Additive Manufacturing: nuove sfide per la ricerca industriale

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1 Campus San Lazzaro Reggio Emilia Additive Manufacturing: nuove Ing. Leonardo Orazi

2 Additive Manufacturing: 30 anni di storia More than 25 years ago Patents of SLM and 3DP Stereolitografia: SLA Selective Laser Sintering: SLS Selective Laser Melting: SLM G.N. Levy - Additive Manufacturing in Production Engineering: Chances and Challenges. 9th CIRP Conferences on Intelligent Computation in Manufacturing Engineering - Capri

3 Additive Manufacturing: il nuovo artigianato digitale Figure The customer role in the four paradigms Yoram Koren The Global Manufacturing Revolution Dedicated Manufacturing lines Flexible Manufacturing Systems Push BUSINESS MODEL Push Pull BUSINESS MODEL Pull Reconfigurable Manufacturing Systems Additive Manufacturing General Purpose Machine Tools Figure The drivers to new paradigms are market and society needs Yoram Koren The Global Manufacturing Revolution 3

4 Gartner Hype Cycle of Emerging Technologies, Trends for

5 Ricerca a livello mondiale: Asia, Europa, USA STREAM ( Belgium ) FRPA ( France ) DMRC - Lander - Central ( Germany ) TNO ( Netherland ) LIDER ( Poland ) PAMI ( Portugal ) ASERM ( Spain ) XXXX ( UK ) 5

6 Additive Manufacturing: ricerca europea da FP3 FP7 SIS 1 a FP7 ( ) related projects by programme funded from FP3 to FP7 ( ) FP7 INCO 1 FP7 JTI 5 FP7 KBBE 1 TOTAL 88 Table 3: Additive Manufacturing related projects funded by field from FP3 to FP7 ( ) EC Programme Number projects FP3 4 FP4 8 FP5 3 FP6 12 FP7 IDEAS ERC 3 FP7 NMP 34 FP7 ICT 2 FP7 PEOPLE 8 FP7 SME 5 FP7 TRANSPORT 1 FP7 INCO 1 FP7 JTI 5 FP7 KBBE 1 FP7 SIS 1 TOTAL 88 ditive Manufacturing related projects funded by field from FP3 to FP7 ( ) Materials 29.6% Technologies 225 M Metals 11.3% Polymers 7.0% Biomaterials 5.6% Ceramics 2.8% Other materials 2.8% Process technologies 23.2% Report of EC Workshop on Additive Manufacturing - Brussels - 18/06/2014 Materials 29.6% Technologies 34.5% Applications 35.9% Metals 11.3% Polymers 7.0% Biomaterials 5.6% Ceramics 2.8% Other materials 2.8% Process technologies 23.2% Informatics 10.6% Standardisation 0.7% Industrial processes 7.7% Health 4.9% Bio-printing 4.9% Aerospace 3.5% Moulds and tools 3.5% Micro 3D-Printing 2.8% Foot and textile 2.1% Consumer goods 1.4% Electronics 1.4% Skills and education 1.4% Microfluidics 0.7% Design 0.7% Food 0.7% The Industrial Leadership pillar of Horizon 2020, including the KETs, will certainly play a major role in the development of Additive Manufacturing technologies. One of the main drivers for AM will be 6

7 Additive Manufacturing in Horizon 2020 Struttura del programma 31 EXCELLENT SCIENCE ERC Ricerca di frontiera per i migliori team individuali FET (Future and Emerging technologies) Ricerca collaborativa in nuovi settori d innovazione (non più solo ICT) MARIE CURIE Opportunità di formazione e carriera per Ricercatori eccellenti Infrastrutture di ricerca (& infrastrutture elettroniche in rete) Accesso ad infrastrutture di livello mondiale INDUSTRIAL LEADERSHIP Leadership nelle tecnologie abilitanti e industriali ICT, nanotecnologie, materiali avanzati, biotecnologie, produzione 1 e lavorazione avanzata, spazio Accesso ai finanziamento con capitale di rischio Sostegno ai finanziamenti privati e di capitale di rischio per la ricerca e l'innovazione Innovazione nelle PMI Stimolare tutte le forme di innovazione in tutte le tipologie di PMI Istituto Europeo di innovazione e tecnologia (EIT) SOCIETAL CHALLENGES Sanità, cambiamenti demografici e benessere Sicurezza alimentare, agricoltura sostenibile, ricerca marina e marittima e bioeconomia Energia da fonti sicure, pulita ed efficiente Trasporti intelligenti, ecologici ed integrati Azione per il clima, efficienza sotto il profilo delle risorse e materie prime Società inclusive, innovative e riflessive Società sicure 2 3 Centro di Ricerca Congiunto (JRC) EURATOM ( ) Report of EC Workshop on Additive Manufacturing - Brussels - 18/06/2014 AM è prevista nel II e III pilastro di H2020 Industrial Leadership in particolare KET e FoF e Societal Challenges. EFFRA indica AM come uno dei topic più importanti nel biennio

8 Additive Manufacturing: approccio multidisciplinare PI issues Application dedicated Automation Part and Powder handling.. SYSTEM/ PROCESS Adaptive Control Closed Loop Productivity Repeatability.. PI issues OK Design for AM 3DP Design Tool Part Finishing Coatings Modifications.. UP- STREAM DOWN- STREAM MATERIAL Polymers Metals Ceramics Composite Biologic.. High Financial density Close to the end user Medical Devices Scaffolds Organ Printing.. APPLICATIONS Industry Aerospace Automotive Jewelry.. Close to the end user G.N. Levy - Additive Manufacturing in Production Engineering: Chances and Challenges. 9th CIRP Conferences on Intelligent Computation in Manufacturing Engineering - Capri

9 Linee di intervento della ricerca industriale Materials Pre Processing: DFAM, CAD for AM Additive Manufacturing Post Processing: Finishing & polishing 9

10 Linee di intervento della ricerca industriale: materiali Fig. 1: SEM-micrograph of the composite metal powder used for laser sinter experiments (Ni powder appears bright in the micrograph) Materials Pre Processing: DFAM, CAD for AM Additive Manufacturing Post Processing: Finishing & polishing a) b) c) Fig. 1: SEM-micrograph of the composite metal powder used for laser sinter Fig. 2: SEM-micrographs of the as laser sintered metal powder, low (a), medium experiments (Ni powder appears bright in the micrograph) (b) and high laser intensity (c), top view 10

11 LENS: esempi 11

12 Linee di intervento della ricerca industriale: il processo additive Materials Pre Processing: DFAM, CAD for AM Additive Manufacturing Post Processing: Finishing & polishing Concorrenza di tecnologie additive e sottrattive produttività, materiali ibridi, superfici funzionali 12

13 Metal Laser Sintering 13

14 SME RAPID Detroit 2014 Trend futuri: dimensioni stment in AM SME RAPID Detroit 2014 Dimensioni Winsun 3D printed house (China) An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China. Courtesy of Guancha Zhe. Hybrid Systems in metal and polymers 14

15 Linee di intervento della ricerca industriale: il pre-processing Materials Pre Processing: DFAM, CAD for AM Additive Manufacturing Post Processing: Finishing & polishing Riprogettazione di componenti aeronautici. Leggerezza minor materiale minor tempo di fabbricazione 15

16 Trend futuri: biomedicale Biomedical engineering (BME) advanced complexity Artificial body part Neural engineering Medical devices Tissue engineering Pharmaceutical Eng. Implants 16

17 Raffreddamento convenzionale 17

18 Raffreddamento conformato 18

19 Esempi 19

20 Trend futuri Alta complessità ed interdisciplinarietà. La chiave sarà la sostenibilità del processo Produttività, automazione e controllo per un miglioramento continuo. Nuovi modalità di fabbricazione guidate da esigenze del prodotto sono in arrivo. Nuove modalità di progettazione guidate dalla modalità di fabbricazione. 5 anni da ora. 20

21 Campus San Lazzaro Reggio Emilia Additive Manufacturing: nuove