1,The nature of technology: paradigm shift from "stacking elements" to "integrated structure"
The biggest advantage of the printing in metal 3D printer is its ability to break through the limitations of the conventional method of subtractive processes, and to obtain a direct complex structure forming in the melting of the metal powder in succession. For the Platinum BLT-S1500 equipment, its 32 laser collaborative scanning system in a molding chamber of Φ1.5m can produce high density parts of the metal with full metallurgical bonding, and the layer thickness is 0.06mm. This is a technical means to realize structure integration of the parts that need to be processed separately and then assembled in conventional manufacturing by topology optimization design.
Common example 1: Fuel nozzle of an aircraft engine
The GE produced SLM additive manufactured (3D printed) LEAP engine injector fuel nozzle takes a part made from 18 pieces and combines them into one single 3D printed piece. Not only does this reduce 127 welds but internal channel optimisation increases fuel efficiency by 15% and weight by 25%. The structural integration also results in a direct reduction in the tooling, testing equipment and people required to interface the structural features.
Case 2: Typical heat transfer tubes of nuclear power steam generators
Nickel-based alloy heat exchange tube 3D printing technology 3D printing nickel based alloy heat transfer tube, conformal cooling water circuit design state power investment corporation, 4th generation nuclear power equipment Conventional methods have to manually build the cooling channel by drilling, welding and so on, whereas the 3D printing technology can produce spiral channels just inside the wall of the pipe, improving the cooling efficiency by 30% and eliminating more than 200 weld seams from which leakage might result. The construction process decreased from 12 to 3.
2,Applicable scene: comprehensive penetration from high-grade equipment to general machinery
assembly procedure of metal parts has been greatly exercised on a variety of industries 2.2Benefits of Metal 3D Printing for assembly processes.Constraint Manufacturing constraints (parts size and shape) Manufacturing constraints (Conventional machining processes) Influence on Product DesignTopological optimization shape Metal 3d printing And Metal parts surface finish level Metal parts tolerances level Required joint strength Environmental Friendlinessprocess time Reduction in energy demand Product Benefits Assembly Charges Remanufacturing FacetsDesign for Assembly Efficiency Ability to integrate many small parts in one Ripple Effect of existing design Improvement in design aspects of existing Assembly ProcedureDetail part requirement in product designNew product approach Responsiveness New design approachMarket Effectscope of product design competitiveness IRC foster Platform stakeholder client Supplier Partner Table Business PerspectiveSWOT Analysis for Printing- Metal Parts and MAECorporate Opportunities and ThreatsAdvantages Set standard with main customer(s) Open up new markets Teaming opportunities Open advertising, Engage Research Institutes, and Universities Weakness Reinforce the collaboration with all stakeholders Forge alliances with prospective expert client(s) Launch cost reduction demonstration plant Insecure against signal tech- nological breaktroughs Reinforce CRM and inflict strategic purchasing policy Solidify/Reinforce Open Innovation policy reinforcing the open innovation policy Minimize the negative impact Copyright © 2018, IGI Global.
Aerospace industry: lightweighting and structural integration with functionality
The Airbus A350XWB also features 3D printed titanium alloy brackets, which streamline production by converting 36 different parts to 18 to improve the way the wings connect to the fuselage by 40% while saving time on assembly 60%. More importantly, the bracket reduces weight by 30% through the design of lattice structure without sacrificing the strength. This construction needs dozens of stay plates to be rivetted together in the conventional way.
Application on Energy equipment field: Complex flow passage and thermal management optimization
Siemens Energy applies 3D printing technology for a double-layer wall cooling structure in the production of gas turbine combustion chambers. Under this design, the conventional cooling system, composed by 50 elements from installation group, was replaced by a single piece, which raised the burning camera temperature uniformity by 20 °C. Meanwhile, the mounting process shortens, from 127 in to 18 in and the product qualification rate improves, from 82% to 98%.
Automotive manufacturing: Modular design and rapid iteration process platform.
BMW Group integrated 3D printed aluminum alloy battery tray into the iX3 electric vehicle car model, using topology optimization to evolve the original sheet metal welding structure into a monolithic frame. This design not only reduces from 23 to 5 the number of modules and the number of connections required to assemble the battery, but also optimizes the fluid dynamics to enhance battery heat dissipation efficiency by 15%, extending the driving range by 15km. In the transformation of the production line, the 3D printing tray reduces 8 welding stations to 1, saves the equipment investment by 70%.
3, Industrial Value: From Cost Reduction to Rectoring of Entire Supply Chains for Maximum Efficiency
The manufacture of transport carriers, for example, costs little as the metal dies are not impacted by wear and tear)» and benefits from the advantages of a process that will revolutionize the manufacture of transport carriers due to the simplification of assembly processes enabled by metal 3D printing.
Lower inventory price and logistics complexity
In a traditional manufacturing approach, a complex device may have hundreds of specific requirements for bolts, gaskets and couplings, while 3D printing technology can reduce the number of components by 60% -80% with structural fusion. Case study of a wind power equipment manufacturer indicates that, e.g. adopting the 3D printing for the main bearing seat, the quantity of the supporting parts was reduced from 127 to 23 and the material turnover of inventory was 3 times faster in 3D printed parts, and the relocation cost was reduced by 45%.
Quality control and production flexibility enhancement
For the medical implants the design of the 3D printed hip cup replaces 12 welding seams in conventional processes and its fatigue life is larger than 10 cycles. The inspection in the assembly operation is thus kept to a minimum, i.e. practically reduced to the usability of the finished molded body. According to the practice of an orthopedic instrument enterprise, the defect rate of a 3D printed product is reduced from 2.3% to 0.15%, and small-batch customized production is supported, and a production line switching time is reduced from 72 hours to 8 hours.
Sustainable Development and Resource Optimization Efficiency
The material utilization rate of metal 3D printing can be up to more than 90%, up to 4-5 times higher than that of conventional forging. For ship propulsion shafts manufacturing, with 3D Printing technology, we brought material save from 12 ton to 4.8 ton, meanwhile, the structure design makes the shaft weight reduction 35%. The weight reduction effect causes a reduction in lifting capacity of equipment and manual labor for assembling. Most importantly, 3D printing makes it possible to recycle the waste metal powder. The experience of an aviation parts company indicates that the recovery rate of the powder can be as about 95%, the unit part carbon emissions decreased 56.5%.