From Challenge to Challenger: Your Path to Additive Manufacturing Success

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How can your organization approach additive manufacturing (AM) in the best way possible? The simplest answer is to embrace AM as a massive opportunity for growth instead of a challenge that needs to be addressed.

After all, the goal of any AM initiative shouldn’t be to “catch up” to competitors that may already be using AM. The goal is to become an innovator in your space -- the leader that your competitors are scrambling after. Getting there involves overcoming the challenges that practically every organization faces at the outset of their AM journey. This webinar will explain how to work past those roadblocks, how to explore the full potential of AM from the ground up, and how to become a true innovator in your industry.

The first step requires looking inward at your organization. It involves an end-to-end rethinking of your design process, your manufacturing philosophy, and your entire value chain. You’ll need agile teams that aren’t bound by traditional ways, and your organization must be set up to nurture and optimize that agility. With the right organizational groundwork, you will create new opportunities for your products and your business that will grow more powerful over time.

In this presentation, we will discuss:

• Why a “wait and see” approach to AM can be dangerous for your business
• How you can begin your AM journey with low risk and minimal investment
• How to lay the groundwork for long-term AM success
• How modest AM projects can evolve into transformative business opportunities
• Real-world examples of the many paths you can take on your AM journey
• Where the future of AM can take you

Presented By: Fabian Alefeld, EOS NA Moderator: Peter Zelinski, Additive Manufacturing

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The Journey Toward Additive Manufacturing for Serial Production of Polymer Parts: Opportunities and Challenges for an Automotive Lighting Supplier

Register For Free The journey to additive manufacturing in serial production in an established manufacturing-focused organization is one of many challenges and highlights. This presentation chronicles this in-progress journey for an automotive tier 1 supplier starting with technology selection/overviews, uses in jigs and fixtures, technology/business fits, and nuts and bolts technical level validations. The presentation also explores the creation and details of a “lighthouse” AM project intended to show clearly what the technology can do, as well as some early implementation/trials and a view to the future. Throughout the presentation are highlights of advice “from the school of hard knocks” for those also contemplating or starting a similar journey. Presented By: Dylan Schickel, Varroc Lighting Systems

Advancing Production with HP Metal Jet. How Customers Are Reinventing with HP 3D Metal Jet Printing Technology

Sponsored By: Visit HP's Showroom! Register for FREE! The field of metal 3D printing has been confined to high value and low volume applications, restricting the wider implementation of metal additive manufactured applications within cost conscious market segments. In 2018, HP introduced Metal Jet technology, the most advanced 3D metals printing technology for mass production. Metal Jet builds on HP’s legacy of innovation and leadership in the 2D and 3D printing space by providing an additive manufacturing solution that is competitive with analog technologies. Leveraging metal powder and sintering technologies from the existing and proven Metal Injection Molding (MIM) industry, the HP Metal Jet printing solution has been developed to quickly manufacture samples and scale up to mass production with confidence. By using a digital manufacturing processes to produce both prototypes quickly and then production parts economically, it is possible to reduce the current development time dedicated to re-design for and re-validation of a separate manufacturing process and iteratively designed tooling. Attendees of this presentation will learn about the core technologies and early applications for the HP Metal Jet system, as well as the keys to unlocking AM for cost and time critical applications. Presented by: Matthew Smith, HP Metal Jet Moderated By: Stephanie Hendrixson, Additive Manufacturing

DFAM Beyond the Basics: How Engineering Teams Learn to Think Differently About Design to Realize the Full Benefits of AM

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Too much freedom is not always a good thing. Designers are used to working within a given set of constraints, including what can and can’t be fabricated by conventional means. Additive manufacturing (AM) removes many of the manufacturing limitations that designers have spent years learning, and they are told they can now design anything they want. While this newfound freedom excites many people, it often paralyzes others as they uncover the opportunity to think differently about what—and how—they design. Design principles, guidelines, and rules provide a starting point to change their mindset, but a layered approach that fosters both the restrictive and opportunistic aspects of AM is needed for mastery. Research conducted with engineering students and experiences teaching industry practitioners will be discussed to highlight the opportunities and challenges of teaching people to be creative with AM.
Presented By: Tim Simpson

Moderator: Stephanie Hendrixson

Additive Manufacturing Collaboration Maximizes Thruster Performance for Spacecraft Propulsion

Sponsored By: Visit the Renishaw Showroom! Register for Free! Using a Renishaw RenAM 500 Series AM machine with refractory metals supplied by H.C. Starck Solutions, HiETA and the University of Southampton have unlocked new design thinking for satellite propulsion by enabling engineers to build fine structures and complex 3D geometries that could not be produced using traditional fabrication techniques. Through close collaboration, the team delivered an innovative new resistojet propulsion system named STAR (Super high Temperature Additively manufactured Resistojets) consisting of nested and interconnected heating elements.Through funding from the UK Space Agency Flagship Program and with the additional collaboration from the Satellite Applications Catapult and Surrey Satellite Technology Ltd, the team has been able to demonstrate the potential benefits of an AM design approach for enhancing performance of a refractory metal-based resistojet propulsion system. The webinar will cover all of the challenges that the team had to overcome to successfully build refractory metal-based resistojets using AM. Topics will include the design, modeling, material selection, AM build and testing of the resistojet propulsion system.
Panelists: John Laureto, Renishaw Charlie Birkett, HiETA Technologies Federico Romei, University of Southampton Paul Aimone, H.C. Starck Moderated By: Brent Donaldson, Additive Manufacturing

Building Mission Critical Parts with Metal AM

Register for Free Mission critical parts are those that are essential for the operation of the application; when they fail, there is immediate impact to the business. Many of those parts fall into the turbomachinery category such as impellers, pumps, and manifolds, all of which have had a poor business case with metal AM due to their challenging geometries and heavy post-processing. As a result, many turbomachinery parts are still manufactured via subtractive methods. Knust-Godwin introduced metal AM into their precision-machining environment nearly 8 years ago. They have had tremendous success using AM to breakthrough into new applications and giving mission critical parts a renewed business case with AM. This presentation will cover their journey as a machine shop, their successful integration of AM and how they are winning business.
Presented By: Mike Corliss, Knust-Godwin
Moderator: Brent Donaldson, Additive Manufacturing

How AM Helped Solve Age-Old Injection Molding Problems

Sponsored By: Visit the EOS Showroom!
Registe r for FREE! In the automotive world, additive manufacturing (AM) applications are often considered an alternative to plastic injection molding. But what about making the injection molds themselves?
As it turns out, metal AM is an ideal method of creating plastic injection molds, as it helps solve a variety of problems that have inconvenienced OEMs for decades. The complex geometries of injection molds -- and the intricate vent designs required for gas and material flow – often make conventional machining a poor fit or even impossible. Due to these challenges, many commercially available molds suffer from severe performance issues, becoming clogged quickly and requiring time-consuming cleaning. Using additively manufactured injection molds, GM and EOS developed clog-resistant injection molds that can be cleaned quickly using ultrasonic technology. In this presentation, Jorge Cisneros, Metals Application Engineer at EOS North America, and Paul Wolcott at GM, will discuss: 1. Why traditional injection molds cost OEMs time, money, and tool lifespan 2. The issues GM was looking to address with a new injection mold solution 3. The mechanical properties needed in the solution 4. How EOS solved an age-old manufacturing problem with AM 5. Next steps for the GM and EOS injection mold project 6. How this project could influence related applications in the auto industry Presented By: Jorge Cisneros, EOS NA Paul Wolcott, GM Moderated By: Stephanie Hendrixson, Additive Manufacturing

Benchmarking: The Key to Repeatable Quality in Production AM

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Machine performance is a key indicator of part quality in Additive Manufacturing (AM). Repeatability from build to build and from machine to machine can only be achieved when machine performance is understood and controlled. Hardware can degrade, causing build problems which may be hard to detect and/or diagnose. Therefore, it is necessary to monitor characteristics of the printer which can impact material performance. In a production environment, equipment understanding is vital to repeatable quality. Metrics like gas flow, platform heating, and recoating mechanisms have substantial impacts on performance. Similarly, geometry capability is a critical element to understand in the production of AM parts. Minimum feature size, overhang angle, and as-printed tensile properties are important to understand in order to minimize support structure and maximize part quality through surface finish and mechanical properties. Understanding baseline capability will also be necessary in order to validate performance improvements as a process matures.

Presented By: Brenna McCornac, Cumberland Additive

Moderator: Stephanie Hendrixson, Additive Manufacturing

How a Pandemic Pushed 3D Printing to New Dimensions

Sponsored By: Visit HP's Showroom! Register for FREE! Around the world, COVID-19 revealed infrastructure fragilities we’ve long overlooked. As a result, this crisis became a change accelerant for both manufacturers and consumers. Because of these challenges, 3D printing rose to incredible prominence as an agile and fast solution. And well beyond this pandemic, what 3D printing has accomplished in these months will impact entire industries and individual lives in more ways than one. From supply chain transformation to values realignment within ecosystems, this is just the beginning of a major shift. Presented By: Fabio Annunziata, HP 3DP
Clara Remacha, HP Printing & Digital Manufacturing Moderated by: Brent Donaldson, Additive Manufacturing

Designing from Nature: Modeling Biological Structures and Applying Them to Human Products through 3D Printing

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With the prevalence of engineering design and materials development at the forefront of additive manufacturing, there is still a lot to learn from nature when it comes to the design of advanced components. When accounting for strength-to-weight ratio, biological structures often vastly exceed impact resistance even when compared to the most cutting-edge research out there. The structural principles that define these biological "armors" are profound and groundbreaking. But there is a modeling limitation on these structures - how do you utilize current tools to define these structures in 3D for use? Up until now, researchers have used computational modeling to evaluate certain biological structures, but usually, this is for a one-off test or visualization. The use of such structures as applied to commercial applications has been limited by the current software and modeling technology. This presentation steps through several biological armor examples – the telson armor of the mantis shrimp, the specialized bones of the bighorn sheep, and more – and analyzes their structures, then moves into the complex computational modeling of these structures as periodic (i.e., repeatable) implicit elements that can be readily used to fill 3-dimensional spaces (such as football helmets, body armor, etc.) at any scale – without sacrificing speed of use or quality. They also account for a wide range of user inputs so as to be infinitely controllable. The presentation finishes with some finite element analysis of the structures to show their superiority over commonly used 3D lattices.
Presented By: Matthew Stomper, Tangible Solutions
Moderator: Brent Donaldson, Additive Manufacturing

From Powder to Performance – Metrology and Characterization Across the Additive Manufacturing Process Chain

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Register for FREE! Additive Manufacturing (AM) is being adopted by industry, primarily due to its freedom to create complex geometries and ability to create unique properties at selected part locations. However, the AM process is quite complex unlike in subtractive manufacturing where material stock is created independently and then shapes are created with cutting to form desired parts. In AM the “foundry” and part shaping happens all at once, significantly increasing the complexity of the process. Therefore, it is critical, to obtain proper understanding of how the form, size and microstructure of the final components are influenced by the processing parameters. Important points to understand would include how to ensure the quality of the powder; how the powder affects powder bed compactness and sintering process; what microstructure is created and how to heat treat the sintered part; how to define part chemistry to validate proper material composition; how to identify part dimensional accuracy, surface finish inside and outside of the part, as well as correlating different characteristics to ensure much faster recipe development. This approach utilizes a multi-scale, multi-modal workflow, designed to handle the complexity of the entire AM process chain, starting from raw materials to the finished parts. The outcome would be much faster and a much more cost-effective recipe development process, which today might cost millions of dollars and might take even a few years to develop in some industries.
Presented By: Dr. Pradeep Bhattad, ZEISS Industrial Quality Solutions Moderated By: Peter Zelinski, Additive Manufacturing