Commission | Branch: FP7 | Program: CSA-SA | Phase: NMP.2012.4.0-2 | Award Amount: 682.65K | Year: 2012

SASAMs mission is to drive the growth of AM to efficient and sustainable industrial processes by integrating and coordinating Standardisation activities for Europe by creating and supporting a Standardisation organisation in the field of AM. The Additive Manufacturing (AM) concept is based on additive freeform fabrication technologies for the automated production of complex products. Additive Manufacturing is defined as the direct production of finished goods using additive processes from digital data. A key advantage is that AM eliminates the need for tooling, such as moulds and dies, that can make the introduction of new products prohibitively expensive, both in time and money. This enables the production of forms that have been long considered impossible by conventional series productionin fact, they can be created fast, flexibly, and with fewer machines.


Grant
Agency: European Commission | Branch: FP7 | Program: CP-TP | Phase: NMP-2007-3.4-1 | Award Amount: 5.66M | Year: 2009

The proposal offers a solution for the growing quantity of product types on the market requiring enormous warehouses to keep stock for spare parts, with corresponding high costs and complex logistics. This emerging problem is caused by the continuously decreasing product life time, decreasing time-to-market and increasing regulatory affairs. A solution is foreseen using Rapid Manufacturing (RM) technology, enabling economically viable, one-off manufacturing on demand. The full DirectSpare business model allows for manufacturers to rapidly produce only those spare parts that are required, at a location close to the equipment that needs to be repaired. This leads to the following advantages of DirectSpare and objectives of this project: Aiming at this way of spare part supply, companies (especially SMEs) can keep or increase their competitive position. The step to introduce new products is made smaller because the compulsory spare parts supply becomes easier by the on-demand technology. This as alternative to stock supplied by high-volume production from low wage countries. Huge cost reduction can be achieved on stock warehousing, such as warehouse building space, part depreciation costs, warehouse energy (light, heat), storage of tools, and the high start up costs for conventional part manufacturing. Huge waste reduction as a large part of the stock will be destroyed in the end anyway because conventional volume manufacturing always exceeds the required quantity. Huge environmental profit as conventional manufacturing of small quantities requires relatively high energy resources. The decreasing product-life-cycle is not limited anymore by the corresponding warehouse characteristics. Local service providers ensure local (EU) employment. Before manufacture, a defect part will be improved to lengthen the spare parts life. The spare part can even be individualised for the specific user, usage and environment.


Rickenbacher L.,ETH Zurich | Spierings A.,Inspire AG fur Mechatronische Produktionssysteme und Fertigungstechnik | Wegener K.,ETH Zurich
Rapid Prototyping Journal | Year: 2013

Purpose - The integration of additive manufacturing (AM) processes into a production environment requires a cost-model that allows the precise estimation of the total cost per part, although the part might be produced in the same build job together with other parts of different sizes, complexities and quantities. Several cost-models have been proposed in the past, but most of them are not able to calculate the costs for each single part in a mixed build job or are not suitable for Selective Laser Melting (SLM). The purpose of this paper is to develop a cost model, including all pre- and postprocessing steps linked to SLM. Design/methodology/approach - Based on collected data and the generic cost model of Alexander et al., an adapted model was developed for the SLM process including all required pre- and post-processes. Each process was analysed and modelled in detail, allowing an evaluation of the influences of the different geometries on the cost of each part. Findings - By simultaneously building up multiple parts, the manufacturing as well as the set-up time and therefore the total cost per part can be significantly reduced. In the presented case study a cost reduction of 41 per cent can be achieved in average. Originality/value - Using different cost allocation algorithms, the developed cost model enables a precise determination of total cost per part avoiding that any geometry is preferred in simultaneous manufacture. This helps to optimize build jobs and to manufacture SLM parts more economically by pooling parts from different projects, whereas the cost per part can still be precisely determined. © Emerald Group Publishing Limited.


Spierings A.B.,Inspire AG fur Mechatronische Produktionssysteme und Fertigungstechnik | Herres N.,Campus Buchs | Levy G.,Inspire AG fur Mechatronische Produktionssysteme und Fertigungstechnik
21st Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2010 | Year: 2010

A recent study confirmed that the particle size distribution of a metallic powder material has a major influence on the density of a part produced by SLM. Although it is possible to get high density values with different powder types, the processing parameters have to be adjusted accordingly, affecting the process productivity. However, the particle size distribution does not only affect the density but also the surface quality and the mechanical properties of the parts. Therefore, this study compares three different particle size distributions depending on the laser scan velocity and two layer thicknesses of 30μm and 45μm. By using an optimized powder material a low surface roughness can be obtained. A subsequent blasting process can further improve the surface roughness for all powder materials used in this study although this does not change the ranking of the powders with respect to the resulting surface quality.


Spierings A.B.,INSPIRE AG fur Mechatronische Produktionssysteme und Fertigungstechnik | Starr T.L.,University of Louisville | Wegener K.,INSPIRE AG fur Mechatronische Produktionssysteme und Fertigungstechnik
Rapid Prototyping Journal | Year: 2013

Purpose - Additive manufacturing technologies such as, for example, selective laser melting (SLM) offer new design possibilities for a wide range of applications and industrial sectors. Whereas many results have been published regarding material options and their static mechanical properties, the knowledge about their dynamic mechanical behaviour is still low. The purpose of this paper is to deal with the measurement of the dynamic mechanical properties of two types of stainless steels. Design/methodology/approach - Specimens for dynamic testing were produced in a vertical orientation using SLM. The specimens were turned to the required end geometry and some of them were polished in order to minimise surface effects. Additionally, some samples were produced in the end geometry ("near net shape") to investigate the effect of the comparably rough surface quality on the lifetime. The samples were tension-tested and the results were compared to similar conventional materials. Findings - The SLM-fabricated stainless steels show tensile and fatigue behaviour comparable to conventionally processed materials. For SS316L the fatigue life is 25 per cent lower than conventional material, but lifetimes at higher stress amplitudes are similar. For 15-5PH the endurance limit is 20 per cent lower than conventional material. Lifetimes at higher stress also are significantly lower for this material although the surface conditions were different for the two tests. The influence of surface quality was investigated for 316L. Polishing produced an improvement in fatigue life but lifetime behaviour at higher stress amplitudes was not significantly different compared to the behaviour of the as-fabricated material. Originality/value - In order to widen the field of applications for additive manufacturing technologies, the knowledge about the materials properties is essential, especially about the dynamic mechanical behaviour. The current study is the only published report of fatigue properties of SLM-fabricated stainless steels. © Copyright - 2013 Emerald Group Publishing Limited. All rights reserved.


Spierings A.B.,Inspire AG fur mechatronische Produktionssysteme und Fertigungstechnik | Herres N.,Inspire AG fur mechatronische Produktionssysteme und Fertigungstechnik | Levy G.,Inspire AG fur mechatronische Produktionssysteme und Fertigungstechnik
Rapid Prototyping Journal | Year: 2011

Purpose - A recent study confirmed that the particle size distribution of a metallic powder material has a major influence on the density of a part produced by selective laser melting (SLM). Although it is possible to get high density values with different powder types, the processing parameters have to be adjusted accordingly, affecting the process productivity. However, the particle size distribution does not only affect the density but also the surface quality and the mechanical properties of the parts. The purpose of this paper is to investigate the effect of three different powder granulations on the resulting part density, surface quality and mechanical properties of the materials produced. Design/methodology/approach - The scan surface quality and mechanical properties of three different particle size distributions and two layer thicknesses of 30 and 45mm were compared. The scan velocities for the different powder types have been adjusted in order to guarantee a part density ≥ 99.5 per cent. Findings - By using an optimised powder material, a low surface roughness can be obtained. A subsequent blasting process can further improve the surface roughness for all powder materials used in this study, although this does not change the ranking of the powders with respect to the resulting surface quality. Furthermore, optimised powder granulations lead generally to improved mechanical properties. Practical implications - The results of this study indicate that the particle size distribution influences the quality of AM metallic parts, produced by SLM. Therefore, it is recommended that any standardisation initiative like ASTM F42 should develop guidelines for powder materials for AM processes. Furthermore, during production, the granulation changes due to spatters. Appropriate quality systems have to be developed. Originality/value - The paper clearly shows that the particle size distribution plays an important role regarding density, surface quality and resulting mechanical properties. © Emerald Group Publishing Limited. © Emerald Group Publishing Limited.

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