Additive Manufacturing - Hessen

Transcrição

Evonik.
Power to create.
“Materials for Additive
Manufacturing”
3D-Additive Manufacturing
Herstellungstechnologie der Zukunft
Hessisches Ministerium für Wirtschaft, Energie,
Verkehr und Landesentwicklung
Sylvia Monsheimer
September, 23th, 2014
Agenda
Short Introduction Evonik
3DP – a hype
Materials for AM
Implications of a new product/technology/design options
3D-Additive Manufacturing| Hessen Nanotech | Evonik Industries
Page 2
Evonik Industries AG
Key figures 2013
Sales
Adjusted EBITDA
€12.9 billion
€2.0 billion
Profitability (adjusted EBITDA margin)
15.6%
Return on capital employed (ROCE)
14.5%
Employees as of Dec. 31, 2013
33,650
Page 3
Marl Site
Page | 4
A modern Structure
Evonik 2013
Segments
Business
Units
Consumer,
Health & Nutrition
Consumer
Specialties
Health &
Nutrition
Resource Efficiency
Inorganic
Materials
Coatings &
Additives
Specialty Materials
Performance
Polymers
Services
Advanced
Intermediates
Page 5
BU-PP BL High Performance Polymers
Performance Driven
= Polymers from Evonik
= semifinished products
from Evonik
PI
PAI
PPSU
High-performance
polymers
PEI
PMI
PEEK
FPs
PPA
LCP
PPS
PES
PA12
PA 1012
PMMI
PAR
PSU
Transp. PA
PA11
PA 1010
PPE
PBT
PET
PA6 / PA66
PC
POM
Cost Driven
PA612
PA 610
PMMA
Engineering
polymers
PA4.6
PUR
ABS
Commodity
polymers
SAN
PP
PS
PVC
PE
amorphous
PE-LD
PE-HD
crystalline
Page | 6
Evonik Industries AG – BL HP
Product Portfolio Integration
Butadiene
Polymers
Compounds
&
Powders
Semi-finished
goods
• PA 12
• PI fibers
• PA 612
• PPS fibers
• CDT
• PA 1012
• PMMA sheets
• CDAN
• PA 6-3-T
• PMMA films
• CoPA
• PMI foams
• LL
• PPA
• PI foams
• COD
• PEEK
• PC films
• PMMA
• PC sheets
• TM-CDT
• PMI
• PPSU films
• DM-COD
• PI
• PPSU sheets
• PVDF
• PMMA -
Building Blocks
&
Monomers
• CDON
• DDS
• COE
• VCH
PVDF films
Page | 7
Evonik drives innovation with a
global network
Resources and philosophy
Global footprint
Innovation for attractive markets with high
growth potential
Modern management, strong culture
Regional focus of R&D activities are
Germany, USA and Asia
Key statistics 2012
Major R&D centers
–
–
–
–
–
R&D spend: € 393 m. (~ 3 % of sales)
Employees: ~ 2,500
Facilities: ~ 35
>26,000 patents
>7,700 trademarks
8
Structured R&D approach with high
output focus
€393m
New/improved
processes
∼25%
New products
∼40%
Strategic research
~20%
Corporate based
2012 R&D expenditures
New/advanced
applications ∼10%
Business Unit based
Other ∼5%
Focus on existing technologies and
markets
Short to mid term perspective
Close customer orientation and
strategic partnerships
Largest component of portfolio value
Dedicated entity Creavis on group level
with special organizational units:
– Growth lines
– Project Houses (e.g. Light &
Electronics, Taiwan)
Mid to long term perspective
Focus on new markets and/or new
technologies and new business models
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3DP – some words about the
HYPE….
3DP
Page | 10
HYPE….
From the historical point of view the expression „3DP“
changed ist meaning several times :
1. MIT-process (binder is printed onto a powder layer)
2. Office friendly processes (independent from the technology used)
3. In the HYPE now: meaning not quite defined, covers all market
segments, or only the „fabber“ segment
Page | 11
HYPE….
From Rapid Prototyping to a more segmented market
Concept Modeling
Prototyping
Additive
Manufacturing
Fabber Market
Page | 12
Additive Manufacturing
Characteristics of Additive Fabrication Processes
Creates a
physical
model
3Dresults
Working
layerwise
additive
process
Merkmale
Arbitrarily
shaped
use of
numerical
data (CAD)
process is
automated
process is
flexible
process is
quick
Page 13
SL
MIT/3DP
LOM
SLS, LS
FDM
Inkjet
Page 14
Principle SLS
Page 15
Important features of the powder based processes:
Good mechanical properties
no support structures necessary
arbitrary complexity of the parts possible
big volume usable
High potential for real (small) series production
Page 16
Additive Fabrication: Motivation to use
Motivation for the use of toolless fabrication processes
•Price issue for injection moulding of small series (dependent on the part itself)
•Individual parts (needs software and handling etc)
•Impossible to produce by injection moulding (undercuts etc)
•Integration of several parts to one part (difficult to show)(whole production process)
Page 17
Technology and Economic Aspects
„Rapid“ is no longer important in the sense of Rapid Prototyping
The whole production process has to be economically
Competition against injection moulding
Cost per
unit
Principle only
Injection Molding
Dependent on the specific
part
Small parts have higher
break even values
AM superior
over IM
AM
Comparison 1:1, without
using advantages like
integrating functionality, or
more freedom of design
no. of units
3D-Additive Manufacturing| Hessen Nanotech | Evonik
Industries
Page | 18
BL High Performance Polymers
- Development of Materials for AM
Mechanical properties
Surface quality
Processability
Page | 19
Materials Development –
The Toolbox and Examples
Analytics
Standards Committee
Polymer Testing
Application Tests
Reactive Systems
Ink Formulation
Modification and Fractionation
Powder
Polymer
Monomer
Page 20
- New Materials for AM
VESTAKEEP
AM 9000
E modulus
3720 MPa
Elongation at break
2,2 %
Tensile strength
72 MPa
Melting point
340 °C
Continuous operating
temperature
280 °C
O
O
Easy to process
Sharp edges
Rough surface
•
•
•
•
•
Poly Ether
O
Ether
Keton = PEEK
Inherent flame retardant ; UL94 V-O
Low smoke density and no toxic gases
High heat temperature resistance, excellent chemical resistance
Resistance against X-ray, beta – and gamma radiation
High strength and flexibility
Seite | 21
Comparison of material properties
E modulus
Elongation at break
Tensile strength
Notched impact strength
Melting point
Common refreshing rate
standard
grade
new rubberlike
material
Vestosint
Z2611
1700 MPa
100 - 250 MPa
(246.500 psi)
(14.500 – 36.200 psi)
15 %
>100 %
45 MPa
8 MPa
(6.250 psi)
(1.160 psi)
3,5 KJ/m2
No break
186 °C
150 °C
(366 F)
(302 F)
50 %
50 %
Shore A 90
Shore D 40
Page | 22
Air Duct
With some integrated
functionality (heat shield,
injection nozzle)
New Material Grade
• Temperature Resistance
• High Impact Strength
• Improved Stiffness
Page | 23
RealityTests of a new grade with
improved mechanical properties
Air Duct had been in
the car since
26./27.7. in
Hockenheim,
23./24.8. Red Bull
Ring in Austria,
6./7. 9. in Dijon
Good performance,
no failure!
Page | 24
Biobased SLS material
Pilot plant for omega-amino lauric acid (ALS) since beginning of 2013
Alternative to petroleum based laurin lactam
Material 100 % bio based
Applicable to SLS
Page | 25
- QA for AM
Responsibility
• validated in 1997 under the EU
Eco-Audit (EMAS) regulations.
• certified according to ISO
14001:2005
• The management systemcertified to ISO 9001:2000
Page | 26
- Where quality control of the powders
takes place:
Page | 27
Fields of R&D - Value Chain
Fundamentals
Pre
Processing
Process
Machine
Material
Post
Processing
Assembly
Application
Develop
ment
Page 28
Additive Fabrication Processes
Benefit of FEM
Modell
Variation
hakenvoll
hakenvoll
1+5 mm Radius
5 mm dick, 1+5 mm
Radius
3+5 mm Radius
optimal
hakenhohl
hakenhohl
Volumen
(mm³)
5792
9587
σ max
N/mm²)
15,2
5,1
ε max
(%)
0,85
0,29
Auslenkung
(mm)
15,7
3,1
4305
5766
13,8
3,3
0,80
0,18
17,7
3,2
Tensile stresses and elongations as well as the movement of the tip can be
reduced to an amount of 20 % - with the same amount of material used.
Page 29
The OEM‘s perspective: GE‘s plans for AM
General Electric (GE) is expanding the uses of 3D printing and
expects the technology to be involved in more than half of its
manufacturing in 20 years.
GE uses less than 10% of 3D printing in its manufacturing
processes today, but that share should rise to 20% to 25% in 10
years and 50% or more in 20 years, says Christine Furstoss, GE's
technical director of manufacturing and materials technologies in an
interview with IBD.
Oct 10 2013
Page | 30
Future Zone - AM
Large steps forward need their time !!!
Big Bang
New upcoming applications in different branches
Page 31
Contact Information
Sylvia Monsheimer
Director Additive Manufacturing
Performance Polymers
Phone +49 2365 49-5911
Mobile +49 151 151 010 55
Fax +49 2365 49-805911
[email protected]
Paul-Baumann-Straße 1
45772 Marl
Germany
www.evonik.com
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Additive Manufacturing - Hessen

Transcrição

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