Representative End User Clients
Representative Automation Clients
Representative Software Clients
As a philosophy, additive manufacturing falls under the Industrie 4.0 umbrella due to its enabling of mass customization with the absence of penalties for geometrical or topological freedom in the design of a part. However, objects fabricated using additive manufacturing do not always move through production so seamlessly requiring additional processing steps and slow cycle times. The bright spot is that additive technology is showing signs of entering the next evolutionary phase as machine builders focus on resolving these issues.
Most additive processes cannot reach production-grade surface finishes thereby requiring additional post-production finishing. The industry has attempted to solve this challenge through introducing hybrid machines, which combine additive and subtractive technologies in the same machine envelope. Hybrid machining mitigates some of the throughput time involved with set-up of the work piece on a subtractive machine. Some companies are solving this challenge through the paradigm of Industrie 4.0.
Hybrid Machining and the Digital Thread
On the automation level, Siemens’ PLM and automation solution is capable of providing a digital thread from product design to machine control. NX software includes the capability of 3D product design and test through virtualization, but further enhancements have been incorporated in NX that improve the quality of the finished part. Specifically, NX specifically incorporates mesh creation that results in a more accurate production of the part on the additive machine. Siemens has a very unique position in the additive manufacturing value chain as the digital thread continues directly into the automation used on the additive manufacturing machines.
In particular, the Siemens 840D is the CNC control used on the DMG Mori Lasertec additive hybrid machine tool. Optimization of the process can go much deeper when the CNC system on the machine and design tools are aligned. Today, these hybrid additive machines are only using traditional 3D geometries; however, with Siemens expertise in 5 axis machining there are many possibilities to improve production throughput and eliminate some of the constraints imposed in additive manufacturing processes. Specifically, the use of temporary supports is often necessary in many additive processes. Five axis geometries, which are widely used in traditional metal working applications, will create future possibilities for productivity gains in additive manufacturing machines. These are only the beginning of productivity improvements in additive manufacturing, as others will emerge as the result of improving machine utilization, wider availability of materials, and tools that enable design engineers to evaluate the cost benefits.
Autonomous Module Additive Concept
Concept Laser GmbH, a supplier of powder bed fusion additive manufacturing machinery, embodies the tenets of Industrie 4.0 with its “AM [Additive Manufacturing] factory of tomorrow” concept. Industrie 4.0 provides a vision of a future factory in which smart products collaborate with smart workstations in order to move through production in an effective, efficient, and flexible manner. Each production unit can be personalized, and changes can be accepted throughout production. Ideally, Industrie 4.0 production lines adapt. Process steps are based on individual product requirements. “Smart" products will be associated with an individual set of production rules as it is transported to each workstation. At each workstation the process step is dictated by the product requiring dynamic reconfiguration. Collaboration between workstations will be required to optimize this flow. Concept Laser’s factory of tomorrow is an example of modular machining with additive manufacturing at its core. Various “handling stations” complete pre-production, production, and post-production finishing as needed. Modules adjust accordingly to process steps to increase the flexibility of the process, resulting in decreased downtime. The company is addressing throughput and utilization of a very expensive capital expenditure in additive manufacturing machinery.
Up until now, the focus in additive manufacturing for metals has been the development the underlying technology of powder bed fusion or direct energy deposition in conjunction with material formulations. However, the trend is shifting to improving upon productivity throughput suggesting that the technology developments have reached a plateau. Improving utilization and throughput will expand the market for additive machinery making it a viable alternative for a broader range of products.
Most additive processes cannot reach production-grade surface finishes thereby requiring additional post-production finishing. The industry has attempted to solve this challenge through introducing hybrid machines, which combine additive and subtractive technologies in the same machine envelope. Hybrid machining mitigates some of the throughput time involved with set-up of the work piece on a subtractive machine. Some companies are solving this challenge through the paradigm of Industrie 4.0.
Hybrid Machining and the Digital Thread
On the automation level, Siemens’ PLM and automation solution is capable of providing a digital thread from product design to machine control. NX software includes the capability of 3D product design and test through virtualization, but further enhancements have been incorporated in NX that improve the quality of the finished part. Specifically, NX specifically incorporates mesh creation that results in a more accurate production of the part on the additive machine. Siemens has a very unique position in the additive manufacturing value chain as the digital thread continues directly into the automation used on the additive manufacturing machines.
In particular, the Siemens 840D is the CNC control used on the DMG Mori Lasertec additive hybrid machine tool. Optimization of the process can go much deeper when the CNC system on the machine and design tools are aligned. Today, these hybrid additive machines are only using traditional 3D geometries; however, with Siemens expertise in 5 axis machining there are many possibilities to improve production throughput and eliminate some of the constraints imposed in additive manufacturing processes. Specifically, the use of temporary supports is often necessary in many additive processes. Five axis geometries, which are widely used in traditional metal working applications, will create future possibilities for productivity gains in additive manufacturing machines. These are only the beginning of productivity improvements in additive manufacturing, as others will emerge as the result of improving machine utilization, wider availability of materials, and tools that enable design engineers to evaluate the cost benefits.
Autonomous Module Additive Concept
Concept Laser GmbH, a supplier of powder bed fusion additive manufacturing machinery, embodies the tenets of Industrie 4.0 with its “AM [Additive Manufacturing] factory of tomorrow” concept. Industrie 4.0 provides a vision of a future factory in which smart products collaborate with smart workstations in order to move through production in an effective, efficient, and flexible manner. Each production unit can be personalized, and changes can be accepted throughout production. Ideally, Industrie 4.0 production lines adapt. Process steps are based on individual product requirements. “Smart" products will be associated with an individual set of production rules as it is transported to each workstation. At each workstation the process step is dictated by the product requiring dynamic reconfiguration. Collaboration between workstations will be required to optimize this flow. Concept Laser’s factory of tomorrow is an example of modular machining with additive manufacturing at its core. Various “handling stations” complete pre-production, production, and post-production finishing as needed. Modules adjust accordingly to process steps to increase the flexibility of the process, resulting in decreased downtime. The company is addressing throughput and utilization of a very expensive capital expenditure in additive manufacturing machinery.
Up until now, the focus in additive manufacturing for metals has been the development the underlying technology of powder bed fusion or direct energy deposition in conjunction with material formulations. However, the trend is shifting to improving upon productivity throughput suggesting that the technology developments have reached a plateau. Improving utilization and throughput will expand the market for additive machinery making it a viable alternative for a broader range of products.