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EOS – Leader in e-Manufacturing Solutions
Corporate Presentation
Settembre 2014
This presentation may contain confidential and/or privileged information.
Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
EOS: Technology and Market Leader for DesignDriven, Integrated e-Manufacturing Solutions
EOS Management
Family-owned, founded in 1989,
Headquartered in Krailling near
Munich, Germany
Integrated solution provider for
Additive Manufacturing
Solution portfolio: Additive
Manufacturing (AM) systems,
materials (plastics and metals),
software and services
Complete end-to-end solutions: from
part design and data generation to
part building and post-processing
EOS enables competitive advantages
for a variety of industries, such as
medical, aerospace, tooling, industry,
lifestyle products and automotive
Christian Kirner
Dr. Tobias Abeln
Dr. Hans J. Langer
Dr. Adrian Keppler
EOS Headquarters in Krailling, Germany
EOS is committed to:
Innovation – Quality – Sustainability
EOS Corporate Presentation | 2
EOS: A Success Story
140
Accumul ated No. of Systems Sold (ri ght-hand scale)
120
€
130
Gros s Sales in m€ (left-hand scale)
Empl oyees
1000
113
100
Aspettativa per 13\14 +40%
1200
99
800
80
72
60
600
62
61
63
54
40
43
44
400
48
200
20
0
162
177
208
232
252
284
328
332
390
463
520
0
2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12 2012/13
Source: EOS. Figures for EOS Group, for financial years ending 30 September. Number of Employees: Headcounts.
EOS: Global Presence
EOS worldwide installed base
EOS global footprint
1,330 Systems
Customers in 51 countries
EOS Sales & Service offices in 11 countries,
distribution partners in 22 countries
More than 500 employees worldwide
(74% Germany, 26% International)
Strong patent portfolio: More than 700 active
patents in nearly 100 patent families
R&D Spendings of approx. 15% of Sales
⅓ Metal systems
⅔ Polymer systems
266 customers with more than 1 system
North
America
Europe &
Rest of World
AsiaPacific
15%
67%
18%
of global client base
Source: EOS. Installed base (includes purchased and rented systems) as per 12/2013. Staff figures as per 09/2013.
EOS: ITALIA
SISTEMI INSTALLATI
FILIALE
OLTRE 100
40% Metallo
60% Plastica
Circa 20 clienti con più di un sistema di cui 8
con un numero di installato pari oppure
superiore a 4 .
trend 2014 molto positivo con ordini di nuove
macchine per oltre 20 unità.
Implementato da maggio la funzione di Service
Manager (Luca Taverna) per l’ottimizzazione
nella gestione delle problematiche di assistenza
tecnica
Lo staff dei tecnici incrementerà di un’unità
entro la fine del 2014.
Migliore integrazione nell’organizzazione
internazionale della EOS
GRAZIE
A TUTTI
Source: EOS. Installed base (includes purchased and rented systems) as per 12/2013. Staff figures as per 09/2013.
„Enterprise 3D Printing“ –
we are on the “Slope of Enlightenment”
“The Manufacturing
Technology that will
change the World“
The Economist, 2011
The Economist, 2012
Source: Gartner (July 2013)
Computerworld, 2013
EOS_Company-Presentation.pptx | EOS | 6
McKinsey considers 3D Printing one of the
12 potentially most disruptive technologies…
„12 potentially disruptive technologies”
Advantages of 3D Printing
Productivity advantage
Automation of
Knowledge
Work
Renewable
Energy
Rapid prototyping and serial
applications
Advanced
robots
$
Energy
Storage
NextGeneration
Genomics
3D
Printing
Cost advantage
Integrated functionality
without assembly
Freedom of design
Cloud
Technology
Mobile
Internet
Lightweight
Complex component
Autonomous
Vehicles
Customisation
Internet
of
Things
Advanced
Materials
Source: McKinsey Global Institute Analysis 2013
Advanced Oil &
Gas
Exploitation
Customer specific adaptations
Cost efficient small series
…However, we are not there yet
Gartner Hype Cycle 2013
AM Processes
Maturity drivers
Consumer
3D Printing
Further improve process
robustness
Consumer
3D Printing at peak
of expectations
Optimize monitoring and
QA capabilities
Increase overall
productivity to reduce costper-part
Enterprise
3D Printing
Realistic view
on Enterprise
3D Printing
Source: EOS, Gartner (July 2013)
Ensure seamless data flow
from CAD to production
machine
Drive integration into
production environment
Introduce advanced tools
(e.g. process simulation)
Our vision is to establish ‘Industrial 3D-Printing’
as a manufacturing technology
EOS vision and derived strategic actions
Our Vision :
EOS additive manufacturing (“Industrial 3D-Printing”)
technology is an established & efficient way of serial
production
Our Role:
EOS will be the partner of choice for developing and
providing integrated “e-Manufacturing” solutions
Our overall Goal:
Profitable and sustainable growth
Our Strategic Corner Stones:
Market & Customer: Create more market awareness
Technology & Portfolio: Stay innovation & quality leader
for “Industrial 3D-Printing” technology
Go-to-Market: Offer valuable solutions in innovative
business models
Process & People: Continuously improve EOS organization
Source: EOS
As a result, we drive all our activities to generate
maximum value for our customers
Customers
EOS solution portfolio
EOS basic portfolio
Software
Material
Source: EOS
Services
Parameters
Systems
Lead industries (e.g. Aerospace, Medical, Rapid Prototyping,
etc.)
Process
Application
know how
know how
Customer
applicatio
n
Additive Manufacturing Meets Industrial
production – a Paradigm Shift
Yesterday’s requirement
High flexibility (''one of a kind'')
Fast turnover time
Focus on aesthetics/surface structure
Similar (but not identical) parts
No focus on:
Reproducibility
Up-scaling
Manufacturing chains
Future requirements
Specified part quality
Economic up-scaling
High(er) output
Reduced cost-per-part
End-to-end solution
High degree of automation
100% quality
Cost
Quality
Output
t
Source: GE – Greg Morris - Additive Metal Applications within the Aerospace Industry
The EOS M400 system is designed for integration
into a series production environment
The EOS M400
Further enhanced by
Control Cabinet
Process Station
Unpacking St.
14 sq ft
25 sq ft
21 sq ft
Setup Station
Automatic Recirculating
Powder Handling
Centralised Cooling Station
Self-cleaning Filter Units
30 sq ft
Proposed configuration:
Combining six process stations with one unpacking
and set-up station (depending on job time)
Saving ~ 50% of valuable floor space
Saving ~ 20% invest
Le parti sono fabbricate lungo una sequenza di sezioni
successive dove ad ogni strato un laser espone in modo
controllato un letto di polvere.
Additive Manufacturing – il principio funzionale
Medesima tipolagia sia per plastica sia per metallo
Dal modello 3D CAD
…
Creazione letto di
polvere
Esposizione laser
La piattaforma si
abbassa di uno
strato
Ri- applicazione del
letto di polvere
Nuova esposizione
fascio laser
… alla parte
definitiva
Diretta – Generativa- Efficiente e Funzionale
Source: EOS
Tutte le industrie devono affrontare sfide identiche –
Additive Manufacturing offre soluzioni uniche
Sfide del meracto globale
vantaggi
Time-to-Market rapido combinato
con cicli di vita prodotto più corti
$
Produttività:
necessità di riduzione dei costi
Produzione flessibile
("factory around the corner")
Innovazione →
Miglioramento del valore aggiunto
Personalizzazione dei produtti
Focus sulla Sostenibilità
Produttività
Prototipia coniugata con
produzione di serie
$
Vantaggi costi
Funzionalità integrata senza
assemblaggi
Freedom of design: libertà
progettuale
Strutture leggere
Geometrie complesse
Customisation
Gestione efficiente dei costi per
parti uniche oppure piccole serie
Additive Manufacturing (AM) risponde alle sfide
del mercato
Freedom of
Design
Strutture
biomimetiche e
leggere
$
Ottimizzazione
della funzionalità
Nuovi
materiali/nuove
proprietà (es.
Strutture
porose\spugnose)
Riduzione
costi
Produzione
“integrata” e
diretta di piccole
serie oppure
parti singole
Componenti con
funzionalità a
progetto senza
assemblaggi
Miglioramenti
nella
produttività
Rapid
prototyping e
produzione di
serie
Verifica
immediata della
progettazione
Customizzazione
Articoli “unici” e
personalizzati
con modalità
costruttiva
flessibile
Scambiatore di calore a
struttura biomimetica
Additive Manufacturing (AM) offre due diverse vie per
vincere nel mercato
Scenario 1: Risolvere vincoli dei sistemi di
produzione convenzionali
Rotore: da 32 componenti a due parti sinterizzate
l a ser + 1 a nello di congiunzione, nessun stampo,
i ntegrazione funzionale, produzione on-demand su
es i genze specifiche dei clienti
Text
Text
Riduzione della complessità della parte da
produrre
Riduzione dei costi associati agli attrezzaggi di
produzione e\o tecniche di lavorazione ed
assemblaggio
Scenario 2: Consentire approcci di
progettazione nuovi
Geometrie e\o soluzioni di progetto impossibili
per tecnologie convenzionali
metallo progettato come plastica (spessori
sottili, nervature)
Alleggerire i componenti
Ca vi tà interne i ntegrate; s cambiatore di calore a
geometria biomimetica . Pensare prima alla fluido
di namica e quindi alla meccanica associata
Additive Manufacturing offre diversi approcci vincenti!
Image sources: Hettich, Within, 3T RPD
Together with Partners, EOS Provides End-to-End
Additive Manufacturing Solutions
Industry Partners
e-Manufacturing Partners
& others
Partnerships with leading industry
experts to explore new business
areas for Additive Manufacturing
Partners include:
Cooksongold for the jewellery
industry
Bego for the dental industry
Technology Partners
& others
Co-operation with highly
experienced AM service
providers to offer customers:
Industry-specific application
and/or process development
Presentation
High quality parts production
& others
Partnering with technology
champions who develop and offer
products complementary to the
AM technology.
Partners include:
Within Lab: Custom design of
optimised lattice structures
and surface skins to meet exact
specifications
Best-in-Class: Precision surface
finishing
Business Positioned in Line with Market Demand:
EOS Offers Solutions for Many Industries
Rapid
Prototyping
Aerospace
Medical
Industry
Tooling
Lifestyle
Automotive
Market
priorities
Sustainability
Productivity
EOS Distribution Channels: Regional, Industry-Specific, Distributors, Sales Partners
Customisation
EOS Portfolio
Products
Design*
Application
specific
(e.g. lightweight)
*With EOS technology partners
Solutions
Build
Systems
Material
Software
Process
Service
Services
Finish*
Surface
engineering
Customers from Numerous Industries
Rely on EOS Technology
OEMs
Sample customers.
Service Providers
Additive Manufacturing (AM)
Esempi in aerospazio
Jet Engines
Swirler
Stator ring
Interiors
Airduct
AM è una tecnologia validata nella
produzione di componenti per
motoristica (eg dichiarazione GEA)
Sono disponibili superleghe per
applicazioni ad alta temperatura
Differenti componenti in fase di
cetificazione: e.g. fuel systems,
guide vanes, rotating blades,
modular systems, specific heat
protection components
UAV
UAV
In uso in diversi veivoli
Alto valore aggiunto via AM
Approcci di ingegneria per
meccanica a peso ridotto
Oggi molti UAV’s contengono
componenti fabbricati con
tecniche AM
Ottimo banco di test per nuove
tecnologie
Riduzione dei costi
Consente soluzioni customs / VIP
solutions
Differenti applicazioni: e.g. climate
and heating systems, air ducts,
loading systems, components in
lavatory and catering areas
Sources Images (left to right): Morris Technologies, EOS, University of Southampton, 3T RPD
Ideale per la produzione di
prototipi oppure piccole serie
We see big OEMs to start setting up production
Example General Electric Aviation
19 fuel nozzles to be
installed on every
CFM LEAP engine
(more than 4500 sold)
David Joyce
president and CEO
100.000 additive parts will be
manufactured by GE Aviation by 2020
1.000 lbs potential reduction in weight
of a single aircraft engine through
additive production
300 plus 3D printing machines
currently in use across GE
Source: Morris Technologies, General Electric
Challenge
Improve fuel efficiency of jet engines
Optimize airflow and fuel swirling
Cooling with integrated fuel channels
Solution
Laser sintered on M 270
Material: EOS CobaltChrome MP1
Benefits
Highly complex design built as "one piece"
Cost - < 50%
Weight reduction - < 40%
Increased robustness – no joining sections
Laser sintered injection nozzles enables to distribute fuel
more equally in the combustion chamber
“Multiply”
Technology example “fuel injection nozzle”
Fuel injection nozzle
Application Features
Up to 76 small channels for equal fuel
distribution in the combustion chamber
at an aperture angle of 150°
Product details:
Weight: 5g
Dimensions (x,y,z): 15, 12, 15 mm
Diameter injection channel: 100µm
narrowing down to 20µm on the outlet
Advantages
Channels can be sintered in any shape
Channels arranged closely nearby (not
possible with eroding)
Injection nozzle, back view
Source: EOS
Additive Manufacturing (AM) Application
Esempi Automotive
Grazie a progetti con pochi
vincoli di fabbricazione
(freedom of design) sono
realizzabili parti complesse e
leggere
Funzioni integrate in componenti
singoli e produzioni dirette senza
attrezzaggi implicano una forte
riduzione dei costi
Conceptual car seat
Drive shaft
AM permette
Riduzioni di peso fino al
70% (lattice structure)
Tecnologia adatta a
sviluppare soluzioni a
basso impatto ambientale
ed emissioni di CO₂ ridotte
La pressione sui margini
operativi induce
l’industria
automobilistica a far
raggiungere l’efficienza
dei costi a concetti
innovativi in
progettazione e
produzione
Articoli individuali servono
per soddisfare le esigenze
dei singoli clienti
Gear stick
L’automobile deve
trasferire emozioni. Parti
individualizzate servono a
questo scopo
AM consente una
produzione di massa con
lotti di una sola parte
Geometrie complesse
sono realizzabili senza
costi sugli attrezzaggi
Sources Images (left to right): Formula Student; M. Kandler, Frauenhofer IPA; Design – Lionel T. Dean
Diverse aree dell’autovettura che potrebbero essere
rivisitate attraverso nuovi paradigmi di progetto
Pistoni; bielle;
valovole
Componenti massivi
(es. Scatola
cambio)
sedili
Testa cilindri
Supporti di
montaggio
Cerchioni
Dischi freno
A-Pillars (e.g.: in
convertibles)
Componenti della
trasmissione
Accessori (e.g.:
luggage rack)
Freedom of design: alleggerire la meccanica
Parti Dinamiche
Parti accelerate\decelerate
Masse in rotazione
Esempio:1g dinamico nelle valvole
equivale a 2Kg di peso statico
Lightweight
Parti Statiche
Esempio: una riduzione di 100Kg di peso
statico significa un minor consumo di circa
0,5l per 100Km
Sedile per auto. Studio concettuale per
integrare funzionalità ergonomiche a
peso ridotto.
Grande risparmio in peso
Alto comfort grazie ad elementi
adattivi a funzione passiva
Adattaori pneumatici
Sistemi di ventilazione integrati
Integrated functionality: (examples)
Attuatore
pneumatico
Ventilazione
Source: M. Kandler, Frauenhofer IPA
The Freedom of Design Allows to Integrate Two
Seperate Functional Parts in One Design
Oil Separator and Cooler
Application
Integration of two usually separated parts: oil separator and cooler
Upper part: deposits oil from air by centrifugal force (rough surface enhances
effect)
Lower part: oil tank with maximized surface for cooling-down effect
Reduction of space and weight
Additive Manufacturing only way to build this part
Product details
Dimensions: ca. 450x260x180 mm
1) Compared to last seasons wheel suspensions manufactured with investment casting
Source: Rennteam Uni Stuttgart, Within, EOS
Integrated Cooling Channels Help to
Reduce Weight and Increase Performance
Lattice Structure Brake Disk
Application
Conceptual brake disk for formula
student race car
Integrated cooling channels to reduce
weight and optimize cooling effect
Product details
Dimensions: d 230 mm; t 5 mm
Weight:
Material:
390 g
Cobalt Chrome
Advantages
Reduced weight by 25%
Significant increase of performance due
to controlled cooling flow
Source: ka.race.ing Karlsruhe ,
EOS
Topology Optimized Wheel Suspension with Increased
Stiffness of 20% and Reduced Weight of 35%
Wheel Suspension
Application
Extreme light and stiff wheel suspension
Topology optimized & customized design
In cooperation with Within software
Product details
Weight:
Front 435 g/Rear 390 g
Max. forces: ca. 100 MPa
Material:
Aluminum
Advantages
Weight savings 22% (front), 35% (rear)
Increased stiffness of 20%
Fast production and high accuracy
1)
1) Compared to last seasons wheel suspensions manufactured with investment
casting
Additive Manufacturing (AM ) For Industry
Applications
Gripper: lightweight and
complex components via
freedom of design
Special purpose machinery:
Integrated functionality and toolless manufacturing
Heat exchanger etc.
Festo gripper
Laser adjustment unit
Heat exchanger
Machine productivity highly
depends on acceleration
possibilities of integrated
grippers
Different products need
different gripper systems
Special purpose machinery
needs a lot of small, nonstandardized metal or plastic
component
Manufacturing these is often
time and cost-intensive
AM offers extensive
advantages for gripper
manufacturing, enabling
lightweight structures,
functional integration,
adaptable gripper geometries
and quick modification
possibilities
AM enables cost-efficient,
tool-less manufacturing of
such components up to lot
size one
Manufacturing is asap
possible, enabling last minute
adjustments and offering on
demand spare parts
Sources Images (left to right): Festo; kuhn-stoff; EOS; components build into EOS systems; 3T RPD/WIHTIN Labs
In industry environments,
different types of heat
exchangers are being
implemented
Challenges: efficiently
increase or dissipate heat;
geometry needs to be
adapted to the part that
needs adequate cooling
AM enables freedom of
design and new geometries
thus ensuring a highly
efficient and tight design
Strutture alleggerite e progettate per
soddisfare esigenze specifiche (ottimizzazione
della fluidodinamica e dello scambio
termico combinati con riduzione
del peso )
Strutture geometriche disegno biomimetico
Progetto con cavità e pareti sottili
Manicotto con angoli sformati e sezione variabile per ottimizzazione fluidodinamica. Geometria che integra uno scambiatore di calore
Costruzione (PH1) in 25 ore
Project: 3T RPD, Within
“freedom of design” consente
funzionalità totalmente nuove
Freedom of Design
Scambiatori di calore di nuova
concezione
Forme diverse possono essere
costruite tramite l’assemblaggio di
sotto elementi
Recupero condensa integrato nella
struttura delle superfici di scambio
Advantages
Componenti compatti e geometria
scalabile
Significativo miglioramento nel
trasferimento di calore
Riduzione peso di oltre 80%
Source: Wi thin, 3T, EOS
Festo ha progettato un manipolo pronto ad
operare immediatamente su oggetti “delicati”.
Esempio Festo
Bionic handling assistant
Applicazione
Manipolo bionico; autoadattivo rispetto
alla geometria dell’oggetto.
Movimenti realizzati da membrane
pneumatiche integrate nel manipolo
medesimo
Vantaggi
Manipolo per oggetti “delicati” da
movimentare in alta sicurezza
Peso ridotto al massimo
Alta flessibilità di manipolazione. Facilità
di costruire terminali (fingers)
personalizzati
Bassi costi di produzione: nessun
assemblaggio richiesto
Source: Festo, Fraunhofer IPA, EOS
Oltre 30 parti in plastica sinterizzata
utilizzate nel sistema FORMIGA P 100
Powder dispenser unit
Laser adjustment unit
Temp. control module
Frame system
Lens cleaning module
Componenti ad alta integrazione funzionale
Supporto specchio
Dispositivo di aggiustamento fascio
laser in direzione Y e Z
Materiale: PA 2200
Funzionalità integrate
Sedi eccentriche per
movimenti di centraggio
Bordo di chiusura elastico
con effetto guarnizione
Integrazione funzionale minimizza I costi ed I
tempi degli assemblaggi
32 individual parts
Washing rotor ‘Rotolavit’
Applicazione
Unità rotore per sistema di
lavaggio farmaceutico
Progetto tradizionale
comprende assemblaggio di
32 componenti
Montaggio complesso di
pipette interne in acciaio inox
Advantages
Integrazione: solo tre parti (2x
Laser-sinterizzate, 1x anello
tenuta)
1 steel ring
2 laser-sinter parts
Consente produzione a
domanda incluse variazioni e
personalizzazioni
EOS GP1 (inox 17-4) e componentistica meccanica di precisione
Tempi di produzione
del singolo
componente per
lavorazione completa
di poche ore.
Benefici:
Pareti sottili (anche
inferiori a spessori di 1
mm) in acciaio inox
alimentare
Forature a
distribuzione qualsiasi
create durante la
lavorazione medesima
lungo superfici 3D
C omponente per impianti di
impacchettamento di prodotti
alimentari in EOS GP1
EOS Additive Manufacturing
Lifestyle Products Applications
Footwear & Sports
Accessories & Gadgets
Jewellery
Digital Forming
Cooksongold
Ross Barber shoes
Challenge: Develop DMLS suitable
for gol d
Solution: New technology ca pable
of s eries production offering a high
degree of design flexibility
Challenge: Individualisation of
products requires a dedicated
s oftware as well as a flexible
ma nufacturing technology
Solution: Di gitalForming ‘s UCODO
s oftware combined with EOS
Addi tive Ma nufacturing
Challenge: Produce high-fashion
men footwear with a complex
des ign
Solution: EOS pl astic laser-sintering
of s ol e and cushioning structure
Optimised: Specially built laser
opti cs a nd raw material
Sustainable: Les s raw material
required
Creative: Compl etely new
pos sibilities for designers
Optimised: 3D fi l es can be
cus tomised within the design rules of
AM technology
Economic: e-Ma nufacturing provides
the possibility of producing s mall
ba tch sizes
Creative: UCODO opens up new
wa ys for mass-customised products
Freedom of Design: 8 uni que
des igns wi th organic structure
Optimised: Innovative AM
technology (sole production)
combi ned with traditional
cra fts manship (leather shoe uppers)
Economic: Des ign could only be
ma nufactured with EOS technology
Sources Images (left to right): Cooksongold (Heimerle + Meule Group), Digital Forming, Ross Barber
Esempi di Lifestyle Products
Footwear
Midsole
Focus su soluzioni
individuali
Web and Gadgets
Architectural
Modeling
Interior Design
Fashion/Accessories/
Jewelry
i Phone covers
British Museum, London
Lamp
Bikini / Gold jewelry
Focus su soluzioni
individual
Dettagli plastici
molto spinti
Tendenza a parti di
grandi dimensioni
Focus su soluzioni
i ndividual I
Sources Images (left to right): WITHIN Labs/EOS, FreshFiber, Foster + Partner, Digital Forming, N12, Cookson
Lampada .exnovo
Componenti per calzature
Prototipi, elementi stile e parti funzionali finali
Source: Sia Mahdavi (Within), Kerrie Luft
Additive Manufacturing (AM) Application
Examples For Medical
Dental Applications
Orthopedic Devices
and Implants
Surgical Instruments
Medical Devices
Dental restorations
Finger implants
MicroTargeting™ platform
Washing Rotor
Soluzioni per corone,
ponti, scheletrati e
Toronto. Processi e
materiali certificati.
Registrazione presso
Ministero della sanità
come componente
impiantabile
Impianti con soluzioni di
una migliore
osteointegrazione
Qualità più consistente,
minori errori
Dispositivi ed impianti
progettati per
trattamenti specifici
Superfici e miglior
osteointegrazione
garantiscono costi di
opsedalizzazione
inferiori. La riduzione
degli errori e dei rischi
induce miglior benefici
sia per pazienti sia per I
medici grazie a coperture
assicurative più basse.
Sources Images (left to right): EOS, WITHIN Labs, FHC Inc., Hettich
Strumentari:
Standard, a perdere
oppure configurati sul
paziente
AM è ideale per la
costruzione di piccole
serie di oggetti a
geometria complessa.
Possibili integrazioni
funzionali con
conseguente riduzione
die costi di
assemblaggio.
Why are customers interested in lattice
structures for medical implants?
Cementless
fixation
Rough
surface
topography
Lattice
structures
There are two methods to secure the fixation of a
permanent prosthesis to the bone:
Cemented fixation uses a fast-curing bone cement
(PMMA) to hold the prosthesis in place
Cementless fixation relies on bone growing into the
surface of the implant for fixation
Rough
surfac
e
Cemen
t
Metal
Metal
Bone
Bone
Cemented fix.
Cementlessfix.
Etched
Sintered beads
Lattice structure
Bone structure
Cementless fixation requires a “rough” surface
topography that allows new bone to grow into the surface
of the implant
Conventionally, such implant surfaces are either textured
(by etching, blasting, …) or have a porous coating (by
plasma spray, sintered beads, …)
Advantages of lattice structures
Trabecular lattice structure resembles bone structure
and results in improved bone-implant integration
Solid part and lattice structure built in one step, no
additional process step needed
Strutture ibride con superfici trabecolarei
ottimizzate per osteointegrazione
Within Medical Software
Facile da usare
Applicazione di strutture porose
a qualsiasi superficie
Controllo della rugosità
superficiale
Dimensione dei pori
controllabile
Contact at Within Technologies Ltd:
Kaveh Mahdavi
Global Sales Manager
+44 7447 692150 (Europe)
+1 570 239 4912 (US)
[email protected]
Free download and training: http://withinlab.com/medical/
Source: WITHIN, EOS
Unique random structure
Pore size fully
tuneable
Applicazioni dentali: vite per implantologia in titanio. Linea di prodotto
TiXos di Leader Italia
Costruzione diretta dalla progettazione
CAD.
Componente inerentemente
decontaminato perché fabbricato
senza contatti con utensili oppure
olii minerali in atmosfera inerte.
Possibilità di generare strutture ibride
ed isoelastiche a densità variabile
grazie all’esatto controllo della
potenza del fascio laser.
Rugosità superficiale e caratteristiche
della superficie di interfaccia per la
ricrescita ossea precise e ripetibili,
senza la necessità di applicare
rivestimenti specifici
Dettagli ed ulteriore bibliografia
www.leaderitalia.it
Key Benefits of Additive Manufacturing for
Medical Applications
Customization
Patient-specific design for highly precise surgical
results
Freedom of design
$
Cranial Implant – CEIT-KE
Cost advantage
Targeting Platform - FHC
Source: CEIT-KE / FHC
Porous surface for optimal osteo-integration
Customization
Freedom of design
Lattice structure
Bone structure
Hip Cup
$
New design opportunities for functional integration
Cost advantage
32 single parts
2 parts
Hettich washing rotor ROTOLAVIT
Source: WITHIN / Hettich
Customization
Freedom of design
Pre-surgical planning, patient-specific instrumentation
and customized implants:
▫ Faster & secure surgery
▫ Increased patient throughput
▫ Reduced implant inventory
Small series & one offs for patient-specific applications
$
Cost advantage
Cut & Drill Guide for Knee Surgery
Source: smith&nephew
Dispositivi in plastica monouso per applicazioni
biomedicali
Dime chirurgiche monouso progettate
sull’anatomia specifica del paziente:
protesi ginocchio.
Requisiti applicativi::
Biocompatibilità (ISO 10993 ed USP6)
Sterilizzabilità
Geometria progettata a CAD da dati CT
Dima. Linea VISIONAIRE
EOS Additive Manufacturing
Tooling Applications
Smarter design of conformal cooling channels:
Cost savings, cycle time reduction, increased performance, scrap rate reduction
Injection Molding
Repairing
Salcomp tool insert
and injection-moulding part
Challenge: Ena ble precision
cool ing for production of
mobi le phone plastic parts
Solution: Improved cooling
des ign. Manufacture of core
i ns erts using EOS technology
Result
Producti on increased by
56,000 uni ts/month
Rejection rate reduced
from 2% to 1.4%
Annual cost savings of
a pprox. 20,000 euros
Die Casting
Ecoparts tool insert
Challenge: Repair a partially
da maged tool i nsert
Solution: Generation of a
new reference s urface;
Pos i tioning of part i n EOS
ma chi ne. On-top constructi on of missing parts
Result
Sa ve costs of a complete
new i nsert construction
Reduction of l ead time:
pa rti al construction i nstead
of compl ete construction
Sources images (left to right): Innomia, Ecoparts, PEP
Innomia tool insert for die casting
Challenge: Bui ld a tool
i ns ert for a die casting
a pplication
Solution: Cool ing s ystem
opti misation; i nsert built vi a
DMLS on EOSINT M 270 i n
EOS Ma ra gingSteel MS1
Result
Si gnificant cycl e ti me
reduction
Improved life ti me of
i ns erts
Rapid Tooling
PEP (Pôle Europeen de Plasturgie) tool insert
Challenge: Injection
moul ding tooling for 50,000
el ectrical component parts
Solution: Redesign of inserts
wi th conformal cooling
cha nnels; i nserts built in
EOS Ma ra gingSteel MS1
Result
Lea d ti me a nd cost
reduction
Hi gher mould productivity
Better thermal management
Confronto
fra
i
due
approcci
DMLS; raffreddamenti conformali
Raffreddamenti tradizionali per
Ciclo N°10 @ t= 15s; Punto a più
alta T: 52.6 °C
foratura Ciclo N°10 @ t= 15s; Punto a
più alta T: 75.5 °C
MAPPATURA TEMPERATURA STAMPO
Complex cooling channels for improved
productivity in injection moulding
Innovative cooling bushing concept improves productivity
Challenge
Improve quality of the part with in novative concept for gate bushing
Solution
Eliminate burning defects on the injection point due to shear heating effect on
the gate
Benefits
No burning defects on the injection gate
Cy cle time reduction from 128 down to 110 s.
Energy savings and plastic waste reduction
thanks to shorter cycle times and scrap rate
reduction
Particularity of the cooling system
Conformal cooling:
- not manufacturable conventionally
- the integrated cooling system increases
tool insert life-time
Design advantages:
- equilibrated linear coolant flow
- improved flow speed in the cooling
channels
Advantage:
- cycle time reduction up to 40%
- better and uniform temperature
balance
Cross-section of the cooling channels with
long hole shape:
- improves the cooling performance of the tool
insert
- not manufacturable conventionally
reduction
Particularity of the DMLS tool insert
Tool insert for the
manufacturing of cup,
material EOS
MaragingSteel MS1
(1.2709)
DMLS
manufacturi
ng
Hardness tool insert:
52-54 HRC
Conventiona
l
manufacturi
ng
High glossy polish
finishing
Hybrid design
reduction
Particularities of the plastic product
Ideal temperature
distribution reduces
warpage in plastic
product
Productivity increase up
to 70%
Reduction of scrap rate
We address the productivity challenge in all
portfolio areas
Systems
Materials
Process
Software
Services
We will further increase productivity whilst ensuring high quality results.
EOS Portfolio
Additive Manufacturing of Polymers
Design
System Set-up &
Production
Production
Monitoring
EOS
Hardware
Systems
EOS FORMIGAP 110 EOSINT P 395
EOSINT P 760
EOS P 396
EOS P 800
Periphery
EOS IPCM / IPCM P plus
EOS Unpacking/Sieving station*
Cooldown Station P7
EOS
Materials
PA 2200
PA 3200 GF
PrimePart® PLUS Alumide®
PA 2202 black
CarbonMide®
PA 1101
PA 2201
PA 2105
PA 2210 FR
EOS
Parameters
ParameterEditor
EOS OLPC
PrimePart® FR
PrimePart® ST
EOS PrimeCast® 101
EOS PEEK HP3
ParameterSets
PPPs: TopQuality (60µm), Performance (100µm),
Balance (120µm), Speed (150µm), Top Speed (180µm)
OEPs: (60µm), 100µm, 120µm, 150µm
EOS
Software
EOS RP Tools
EOS PSW
Partner
Solutions
Materialise Streamics Materialise Streamics
Materialise Magics
*For P1, P3, P7
Removal &
Cleaning
EOS PSW
EOSTATE
Materialise
Streamics
EOS Blasting
Cabinet
Normfinish
Polymer System Portfolio Overview
FORMIGA P 110
EOS P 396
EOSINT P 760
EOSINT P 800
Build size & volume (usable)
Wi dth 200 mm
Depth 250 mm
Hei ght 330 mm
Vol ume = 16.5l per built
Wi dth 340 mm
Depth 340 mm
Hei ght 600 mm
Wi dth 700 mm
Depth 380 mm
Hei ght 580 mm
Wi dth 700 mm
Depth 380 mm
Hei ght 560 mm
Vol ume = 149l per built
Focus on...
Hi gh detail resolution
Robust process
Better usability a nd
cl ea ning effort
Focus on...
Ma nufacturing speed
Mecha nical and
di mensional homogeneity
a cros s built vol ume
EOSAME fea ture
Sys tem design
i mprovements
Focus on...
Pos s ible large part sizes
Hi gh-volume production
Extens ive portfolio of
peri phery for maximum
s ys tem productivity
Focus on...
Proces sing of ultra-hightemperature materials l ike
EOS PEEK HP3, mel ting
poi nt of 372°C
cos t-effective production
s ol utions (e.g. built size
reduction possible)
EOS Periphery for Polymer Production:
Integrated Process Chain Management
IPCM P plus
Available
Al l EOS Polymer Systems can be i ntegrated
Benefits
e-Manufacturing: IPCM P pl us ensures constant
a nd repeatable powder quality throughout the
enti re production process
Reduced cost per part: Preci s e dosing and in-situ
powder qualification ma ke material savings
pos sible
Improved quality assurance: Powder batches ca n
be tra ced, thus meeting the requirements of
qua lity-focused industries
Environmentally friendly: Humi dification of
powder i n Mi xing & Qualification Station through
i n-line control; no energy-intensive and costly
external solutions needed
Easy installation and minimum risk of powder
contamination: Powder remains in protected
envi ronment a t all time
Modular approach provides highest capacity and
expandability: Ea ch a dditional s ystem requires
onl y one extra Docking Station (a nd one Multibox
to ma i ntain ease of handling)
Features
Dos ing, refreshing, homogenization, and
condi tioning (humidification) of powder material
Ena bles traceability of powder batches
Tra ns port to a nd conveying into the system
Sea led, contamination-free storage of the
refreshed powder
EOS Polymer Materials
Composition
Trade name
Colour of parts
Main feature
Polyamide 12
PA 2200
white
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Multipurpose material
Balanced property profile
Economic multipurpose material
Certificates available (Biocompatibility, Food contact)
Pigmented throughoutd
High stiffness
Wear resistance
Improved temperature performance
Easy post-processing, good machinability
High temperature performance
Thermal conductivity (limited)
High stiffness
Extreme strength and stiffness
Thermal and electrical conductivity (limited)
Best strength/weight-ratio
Very high ductility / elongation at break
100% from renewable sources (castor/ricinus oil)
Acceptable tensile strength
•
Functional parts
•
Functional parts
•
Functional parts in anthracite black colour
•
•
•
•
•
•
Stiff housings
Parts with requirements on wear and abrasion
Parts used under elevated thermal conditions
Applications with metal-like look
Parts which need machining
Parts with thermal loads
•
•
Light and stiff functional parts
Metal replacement
•
•
Functional parts which need impact resistance
Parts with functional elements (film hinges)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Multipurpose material
Material certificates available (Food contact)
Highest dimensional accuracy
High surface quality and detail resolution
Economic flame-retardant material
Halogen-free
Economic flame-retardant material
Material certificates available (flammability)
Rubber-like flexibility (Shore D ≈ 35)
No infiltration necessary
High dimensional accuracy
Low residual ash-content
High performance material
Excellent temperature performance, strength, stiffness
and chemical resistance
Excellent wear resistance. Inherently flame retardant
Biocompatibility and sterilizability
•
Medical, food
•
Dental
•
•
•
Aerospace
Electric & Electronic
Aerospace
•
Damping devices, bumpers / cushions, gaskets /
gasket seals, shoe sole elements
Patterns for investment casting
Master patterns for vacuum casting
Metal replacement
Aerospace
Automotive and motorsports. Electric & Electronic
Medical
Industrial
PrimePart® PLUS natural
(PA 2221)
PA 2202 black
anthracite black
Polyamide 12,
glass bead filled
PA 3200 GF
whitish
Polyamide 12,
aluminium filled
Alumide ®
metallic grey
Polyamide 12,
carbon fibre reinforced
CarbonMide ®
anthracite black
Polyamide 11
PA 1101
natural
For special applications
Polyamide 12
PA 2201
natural
PA 2105
light beige
PA 2210 FR
white
white
TPE-A PolyetheramideBlock-Copolymer
Polystyrene
PrimePart® FR
(PA 2241 FR)
PrimePart® ST
(PEBA 2301)
PrimeCast® 101
Polyaryletherketone
EOS PEEK HP3
beige-brown
Polyamide 12,
flame retardant
white
grey
•
•
Typical applications
•
•
•
•
•
•
•
Examples of productivity increasing improvements
Homogeneity
EOSAME feature
further optimizes
consistency of
mechanical properties
over built volume
Quality limitation
„stripes in case of high
layer time differences“
was eliminated
Built rate increase
Up to 52% built time
reduction (depending on job
configuration) compared to
EOSINT
P 39550% reduction of
More than
recoating and heating time
(e.g. through 25% increased
recoating speed)
More than 29% more available
laser power
EOS P 396 Machine design improvements
SpotPyrometer w/
No-built area
(30x30mm)
New overflow bin closures
Recoater blade wiper lips
& increased recoater
speed
New Laser
(70W nominal
LP)
CHARON Controller
replaces TMS Cards &
new Industrial PC
running on Win 7
New screen
with better
resolution
New lock design
@ Removal
Chamber
UPS Uninterrupted
Power Supply
Built time reduction comparison (1)
EOSINT P 395 EOS P 396
Exhaust Manifold
(282x228x138), PA
2200*
1 PPL @ 150.5mm
building height
0.18: 5:28h (P 395)
3:15h (P 396) -41%
0.12: 8:28h (P 395)
4:50h (P 396) -43%
Adapter
(40x36x16), PA 2200*,
49 PPL @ 26mm building
height
Cone cartridge
(190x211x268), PA 2200*,
4 PPL @ 24,7mm building
height
@ 0.12: 2:09h (P 395)
1:20h (P 396) -38%
@ 0.10: 2:53h (P 395)
1:50h (P 396) -36%
@ 0.12: 10:43h (P 395)
6:05h (P 396) -43%
@ 0.10: 14:36h (P 395)
8:20h (P 396) -43%
* Performance improvements of system not valid for all materials, see table on next slide; PPL = parts per layer
Built time reduction comparison (2)
EOSINT P 395 EOS P 396
Highest speed improvement at jobs with lower part density, with main duration
decrease coming from recoating- and heating time reduction („non-productive
time“)
Recoating time: recoater speed
Heating time: improved continous thermal control (spot pyrometer)
Exposure time: higher laser power (70W vs. 50W nominal)
-25%
EOSAME: Homogenisation of mechanical
properties
Tensile strength (Z) EOSINT P 395
very good
Tensile strength (Z) EOS P
396
excellent
Customer Benefits EOSAME
Homogenous properties over built volume: Elimination of one of the hurdles of AM
Scrap rate reduction for parts with very high mechanical property requirements
A reduced or even eliminated part placing complexity – automatic nesting
now possible even with high mechanical requirement parts
Scrap Rate can be Reduced due to Increased
Dimensional Accuracy
Before
mm
After
mm
2 positive effects
Overall higher dimensional
accuracy
EOS Corporate
| 70
Minimal dependency
ofPresentation
Z location
EOS Portfolio
Additive Manufacturing of Metals
Design
System Set-up &
Production
EOS
Hardware
Systems
EOSINT M 280 200W/400W
EOSINT M 270 Dental
EOS M 400
EOS
Materials
EOS MaragingSteel MS1
EOS StainlessSteel GP1
EOS StainlessSteel PH1
EOS StainlessSteel 316L
EOS
Parameters
ParameterEditor
EOS
Software
EOS RP Tools
EOS PSW
EOSPRINT
Partner
Solutions
Materialise Magics
Production
Monitoring
Periphery
EOS IPCM M
EOS Comfort Powder Module
EOS NickelAlloy IN718
EOS NickelAlloy HX
EOS Titanium Ti64
Removal
&Cleaning
EOSTATE
Laser
Measurement
EOS CobaltChrome MP1
EOS CobaltChrome SP2
EOS Aluminium AlSi10Mg
EOS Titanium Ti64ELI
ParameterSets
Surface, Performance, Speed
EOSTATE Base
EOSTATE
LaserMonitoring
EOSTATE
PowderBed
EROWA Alignment System
IEPCO Shot
Peening
EOS Systems for the Additive Manufacturing
of Metal Parts
EOSINT M 270 Dental:
High-Performance DMLS
for Dental Copings & Bridges
EOSINT M 280: Mid-Sized
System for Additive Manufacturing of Metal Parts
EOS M 290: For High-Quality
Metal Parts – with Enhanced
Quality Management
EOS M 400: For Industrial
Production of High-Quality
Large Metal Parts
Usable build size
Width 250 mm
Depth 250 mm
Height 215 mm
Usable build size
Width 250 mm
Depth 250 mm
Height 320 mm
Usable build size
Width 250mm
Depth 250 mm
Height 325 mm
Usable build size
Width 400 mm
Depth 400 mm
Height 400 mm
Laser
Yb-fibre laser
200 W
Laser
Yb-fibre laser
200 W or 400 W
Laser
Yb-fibre laser
400 W
Laser
Yb-fibre laser
1,000 W
Technical data
Precision optics: F-theta-lens,
high-speed scanner
Scan speed: up to 7.0 m/s
Technical data
Precision optics: F-theta-lens,
high-speed scanner
Technical data
Recirculating Filter System
Monitoring of machine and
process parameters
Technical data
Precision optics: F-theta-lens
EOS Metal Materials
Material Group
Maraging Steel
Stainless Steel
Nickel Alloy
Brand name
Material type
Typical applications
EOS MaragingSteel MS1
18 Mar 300 / 1.2709
Injection moulding series tooling; engineering
parts
EOS StainlessSteel GP1
Stainless steel
17-4 / 1.4542
Functional prototypes and series parts;
engineering and medical
EOS StainlessSteel PH1
Hardenable stainless
15-5 / 1.4540
engineering and medical
EOS StainlessSteel 316L
Stainless steel
1.4404
lifestyle, aerospace, medical
Inconel™ 718, UNS N07718, AMS 5662,
W.Nr 2.4668 etc.
high temperature turbine parts etc.
Inconel™ 625, UNS N06625, AMS 5666F,
W.Nr 2.4856 etc.
high temperature turbine parts etc.
EOS NickelAlloy HX
UNS N06002
Severe thermal conditions and high risk of
oxidation, e.g. combustion chambers,
CoCrMo superalloy,
UNS R31538, ASTM F75 etc.
engineering, medical, dental
EOS CobaltChrome SP2
CoCrMo superalloy
Dental restorations (series production)
EOS Titanium Ti64
Ti6Al4V light alloy
aerospace, motor sport etc.
EOS Titanium Ti64ELI
Ti6Al4V ELI (grade 23)
Medical Implants
EOS Aluminium AlSi10Mg
AlSi10Mg light alloy
engineering, automotive etc.
Cobalt Chrome
Titanium
Aluminium
Application
specific 1)
R&D / small
scale
Production
Platform
Large scale
Production
Platform
EOS Pursues a Platform-based
DMLS Strategy – from R&D to Production
Focus on production
Manufacture application in
production environment
Scale up for
production
Semi-automated processes
Modular concept
Single field with 1kW laser
Multi-field with 200/400W lasers*
XL build chamber (400x400x400mm)
Focus on flexibility
Develop & qualify applications
Freeze system settings for
production
Produce small scale volumes
Adapt to
application
Derive application-specific
system, e.g. PRECIOUS M 080
1) Requires dedicated business case * In development, subject to technical changes
Designed for flexible material
exchanges
200 / 400 W laser
Build chamber
(250x250x325mm)
Focus on application
Adapted system to match
requirements of specific
applications 1)
Dedicated materials and
parameters (e.g. gold)
EOS M 400
EOS M 400 – an industrial DMLS platform
Main Features
Modular platform for easy integration of future
innovations
Build volume of 400 x 400 x 400 mm³
Laser power of 1000 W
2 recoater blades and bi-directional recoating
Material dosing from above
Exchangeable frame for easier job handling
Intuitive user interface
Efficient workflow before and during build
Enhanced EOSTATE Monitoring & Reporting
DMLS for e-Manufacturing of a new
class of products
EOS M 400 process & set-up stations
Monitoring – Tool Box to control key process
variables
System
Powder Bed
Melt Pool
Process Indicators
DMLS Build
e.g. powder layer quality,
movi ng axis, emitted light,
temperature, energy i nput
Input variables
e.g. powder quality, s ystem
s ettings (e.g. laser power,
s ca n speed, atmospheric
condi tions, temperature)
Pre-Build QA/QC
Process understanding and
manufacturing experience
Part Properties
Understanding of
correlations
e.g. mechanical properties,
density, porosity, dimensional
a ccura cy, s urface roughness
Post-build QA/QC
EOS M 400
NEW Processes enable….
•
•
•
Heat Exchanger made of AlSi10Mg
AlSi10Mg ParameterEditor
• Focus on productivity, e.g. for die cast
applications
• Flexibility to optimize parameters to suit
your application(s)
IN718 ParameterEditor
• Focus on known Part Properties from
EOSINT M 280
• Flexibility to optimize parameters to suit
your application(s)
More materials and processes in development
based on market input
… higher build rates and thicker layers
Times and Cost-per-Part
Technical Details of Job & Process
•
Part: Heat Exchanger
•
Material: EOS AluminumAlSi10Mg
•
Quantity: 6 parts on build platform
•
Layer thickness: 90µm
•
Build Rate: approx. 105 cm3/h
•
Platform Temperature 200°C
•
Inert Gas: N2
EOS M 400
Heat Exchanger: Times
Time Type
EOS M 400
Set-up
42 min
Heat
60 min
Flood
30 min
Build - Total
68 h 58 min or 11 h 30 min per part
Build – Exposure
67 h 16 min (98% of build time)
Build – Recoat
Cool-down
55 min
Removal
36 min
TOTAL
Maximum productive time, minimal non-productive times
EOS M 400 vs. EOSINT M 280
Heat Exchanger: Time Comparison
Time Type
EOSINT M 280 400W*
EOS M 400
Set-up
39 mi n
42 mi n
Hea t
60 mi n
60 mi n
Fl ood
20 mi n
30 mi n
Build - Total
137 h or 68 h 30 min per part
Build – Exposure
125 h (91% of build time)
Bui ld – Recoat
12 h (9% of bui ld ti me)
1 h 42 mi n (2% of build ti me)
Cool -down
30 mi n
55 mi n
Removal
35 mi n
36 mi n
TOTAL
Significant increase in productivity
Job last half as long AND each part is built almost 6x faster
M 400: 6 pieces/ Layer thickness: 90µm / Build Rate 105 cm 3/h / Platform Temperature 200°C / Inert Gas N2
M 280: 2 pieces/ Layer thickness30µm / Build Rate 26,6 cm 3/h / Platform Temperature 200°C / Inert Gas Ar
*estimated, not actually built yet
IPCM-M for EOS M 400
Refill
Module
IPCM-M
Conveying
Module
Recommendation: 6 containers
for powder handling
IPCM-M
Sieving
Module
Peek into the Lab – Unpacking Station*
Preliminary Information*
Unpacking Station between Process & Set-up Stations
Job – parts and powder – is inverted and
vibrated
faster powder removal from built job
more automated powder handling
Powder handling under inert conditions
Easy to integrate in installed EOS M 400
Preliminary image
Enables efficient powder removal
* In development, subject to change
Depending on the Application, EOS will offer a
Single or Multi-Field Manufacturing Solution
Applicationspecific approach
Focus on speed
Focus on accuracy
Big & bulky parts
Surface roughness allowed
Functional surfaces
typically finished
Rather small parts
High resolution required
Direct similarity to M 280
4 x 400 W 1)
1 x 1,000 W
Multi-field
without overlap*
4 x 400 W 1)
Multi-field
with overlap*
Single field
1) Laser power can be adapted for similarity purposes (e.g. 200 W) * In development, subject to technical changes
Peek into the Lab – EOS M 400-4*
Preliminary Information*
Multi-head optics
Multi-head optics
4x 200 or 400 W lasers
Proven DMLS quality known from EOSINT
M 280
Productivity can increase by a factor of
2-4 depending on the part
Same Materials & Processes as EOSINT M
280 ensures the legacy of qualified
production processes
Increased productivity for eManufacturing that has been qualified
on EOSINT M 280
* In development, subject to change
A Peek into the Lab:
EOSTATE PowderBed
EOSTATE PowderBed: Step II & III*
Step II and III allow software-based image
recognition, error identification and closed-loop
control
Image recognition algorithms for the specific
conditions and needs of the DMLS process
Allocation of detected failure to specific layer and
part
Closed-loop control of recoating quality
Recognize insufficient recoating
Repeat recoating until OK
Control of exposure quality through advanced edge
detection algorithms
Full integration in EOS software including userfriendly graphical user interface
Recognition of contours and
particles in powder bed
* In development, subject to technical changes
A Peek into the Lab:
EOSTATE MeltPool
Principle of operation*
Capturing light emissions from DMLS process with
photodiode-based sensors
A: “On-Axi s“ configuration (through the scanner)
B: “Off-Axi s“ configuration (diode i nside process chamber)
Sensing light intensity and signal dynamics, which are
among the most relevant indicators for process
behaviour
Correlation of sensor data with scanner position and
laser power signal
Current development*
Cooperation with experienced industry partner
leveraging synergies of EOS process know-how and
partner’s expertise in industrial monitoring
Deepening know how about correlations of monitoring
data, process characteristics and part quality
Further development of algorithms for automated data
analysis and visualization
Implementation in user-friendly software
A
B
Mapping of data of a tensile bar
* In development, subject to technical changes
EOS M 290
Evolution of DMLS Technology
2014
2009
EOS M 290
2004
EOSINT M 280
1994
EOSINT M 270
EOSINT M 250
Beginning of a new
technology
generation
First 20µm layer
DMLS process
First DMLS system
with fiber laser
Revolutionary benchmark in part quality
First DMLS system
with 200 and 400W
fiber laser
Laminar gas flow
Process robustness
Maintains legacy to
EOSINT M 270 200W
processes
Self-cleaning filter
unit
Intuitive Software
Process Monitoring
Maintains legacy to
EOSINT M 280
processes
Enhancement of the Benchmark in Additive
Manufacturing of Metal Parts
EOS M 290
NEW Recirculating Filter System
• Automated removal of condensate cake
• Longer filter lifetime for lower operating costs
NEW EOSYSTEM machine software with improved user
interface for intuitive, efficient and stable operation
NEW EOSPRINT Desktop Software for faster job
preparation enables machine to concentrate on
building
NEW Enhanced Monitoring
• Comprehensive monitoring of machine and process
parameters
• Prepared for integration of further monitoring
features and products
Same Materials & Processes as EOSINT M 280
Process similarity to EOSINT M 280 has been
shown which helps ensure legacy
2014
Filtered Process Gas
to ventilation system
Exhaust Gas Filter (H13)
Fine Filter (H13)
Cartridge Filters (F9)
Contaminated Process Gas
from Process Chamber
Filtered
Process Gas to
Process Chamber
Collection
Container
Turbine
2-stage Filter System …
Fewer Filter Exchanges …
Stage 1: Cartridge Filters (F9)
Lifetime Cartridge Filter:
Set of 4 filters
Removes most of the contamination
•
•
Approx. 1,500 laser hours (400W)
Approx. 2,000 laser hours (200W)
Automated filter cleaning: removal of powder cake
from filter into collection container ensures constant
filter efficiency
Lifetime H13 Filter: approx. 3,500 laser hours
Lifetime Collection Container: approx. 400 laser hours
Stage 2: Fine and Exhaust Gas Filters (H13)
Ensures that process gas can be safely released into
onsite ventilation system and back into the process
chamber
99.95% of particles smaller than 1µm are filtered
… ensures optimal process quality.
* Compared to EOSINT M 280
… reduces operating costs considerably*
Process Similarity EOS M 290 vs. EOSINT M 280
What is EOS‘ Approach to show Process Similarity for EOS Processes?
1. Failure Mode and Effect Analysis (FMEA) covering hardware changes, e.g. Recirculating Filter
System, machine control, axis monitoring/sensors, etc.
2. Results of FMEA showed that 2 aspects should be investigated further:
a. Process Flow
b. Part Properties of 2 representative materials
3. Test Procedure defined and implemented, results analysed
a. Process Flow simulation and measurement to check influence of new Recirculating Filter
System
b. Part properties of EOS CobaltChrome MP1
Widely used Aerospace & Medical, industries with high demands on production validation
Main material used for qualifying EOS metal systems therefore a very large database to
compare to
Challenging material to process
c. Part properties of EOS NickelAlloy IN718
Widely used Aerospace & Industry (turbines), industries with high demands on
production validation
Large R&D database to compare to
Challenging material to process
Process Similarity: Comparison of Flow
EOSINT M 280
EOS M 290
Conclusion: Results are within the measurement accuracy and defined
tolerances, therefore no significant effect on process result
Observation in 10mm above building platform
Process Similarity: Comparison of Part Properties
EOS QA Job
Test Set-up
1. Test Job: EOS QA Job
2. ParameterSets
a. MP1_Surface (20µm, 200W)
b. MP1_Speed (50µm, 400W)
3. Systems: 3 EOS M 290
4. Test matrix per ParameterSet:
3 QA Jobs on 3 different M 290 systems each
Properties analysed:
Mechanical properties, e.g. tensile strength, yield
strength, elongation at break, modulus of elasticity
Relative Density
Dimensional accuracy
Conclusion: Part properties are
comparable as per Material Data Sheet
for EOS CobaltChrome MP1
Process Similarity: Comparison of Part Properties
EOS Verification Job
Test Set-up
1. Job: EOS Verification Job
2. ParameterSet: IN718_Performance (40µm, 400W)
3. Systems: 3 EOS M 290
4. Test matrix per ParameterSet:
1 Verification Job on 3 different M 290 systems
Properties tested/analysed:
Mechanical properties, e.g. tensile strength, yield
strength, elongation at break, modulus of elasticity
Relative Density
Conclusion: Part properties are
comparable as per EOS Material Data
Sheet for EOS NickelAlloy IN718
EOS Periphery for DMLS
Integrated Process Chain Management
IPCM-M
Material & Platform Handling Modules
Conveyi ng module
Si eving module
Li fti ng trolley
M 280 Comfort Powder Module
Benefits
Automa ted sieving ensures consistent process
condi tions for reliable part production
Qui ck emptying a nd filling of s ystem, also with
l a rge material volumes
Qui ck, non-contact, dust-free material
ha ndling
Ea s y a nd s afe lifting a nd tra nsport of building
pl a tforms and jobs
Modul es can be easily exchanged or a dded
Ma terial handling can be done parallel to part
production
Ideal for use with multiple systems a nd with
di fferent materials
Sui table for quality ma nagement systems
Ma terial recycling reduces cost and is
envi ronmentally friendly
Quality Assurance with EOSTATE products
EOSTATE Base
EOSTATE Laser
Machine Conditions, e.g.
Laser status
Scanner status (Automatic
self-calibration, ‘Home In’)
Cooling system status
Build platform position
measurement via glass scale
EOSTATE LaserMeasurement
Process Conditions, e.g.
Build platform temperature
Process chamber atmosphere:
oxygen-level
temperature
humidity
EOSTATE PowderBed
Camera in build chamber
Optimized illumination
Photo after exposure and
after recoating
Flipbook of entire job
EOSTATE LaserMonitoring
Quality Assurance with EOSTATE Software
Reporting software for QA documentation
Base Module: Machine status and data for trouble
shooting
Quality Assurance Module: Job Quality Report with
all quality relevant data and statistics
Controlling Module: Controlling Report with all
financially relevant data and statistics
Machine Park Management Module: Machine Park
Report with all system data and statistics
EOS Part Property Management
A concept providing the freedom and flexibility to choose the level of standardisation
Enabling
… the customer to optimise the use of EOS technology and EOS solutions to meet his particular needs
… flexibility to define Part Properties part-by-part and/or job-by-job
… the customer to select from many potential solutions to manufacture parts according to
EOS standard across multiple machines
Individual application requirements
Customer-defined standard
Open and Flexible: From Standardisation to Customisation
EOS Part Property Management: Solutions
EOS Part Property Management
Plug&Print EOS Standard
Part quality defined by EOS
e-Manufacturing according
to EOS-defined Part
Property Profiles (PPP)
Plug&Print EOS Custom
Part quality defined by
customer
Customised solution based
on your specification
enabling unique part quality
Edit&Print
Part quality defined flexibly
Application development
starting from a well-proven
baseline
EOS DMLSTM Monitoring
Monitoring is only the first element
… of three, which are essential for holistic Quality Control / Quality Assurance
2
1
ACT
PURPOS
E
ANALYSE & INTERPRET
Value(s) from
measuring device(s),
state of a system
Comparison of theoretical and actual
value(s) and interpretation thereof to detect
errors and/or trends
Intervention to
prevent and/or
repair errors
DOCUMEN
T
MONITOR
3
Raw Data recorded,
e.g. in Database
Results recorded, e.g. in QA
documentation, error message(s)
Confirmation of
action recorded, e.g.
in QA documentation
In-Build QA/QC is an essential element for a
holistic Quality Assurance System for DMLS
Quality Assurance DMLS
Pre-Build QA/QC
In-Build QA/QC
Post-Build QA/QC
Product
Development
Installation
System
In-Process
Monitoring
Destructive, e.g. cross cuts
of test parts, tensile bars
Powder QA
User
Qualification
Powder Bed
Non-destructive, e.g. X-ray,
CT, MRT
System QA
Equipment
maintenance
Melt Pool
Process QA
Statistical Process Control
(SPC) or other QA
methodology
Future ….
Value Add: Risk reduction
Process QA
System QA
System
maintenance
Powder QA
User
Qualification
Melt Pool
Product
Development
Installation
System
Pre-Build QA/QC
Future….
Powder Bed
In-Build QA/QC
Destructive
Nondestructive
Post-Build QA/QC
Risk reduction is a key aspect when moving DMLS
towards production – together we can reduce it to a
minimum.
Value Add: Cost Reduction
Cost per Part
Capital Expenses
(CAPEX)
Operating Expenses (OPEX)
Quality Assurance
Design
Build
Quality Assurance
Finish
Pre-Build
In-Build
Shifting QA from post- to in-build decreases
cost-per-part
Post-Build
High effort
High costs
EOS’ Approach for DMLS
System
Powder Bed
Melt Pool
Process Indicators
DMLS Build
e.g. powder layer quality,
movi ng axis, emitted light,
temperature, energy i nput , …
Input variables
Part Properties
e.g. powder quality, s ystem
s ettings (e.g. laser power,
s ca n speed, atmospheric
condi tions, temperature), ….
Pre-Build QA/QC
Process understanding and
manufacturing experience
e.g. mechanical properties,
density, porosity, dimensional
a ccura cy, s urface roughness, …
Understanding of
correlations
Post-build QA/QC
The EOS 3-way monitoring approach covers the
key factors to ensure highest product quality
Melt Pool Monitoring
System settings
Recoating quality (reference)
Energy intensity
Process parameters
System periphery settings
Exposure quality (reference)
Failure classes
Good/ Bad process (reference)
Classes of defects
Process Indicators
Powder Bed Monitoring
Moving axis
Missing powder
Laser power
Process atmosphere
Particles or grooves in powder
bed
Process temperature
Filter system
Exposure localization (comparing
layer data and images of
processed and unprocessed
material)
Homogeneity and temporal
behavior of melt pool
Influence of laser power, hatch
distance and scan speed
Influence of flow profile in
process chamber (exposure
strategy and splashy process)
Part Properties
Input Variables
System Monitoring
Prerequisite for good part
quality
Indication for metallurgical
soundness
Dimensional conformance (part
accuracy and detail resolution)
Indication for mechanical
properties
Correlation to metallurgical
properties (pores, lack of fusion,…)
Correlation to surface quality
EOSTATE Everywhere –Release planned for
December 2014
Interface concept (subject to change)
Open
Interface
Real Time Monitoring
Machine park status
Sensor values of every system
Availability for installed base
Customized Messages
Customizable trigger for
messages
Possibility to
prevent job
crashes
Open Interface
Option: EOSTATE Everywhere
Interface edition
Possibility to connect
machines to ERP/ MES
Systems
Possibility for the customer to
develop unique applications
DMLS Monitoring Products
EOSTATE Base
Ma chi ne & process conditions
EOSTATE PowderBed
Machine PC with
Reporting Database
EOSTATE Modules
NEW EOSTATE Base has been enhanced
Monitoring Sensors
NEW Graph of current job shown on touchscreen
Machine conditions
Laser status
Scanner status (Automatic self calibration, ‘Home In’)
Cooling system status
Electrical power surveillance incl. power outage protection
NEW Build platform position measurement (layer thickness) via
glass scale including closed-loop control
Dispenser system measurement
Collector platform position measurement
NEW Recirculation filter system: operating pressure (Set Point and
real value)
NEW Recirculating filter system: filter clogging ,flow rate
Process chamber overpressure
Process conditions
Laser power monitoring
Build platform temperature
Process chamber atmosphere: oxygen-level
NEW Process chamber atmosphere: temperature
NEW Process chamber atmosphere: humidity
NEW Ambient atmosphere: humidity temperature
Optimal and stable machine and
process conditions are a
prerequisite for highest part quality
Quality Assurance for Laser Power
Step 1:
Step 3:
Step 2:
Laser Measurement Kit
Primes Pocket Monitor with laser
sintered bracket
Pre-defined measurement period
Recommendation: Measurement before and
after a build job
Benefits
Quick and easy to place Pocket Monitor
in bracket
Quick and easy to position bracket on recoater
arm
Simple and easy to use meter
For use with EOSINT M 270 and EOSINT M 280
Laser Monitoring Kit
Online laser power monitoring during the job
Operator can define measurement
interval in PSW
Laser exposes a defined test exposure on a
beam trap inside the process chamber
Benefits
Flexible setting of measurement frequency
to suit your QA needs
Monitoring at source (laser) to ensure that
specified laser power is maintained
Error message in case of deviation during job
Job is not interrupted
Laser Monitoring Reporting
EOSTATE 1.2 Quality Assurance Module
in Job Report
Benefit
Quality Assurance documentation
NEW EOSTATE PowderBed
Recoating & Exposure monitoring
Step I: Flip-Book of a good job
Taking Fotos
Ca mera i ntegrated i n ceiling of process chamber i n the
i mmediate vicinity of the optics (off-axis)
Il l umination has been optimized with regard to image
recognition
2 pi ctures of entire build a rea per layer, one a fter exposure
a nd one after recoating
Les s is more, e.g. 1.3 Megapixel standard i ndustrial ca mera,
l ess data for i mage recognition in realtime and realtime
ca l culation
Viewing Fotos
Touchscreen: most recently taken image + flip through past layers
of current job
EOSTATE plug-in on desktop PC: all images + flip through layers of
selected job + flipbook (AVI export)
The EOS Quality Triangle
Affects
Process
Part quality
System
Material
Dependent on each other
The Modular EOS Monitoring Solution covers the
Key Factors to Ensure Highest Product Quality
System Monitoring
Monitoring and controlling all system settings and process parameters
Ensuring optimal machine and process conditions as a prerequisite for highest part quality
Powder Bed
Melt Pool
Recoating quality
Energy input
Exposure quality
Homogeneity of melt
pool
Metallurgical properties
Metallurgical properties
Dimensional
conformance
Mechanical properties
EOS offers much more than Technical Services!
Technical
Services
Training
Services
Application/R&D
Services
Quality Mgt
Services
Financial
Services
Installation /
Relocation
System operation
trainings
Building of sample
parts
FAT (Factory
Acceptance Test)
Renting models
Maintenance
Advanced level
trainings
Feasibility studies
IQ (Installation
Qualification)
Leasing models
Repair
Trainings for
Software
Remote Support
for Applications
Support for
Operational Qual.
Individual
financing solutions
Spare parts
supply
Design rules
trainings
ExposureEditing
Consulting
Support for
Performance Qual.
Remote Service
Application-specific
trainings
Application
Consulting
Support for
Customer SelfCare
Customer specific
developments
We support you for all challenges in Additive Manufacturing!
ExposureEditing Consulting
Delivery scope
Principle: Enablement of customer for optimisation of parameter sets
1
Preparation of visit
by phone
2 On-site Consulting
(1 day)
3
Follow-up
Phone call
Customer background
Application type (materials, type of parts)
Desired optimisation (e.g. Surface, Speed, Mechanical properties)
Analysis of current practice at customer - method trained by EOS
Which initial parameter sets are used?
Is the part orientation done effectively?
Is the job preparation done carefully?
Identification of critical parameters for customer application goal
Recommendation of test scope for customer
Have EOS‘ recommendations been followed?
Have the targets been achieved?
Is further support / consulting by EOS desired?
Customer Parameter set Development (CPD)
Delivery scope
Principle: Development of a parameter set based on a specification agreed with a customer
1
Customer specific
Parameter set
Recommendation
2 for
Data processing
Encrypted parameter set
Software licenses (system + offline licenses); n° to be agreed in
contract
Documentation of parameter values + test results
Sample part, produced on EOS system
Job preparation data:
Part placement + part orientation
Usage of build area
Shrinkage compensation
3
Recommendation
for application
specific external
aspects
Specific climatic conditions
Sieving instructions (M)
Cool down periods
etc.
4
Delivery at
customer site
Installation of parameter set on customer system by EOS expert
Building of reference job (as agreed in customer spec) on
customer system
If specific conditions are identified
before or during development phase
Application Consulting (for selected applications)
Delivery scope
Principle: Enablement of customer for achievement of application goals
Analysis of
customer initial
situation
Application goal
Conditions at production site: system maintenance, validation
process etc.
Practice of EOS methodology
2 Identification of
relevant levers
Analysis of part design, data preparation, build process + post
processing
Selection of relevant levers to achieve application goal
Design and
initiation of test
series
Definition of "test scope“ based on several iterations
Execution of first tests + analysis of intermediate results
Recommendation of further tests to be carried out by customer
Documentation
+ Follow-up
Documentation of measures implemented + results
Documentation of recommendation for customer’s further
measures
Telephone call for review and identification of further support
needs
1
3
4
Adaption of Key Parameters for Every Part Area
Possible
Key Features
Possible adaptions for every area category
(see scheme on the right):
Laser speed
Laser power
Hatch distance
Offset
Skywriting
Edges
Depending on default job: 164 – 240
possible adaptions
Sophisticated exposure strategies
Variable number and sequence of contour
lines (Pre- or Post-Contour)
Scheme
Upskin
Core
Inskin
Contour
Downskin
Possible Parameter Adaptions with the
ParameterEditor
Contour and hatch line
parameter adaptions
Use and adapt different
scan strategies (e.g.
flow-optimized)
PPP and customer
specific parameter sets
Start values for
every part area
In Order to improve Application Development,
Additional Parameters will be Editable
Access to Process Parameters (Metal)
Parameters
(Metal)
PSW 3.3
PSW 3.5
PPP & Dev. Kit
Possibility to use protected
parameters
PSW 3.6 &
ParameterEditor
PSW 3.7 &
ParameterEditor
EOSPRINT &
ParameterEditor
X
X
X
Laser power
X
X
X
X
Scan speed
X
X
X
X
Hatch distance
X
X
X
X
Recoater speed
X
X
X
X
Layer thickness
X
by default job
by default job
X
Start values
X
X
X
Skip layer
X
X
Platform temperature
X
More possibilities for parameter changes will be released in Q3 2014
Modification of an Aluminum Parameter Set to optimize
Surface quality – Possible with the ParameterEditor
Goal was to drastically improve the surface of aluminum parts
Before
After
Ra: 25 µm
Ra: 3 – 4 µm
Build time: 21:20 h / 33 parts
Build time: 22:00 h / 33 parts
Significantly smoother surfaces with slightly longer build time - Possible with
the ParameterEditor
4 Key Steps lead to Improved Parameter Sets
Typical process development steps.
Start values
Goal setting
Experiments
Improve next part
area
Ups kin
Core
Ins kin
Contour
Downskin
Based on thoroughly
developed EOS start
values e. g.
optimized for
mechanical
properties
Surface
Productivity
Mechanical
properties
Process stability
Variation of
parameters
Design of
Experiments
(e. g. with the
Minitab DOE Tool)
Measurement of
results
Skin
Core
Upskin
Downskin
Contour (Up-Down-In
skin)
Further contour lines
EOS Application Services
Example of Quality improvement
Challenge
Surface optimisation of aluminum parts
Used Material: AlSi10Mg; Build temperature: 200° C
EOSINT System: M280 with 400W Laser
Contour Plo t o f Ra [µm] vs e xpo sure speed [mm/s ]; lase r power [W]
Solution
e xposur e spee d [ mm/s]
Development of a specific build parameter set
Variation of exposure speed, laser power and hatch
Optimisation of support structures (higher dimensional accuracy)
Delivery of a parameter set + data processing, incl. training + consulting
1100
Ra
[µm]
< 5
5– 6
6– 7
7– 8
> 8
1050
1000
950
900
350
355
360
laser power [ W]
365
370
Result
Surface optimisation:
Improvement of roughness (before: Ra: 15-19 µm; after: Ra: 4-8 µm)
Avoidance of damages from support removal, due to filigree supports
Improved dimensional accuracy
Several laser sintering competences are
needed to develop a complete solution
End-to-end laser sintering solution
Laser sintering technology
Raw material
development &
supply
Laser sintering
system, software
development &
innovation
End-to-end laser sintering solution
Design and
data generation
Design rules and data
generation
Software interface
Design
Laser sintering
manufacturing solution
Application development
(parameter, building strategy)
Production
Production
Post processing
Post machining
Finishing
Finishing
MMPTECHNOLOGY®: Super Precision Surface Finishing
Post processing: Micro Machining Process (MMP) for 7 main markets
Micro machining process
Surface finishing process
Mechanical, physical and
catalyst technology
Benefits
Access to shape and
dimensional details
Minimum material
removal
Preservation of the
surface micro-structure
Enhanced surface
performance (lifetime,
corrosion, friction)
Cutting Tools
Transmissio
ns
Watches/Jewellery
Medical
Aerospace
Medical
Stamping
Plastic Injection
Moulds
From controlled roughness
to mirror-like brilliance
Post processing: Finishing steps of MMPTECHNOLOGY®
Technical
function
Profile
of raw
surface
Filter
Elimination
of secondary
roughness
Elimination
of primary
roughness
Aesthetical
function
Rz = 10,00
Total
elimination of
roughness
Source: FIRST SURFACE Oberflächentechnik GmbH
Shiny effect
Rz = 5,00
Filter
Gloss aspect
Rz = 1,00
filter
Mirror-like
surface
Rz < 0,10
MMPTECHNOLOGY®: adapted to many materials
and various manufacturing techniques
Post processing – an example
Materials
Processes
Standard steel
Hardened steel
Copper
Titanium
Carbides – hard metal
Coatings (PVD, CVD)
Inconel alloys
Precious metals
Quartz
Ceramics
Plastic materials
…
Source: FIRST SURFACE Oberflächentechnik GmbH
▪ Milling
▪ Turning
▪ Grinding
▪ DMLS
▪ EDM
▪ Shot peening
▪ Casting
▪ MIM/CIM
▪…
MMP treatment
before
after
FIRST SURFACE
Oberflächentechnik GmbH
[email protected]
www.firstsurface.de
Focus: Service
The way to higher Productivity
Katja Hagemann
EOS: A Global Service Organisation
EOS Headquarter
Krailling (Germany)
• 45 Field Service Engineers,
• 9 2nd Level Support Engineers
• 15 Application Specialists
• 4 Hotline employees
EOS North America
Novi (USA)
• 16 Field Service Engineers
EOS China
Shanghai
• 2 Field Service Engineers
• 1 Application Specialist
Regi onal Service Center
Loca l Servi ce unit
EOS has Regional Service Centers on 3 continents
EOS AsiaPacific
Singapore
• 8 Field Service Engineers in 4 countries
A growing number of local Service units with own Field Service Engineers and depots
ensures customer vicinity in key regions
Application Engineers consult on customer specific application challenges.
EOS Service Philosophy:
Services Throughout Customer Relationship
Customer
EOS
Service
Getting familiar with
Introduction of
Maximisation of use of
Feasibility studies
System installation
System Upgrade
Building of reference parts
General technology
consulting
Basic trainings
Follow-up trainings
Development of customer
specific solutions
Design consulting for laser
sinter parts
Certification/ Validation
support
Maintenance
Repair
Remote Support
Spare part supply
Application Consulting
EOS Service Portfolio
Technical
Services
Training
Services
Application/
R&D Services
Quality Mgmt
Services
Financial
Services
Installation /
Relocation
System operation
trainings
Building of sample
parts
FAT (Factory
Acceptance Test)
Renting models
Maintenance
Advanced level
trainings
Feasibility studies
IQ (Installation
Qualification)
Leasing models
Repair
Trainings for
Software
Remote Support
for Applications
Support for
Operational Qual.
Individ. financing
solutions
Spare parts supply
Design rules
trainings
ExposureEditing
Consulting
Support for
Performance Qual.
Remote Service
Application-specific
trainings
Application
Consulting
Support for
Customer SelfCare
Customer specific
developments
The EOS Service offer addresses a variety of customer needs and all levels of know-how.
Service contribution to Productivity
Technical
Services
Ensure maximum
system uptime:
Failure prevention
Efficient trouble
shooting
Remote support
Training
Services
Enable customers
for efficient
operation
Professional
system operation
Efficient data
preparation
Material handling
Application
Services
Support
achievement of
productivity targets
Design optimization
Development of
process
parameters
Build capacity
usage
Ramp-up
Consulting
Quality Mgt
Services
Minimization of
wastage
Quality
Management
Consulting
Identification of
supply chain
improvements
EOS Maintenance & Repair packages
Service Agreement
Premium
24h response time
Regular system ca libration
Hi gh-value wear parts (e.g. laser)
Service Agreement
Complete
48h response time
Repairs to restore s ystem operating
condi tion after break-downs
Sys tem calibration after repairs
Spa re parts
Scope of
Service Agreement
Maintenance Agreement
Complete
Replacement of maintenance parts
Mea s urement of s ystem performance
el ements (laser etc.)
Cl ea ning of inner system components
Ma i ntenance parts
Scope of
Scope of
New elements in our Technical Services
Remote Service
EOS Engineer on site
Customer Self-Care
Improved failure diagnosis
Better preparation of
repairs
Saving of on-site visits by EOS Field Service
Remote Trouble Shooting + Application Support
Remote Software services (e.g. updates)
Dedicated EOS Engineer at customer location
Fastest reaction in case of incidents
Trained by EOS, with access to EOS support
organisation
Usage of own service resources
Flexibility for scheduling repair & maintenance
activities
Enhanced know-how for Management of EOS
solutions
Outlook to future EOS offer: Ramp-up Consulting
Future EOS Consulting offering:
AM
Supply
Chain
1. AM Part
Selection of AM suitable parts
AM design consulting
AM data preparation
2. AM System
Utilization of system build volume
System runtime + utilization
Powder handling
Work-flow optimization
3. Production system
Production process planning
Capacity planning
Human resource utilization
Post processing
4. AM Supply Chain
AM material storage
Dynamic stock management
Just-in-time approach
Integrated forecasting
4
AM Part
1
3
Production
system
2
AM
System
Our integrated approach will increase overall productivity.
Future Vision: From „Curing pain“ to „Preventing pain“
Basic
system analysis
Preventive
Monitoring
System
self-regulation
Online failure
detection
Partial selfcorrection
System
Level
Quality reports
Basic monitoring
features
Online failure
detection
Early warning
mechanisms
Service
Models
Static Maintenance
intervals
Reactive troubleshooting
Reliability
Centered
Maintenance
Preventive
Maintenance +
Repair
Slimmed
Preventive
Maintenance
Mainly mechanic
repair
Increasing system intelligence will enable new service models.
EOS Service –
Leading in the Additive Manufacturing Market
1
Excellent Field Service
Sound initial tra ining programme + regular update trainings
Avera ge experience of Field Service Engineers i n EOS technology: more than 5 years
2
Powerful Support
Organisation
Hotl ine Support a nd Remote Servi ce offer
In-house 2nd and 3rd Level Support; cl ose i nteraction with R&D
Es ta blished processes + continuous Service Excellence programme
3
Global Coverage
More tha n 50 Fi eld Service Engineers on 3 continents
4 Regi onal Technical Centers (GER, SGP, CHN, USA) + regional subsidiaries
Gl obal spare parts logistics
4
Complementary
Training Offer
Tra i ning offer for different target groups a nd know-how levels
Sys tematic combination of theoretical and practical elements
Tra i ners wi th long-term experience on EOS s olutions
5
Application Expertise
More tha n 20 Application Experts on 3 continents
Offer of feasibility studies, consulting s ervices, development s ervices
Focus on s pecial i ndustries and application challenges
6
Quality Management
Services
Qua l ity is a key pillar of the EOS corporate philosophy
Va l idation Support Servi ces with focus on specific i ndustries
Acti ve s upport for customers who build up own Quality Mgmt for AM
What you should know about EOS and
EOS is a
solution
provider
We take ownership of customer challenges and provide
support services throughout the customer relationship.
Our integrated service offer strengthens this position.
AM is
innovative
and requires
high
expertise
Service works on AM systems demand highly skilled
personnel and sophisticated tools.
Our service staff goes through a thorough special
training; know-how is continuously updated.
In-house support processes include third level support by
EOS R&D.
Part quality
and system
uptime are
influenced by
Service
Qualified maintenance helps conserve the condition of
the system.
Experienced Field Service Engineers carry out repairs
efficiently and often prevent unnecessary incidents.
EOS tools and measurement devices are carefully
maintained and calibrated.
Our technology
opens
tremendous
possibilities.
Our Service
makes them
real.
Explanations on parts and travel costs
Explanations on parts
Explanations on travel costs
Maintenance Parts:
Parts with a regular lifetime of less than one
year, such as gaskets, cover bands etc..
Pre-emptive exchange during maintenance.
Consumables which require regular
replacement outside the scope of contractual
maintenance activities are not covered by
contract.
Wear Parts:
Parts with a physical wearing effect and an
average lifetime of more than one year, such as
lasers and laser components, F Theta lenses
etc..
Only replaced on demand during repair
activities.
Travel time:
Time required to travel from the nearest EOS
Service location to the location of the System.
Hourly rate for travel time is lower than for
labour time.
Travel expenses:
For travel by car: charged based on
kilometers actually covered.
Maximum kilometers charged: distance
between the nearest EOS Service location
and the location of the System.
All other expenses: charged in the amount
actually incurred.
Spare Parts:
Other parts which do not show regular abrasion
effects and whose lifetime can strongly vary with
customer’s usage patterns and general system
care, such as axes.
Only replaced on demand during repair
activities.
Customer benefits of maintenance and service
agreements
1
System up-time
Maintenance helps avoid system breakdowns
Preventive exchange of standard maintenance parts
Professional cleaning of key system elements
2
Quality of
produced parts
Abrasion of filters and seals affects pureness of powder.
Re-adjustment of system components ensures accurate
working of process.
3
Telephone +
Remote support
Contract customers get telephone support for first advice on
problems.
Remote system access is possible.
4
Price advantage
Hourly rates for Technical and Application Services for contract
customers are discounted.
Costs of parts incl. transport are covered according to contract
scope.
5
Shorter response
times
Contract customers are treated in a privileged way.
Focus: Software
The way to higher Productivity
Gerd Denninger
The Next Step Towards e-Manufacturing:
Separating PSW into Modules
Current Software Concept
(M 280, P 3, P 7)
PSW
(Offline)
PSW
(Online)
Advanced Software Concept
(M 290, M 400, planned for P 110)
EOSTATE
EOSPRIN EOSYSTEM EOSTATE
T
Everywhere
Transitio
n
(Planned)
Open
interface
Open
interface
Parameter
Editor
Prototyping customers demand highest flexibility
e-Manufacturing and prototyping customers
demand:
Minimal possibilities of errors
Enable complex part geometries (Lattice
structures, cooling channels, complex surfaces)
Nevertheless allow flexibility for experienced
users
The EOS Software Concept enables an Errorproof and Integrated Data Processing Chain
Planned products
Data
“EOSPRINT”
preparation (calculation
of exposure
lines)
“EOSYSTEM”
EOSTATE
Everywhere
Open
interface
Open
interface
Future: Apps like:
Machine Park
App
Job Quality App
Apps
Open developed by
interfacecustomer
Parameter
development
Improved data
prep. workflow
Separation of calculation Integration into software landscape
and machine operation
(e. g. Streamics or ERP system)
One EOSPRINT installation can access every
system with the new software concept
Current software concept (M 280, P 3, P 7)
Advanced software concept (M 290, M 400)
Machine configuration
Exposure parameter set
Sliced files
2 PSW Offline
installations (one
per system type)
w orkstation 1
PSW Offline
for P 396 on
w orkstation 2
PSW Online on M 280
1 EOSPRINT on
w orkstation 1
PSW Online on P 396
1 EOSPRINT on
w orkstation 2
Calculated exposure
lines of the part
EOSYSTEM on M 290
Sliced files
One PSW Offline installation required per machine
type
Exposure line calculation during the build process
Increasingly complex jobs could not be calculated or
slowed down the system
Errors during calculation cause job crashes
EOSYSTEM on M 400
Exposure lines are calculated before job starts (.task
file similar to Formiga, with improvements)
Configuration and parameters stored on system and
accessed by EOSPRINT to avoid redundant information
All systems with the new software concept (M 290,
Mi400, later: P 110) are accessible via one EOSPRINT
Separation between data preparation and system
operation workflows
EOSPRINT: Three key improvements
Key Improvement: Machine software
optimized for production
Screenshot EOSYSTEM M 400
1) Usability
Simplified user interface with touch screen, developed
from scratch with usability experts (including customer
survey, clinics)
Customizable dashboard for full transparency of
system conditions
2) Efficiency
Wizard: Reduces training effort for most common
machine operation tasks (setup, cleaning, etc.)
3) Stability
Reduction of possibilities for wrong operation in
production environment (no unintended part switch
off or wrong exposure parameter assignment possible)
Windows 7 Embedded with write protection ensures a
consistent and stable state of the system. This makes it
much harder for viruses to infect the system.
EOSTATE 1.2
e-Manufacturing log data control software
EOSTATE 1.2
Modules for every task
EOSTATE is split into several modules:
Base
Quality-Assurance
Controlling
Machine-Park-Management
ERP-Interface
Source: EOS
EOSTATE 1.2 Modules
Machine Park Management Module
Machine Park Report
A Machine Report contains data on the utilisation and
productivity of the machine over a selected period.
Building Hours
Warmup Hours
Cooldown Hours
Idle Hours
Recoater Mileage
Laser Hours
Exposure Volume
Source: EOS
EOSTATE 1.2 Base module
Embedded functionality
The Base module is always preinstalled on every system
The Base module is free of charge
Functionality provided:
Machine state view, similar as known from EOSTATE
1.0
Preparing a single file for the EOS hotline containing all
relevant information within the selected period of time
Source: EOS
Quality-Assurance module
All Quality relevant information
The module as all other modules are dongle
protected
Intelligent Job-Quality-Report showing all
quality relevant information known by the
system
Statistics provided as successful builds-volumepart no.; errors and material changes etc.
Source: EOS
Controlling module
The module as all other modules are dongle
protected
Controlling-Report showing all finance relevant
information known by the system
Statistics provided as successful builds-volumepart no.; errors and material changes etc.
Source: EOS
Machine Park Management – MPM-module
The module as all other modules are dongle protected
Machine-Park-Report showing all relevant information known by the
system
Statistics provided as etc.
Source: EOS

Production - EfestoLab

Transcript

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