Tag Archives: 3D Printing

LIA’s Laser Additive Manufacturing Workshop (LAM®) 2017 Explored Top Innovations, Insights in the 3D Printing Revolution

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Notable names in Additive Manufacturing, including GE Additive’s Greg Morris and Marc Esformes of Stryker, gathered in Houston, TX for the two-day event

FOR IMMEDIATE RELEASE

ORLANDO, FL – MARCH 14, 2017 – The Laser Institute of America’s 2017 Laser Additive Manufacturing Workshop (LAM®) took place February 21–22 in Houston, Texas. Researchers and industry leaders from all over the world came together to discuss the latest advances and future challenges within the world of laser additive manufacturing. The two-day event featured
presentations, exhibitors and ample networking opportunities for attendees and industry professionals alike.

“LAM offers its attendees the opportunity to create lasting relationships with key individuals in their industry,” said Jim Naugle, Marketing Director with LIA. “This year was no exception.”

Attendees hear about the latest AM Innovations at LAM 2017 in Houston

Presentation Highlights

Conference General Chair Milan Brandt of RMIT University addressed the conference, officially kicking off the event.

“Laser systems are at the heart of metal additive manufacturing technology,” says Brandt. “This year’s conference provided an opportunity for those involved with laser technology to explore the latest progress and challenges in additive technology, including the latest in Nano-additive technology and medical applications.”

The workshop opened with a keynote presentation from GE Additive’s Greg Morris, titled Accelerating the Additive Revolution, which highlighted the additive manufacturing efforts led by General Electric, including the company’s plans to be vertical by 2022. In regards to the future of additive manufacturing as a whole, Morris suggested that while the current supply chain will not be immediately replaced, a definite shift is occurring, with co-existence happening in the foreseeable future. He added that laser additive manufacturing has revolutionized jet engine production, reducing 855 individual parts down to 12.

Representing the medical side of additive manufacturing, Marc Esformes of Stryker presented Additive Manufacturing of Medical Implants. As a part of one of the pioneering companies utilizing additive manufacturing for medical devices and tools, Esformes emphasized the potential for revolution when it comes to using AM for life-saving medicalpurposes.

“We can design anything,” Esformes said, in reference to how implants can be custom designed by doctors, for patients using additive manufacturing. “Custom implants can go from 3D scan to 3D part in just a few weeks.”

Our final keynote, Simulation and Modeling of the Metal Powder Bed Fusion Additive Manufacturing Process, was presented by Wayne King of Lawrence Livermore National Laboratory (LLNL)

and focused on results of extensive efforts to improve qualification of parts produced using laser powder-bed fusion AM by applying physics-based models. King, a widely-recognized expert andDirector of AM Materials at LLNL described the multi-scale modeling efforts of his team, focusing on powder-scale and parts-scale models.

The powderscale model has become so powerful that it can now predict phenomena that was unanticipated, as well as nearly every spark and splatter, occurring in the powder-bed and melt pool. Even with such powerful simulation tools, there is work to be done to create more complete simulations of every step from design to part.

Exciting Developments Unveiled at LAM

Dr. Wayne King of LLNL speaks at LAM 2017

Sponsor and attendee Optomec featured the new LENS Machine Series for metal additive manufacturing applications at the event. The LENS series comes in three models and combines Optomec LENS Print Engine technology with standard CNC Vertical Milling platforms, making metal AM technology more accessible and affordable.

While using #LAM2017 on Twitter, attendees, vendors and presenters alike shared their thoughts and photos from the event. LAM 2017 provided two days packed full of knowledge and innovation in laser additive manufacturing, kicking off a new year of progress for both lasers and additive manufacturing technology.

For more information regarding LIA conferences and workshops, like LAM, please visit www.lia.org/conferences. For the latest updates regarding conferences, industry developments, and all things lasers, visit and subscribe to www.laserstoday.com.

The Laser Institute of America (LIA) is the international society for laser applications and safety. Our mission is to foster lasers, laser applications, and laser safety worldwide.

 

 

LIA’s Outlook for Lasers & 3D Printing in 2017

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Booming industries like healthcare, oil, automotive and aerospace are quickly becoming today’s 3D printing epicenters. As we saw at LAM 2017, From custom dental parts to working engine parts, the 3D printers used in Additive Manufacturing (AM) are improving and streamlining manufacturing. The advances across industries in 2017 offer the promise of a better tomorrow and the competitive force of being the first to get there.

Lasers & 3D Printing Outlook: 2017

Boeing, Siemens, GE, and Audi are just a few of the companies actively embracing the innovative possibilities offered by this new technology. The benefits to be gained from implementing additive manufacturing processes are many. Production is more efficient by creating complex, individual parts. Manufacturers are now able to expedite production time, use precision geometries and reduce the weight of parts, while at the same time maintaining strength.

What will 3D printing & lasers do for the world in 2017?

Recent Milestones & Challenges

While some companies have already modified their manufacturing processes, others are forecasting AM will be applied to their industries on a macro scale. For example, Siemens just celebrated the completion of the world’s first 3D printed turbine blade trials. The company boasts that this accomplishment will reduce the time between design and testing from two years to two months. Also, Scandinavian Oil and Gas Magazine recently published an article on how metal 3D printing will increase the flexibility of production for oil and gas manufacturing.

In a summary of the 2016 Wohlers Report, Forbes revealed just how widespread the use of 3D printing has become, as there were 278,000 desktop 3D printers purchased in a single year. Taking data from the Wohlers Report, the article went on to describe the financial impact of these purchases. Overall, in 2015 the value of the additive manufacturing industry increased to $5.165 billion.

According to TechTarget’s Albert McKeon, companies now face challenges such as how to change long-established manufacturing processes, how to safely incorporate AM into product development and manufacturing, and how to effectively harness this innovative potential by determining how their industry will benefit most from using 3D printing and AM.  Pushing forward and encouraging further innovation, NASA is in the midst of holding a contest to build a 3D printed habitat for deep space exploration. The intent of the contest is to create sustainable housing solutions which can also be used on earth.

Courtesy: Wohlers Associates

What We Can Expect to See Next

3D printing is a gateway to more: more customizations, more parts manufactured at a faster pace and more opportunities to introduce these technologies into a range of industries. Every day new applications of this technology are developed, and more industries are determining how to best incorporate 3D printing into their value chain.

With the increased applications of 3D printing and additive manufacturing, the need to standardize these procedures has grown. Private and public sector organizations are teaming up to address this need. Just this month, America Makes and the American National Standards Institute (ANSI) published a roadmap which identifies gaps in AM standards and areas requiring more R&D. Per 3DPrint.com, as more industries adopt this technology in different ways, the need to continue to develop regulatory procedures will grow.

Your Turn: Which Additive Manufacturing innovation over the last several months do you think will have the biggest impact on 2017? COMMENT Below.

Stay updated on the latest 3D Printing & AM Trends. Follow the LasersToday.com blog here to receive the latest thought leadership by email. To learn more about LIA’s LAM Workshop, visit the official LAM website.

Metal 3D Printing: A Machine Shop’s 73 Year-old Journey in the Industry

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By Wesley Hart

Imperial Machine & Tool Co. took delivery of their first metal additive manufacturing (AM) machine in 2013 — a Selective Laser Melting system from SLM Solutions. The decision to invest was made after seeing one of these “metal 3D printers” in action, growing a component layer-by-layer from titanium. That demonstration made it clear to Imperial that this was powerful technology, and would play an integral role in the future of advanced manufacturing.

An SLM 280 HL and an SLM 280 HL “Twin-Laser” in Imperial’s additive manufacturing laboratory.

Over the last four years, the folks at Imperial have spent thousands of hours working with their additive machines. According to Christian G. Joest, Vice President of Sales and Business Development at Imperial, that’s what it takes to be successful. “Metal AM has come a long way since its inception, but it’s not a turn-key operation; you’ve got to put in the time to master your machines and lock down your process. Early adopters must be willing to problem solve and learn along the way. We understood that, and decided to make the investment — even though the path forward was not entirely clear.”

The “dive-in” approach employed by Imperial has provided them with unique and useful insight — especially for those wondering how additive manufacturing will affect their own business. LIA invited Imperial to share some of their insight during a 30 minute presentation at the Industrial Laser Conference held at IMTS 2016. This article focuses on some of the key takeaways from that presentation.

Why Invest in Metal Additive Manufacturing?

Christian began the presentation by sharing some background on Imperial, and the primary reasons they decided to get into metal additive manufacturing.

“Imperial is a 73 year-old advanced manufacturing company. Since the 1940s, we’ve been known for tackling the most challenging machining and fabricating efforts in the industry. Our earliest work was for the military and we still do a large amount of work for the DoD, but over the years we’ve expanded to serve many other high-end sectors including the semiconductor, energy and optical equipment industries.

To be successful at challenging manufacturing projects, we rely on the most cutting edge manufacturing technology available; it’s one of the reasons we’ve remained competitive and relevant over the last seven decades and a big part of why we got into metal additive manufacturing. In the 40s that meant advanced Jig-boring machines, in the 70s it was CNC machining centers, and today it’s metal additive manufacturing. We wanted to get out in front of the technology.”

The second reason was more personal.

“The other reason we became involved in additive is because we’re a fourth-generation, family-run business. We consider investments in terms of decades and generations, and we believe metal AM will be required for success for the next generation of Imperial. We understood we wouldn’t see a financial return on our investment right away, but that wasn’t what was driving this decision; we wanted to begin developing expertise as early as possible.”

Christian went on to explain how the impact of additive will be felt across all industries in a variety of ways. For example, current Imperial customers working in laser and energy beam related industries are particularly interested in metal AM for the conformal cooling possibilities.

The Importance of Hybrid Manufacturing

As the presentation continued, Christian built to an important point, “It’s not just press print.”

Christian explained that customers are looking for high-quality end-use components. Additive manufacturing can help realize innovative new designs, but they are not pulled straight from the printer.

“Misconception comes with the territory; the technology is young. Most of the public doesn’t even know that printed parts are actually welded by laser to the build plate, and must be cut off!”

Precision machining a metal 3D printed component, part of the “Hybrid Manufacturing” approach.

To successfully yield end-use components Imperial had to develop a “hybrid manufacturing” approach — using their additive capabilities in conjunction with their traditional machining capabilities. For example, they might use their metal printer to manufacture a topology optimized hydraulic manifold with complex internal channels, but they still rely on high-precision CNC machining centers to mill special SAE threads and flatten critical mating surfaces. That’s in addition to the thermal conditioning operations Imperial performs to yield the best material properties. All of these steps must be planned and accounted for before manufacturing begins! This is a far cry from pulling an end-use component straight from the printer.

The Real-World Applications of 3D Printing

Christian went on to explain the education process that must occur when interacting with new customers; getting the most out of additive manufacturing requires an understanding of what it’s best used for.

“It doesn’t make sense to use a power drill when you need a hammer. A power drill may be a more advanced tool, but that doesn’t mean it’s better than a hammer. You’ve got to choose the right tool for the right job.”

The value of AM is not in making the same part designed for CNC machining on a metal printer, it’s in realizing designs never before possible. Christian spoke of how Imperial works closely with their customers to ensure they understand the reality of when additive manufacturing makes sense, and when it does not.

“Over the years we developed a list that breaks down the best applications for additive manufacturing, based on our experience with customers and our background in manufacturing. Our goal is to provide a strong foundation for our customers to continue exploring from. Once customers understand these applications, they begin to think on their own about how additive manufacturing can positively affect their business and industry.”

A Look Toward the Future

As the presentation wound down, the focus turned to what it will take for metal AM to become mainstream. “You’re all here today because you’re interested in additive manufacturing on some level. That’s the first step. Don’t be afraid to explore further. You’re in the right place, at the right time in history to be a part of this emerging technology. Embrace the opportunity.”

Metal additive manufacturing is already making a big impact for Imperial Machine & Tool Co. and their customers. How will metal AM affect you, and what you do?

Wesley Hart is the Marketing Director of Imperial Machine & Tool Co.

LAM 2017

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Become Part of the Laser Additive Manufacturing Revolution

By Michelle L. Stock

Additive Manufacturing (AM) has already made big headlines this year as companies such as GE and Ford have announced major initiatives. These headlines hint at the ways that AM processes will impact the manufacturing world and reinforce expectations that an increasing number of production parts will be produced using them. What’s more, metal additive manufacturing has become the fastest growing segment of additive manufacturing as processes mature and the economics of the industrially-available tools become more compelling. As AM makes further inroads in many major industries, LIA’s Laser Additive Manufacturing (LAM®) Workshop provides an unparalleled opportunity to meet with leaders in the development and deployment of laser-based additive manufacturing.

LIA is the world’s premier and oldest organization promoting lasers and their applications and is in its ninth year hosting the LAM Workshop which will be held on Feb. 21-22, 2017 in Houston, TX. Well-known as an aerospace hub and home to strong medical and energy (including both traditional and renewable) sectors, the Houston region has become one of the top ranked US manufacturing cities and provides an ideal setting for advanced manufacturing meetings.

How do Lasers Impact Additive Manufacturing?

As LAM 2017 General Chair Prof. Milan Brandt explains, “The laser has played a pivotal role in the growth of metal AM systems globally in the last few years and will continue to do so in the future. Because it is at the ‘heart’ of metal AM technology, laser developments in terms of power, efficiency, beam quality and reliability parallel the growth and application of metal AM systems globally.”

Brandt continues, “LAM 2017 will provide an opportunity for national and international practitioners involved with laser technology to discuss and explore the latest topics, challenges and progress in additive technology and applications.” He adds that, “the new hot topics include nano-additive technology, medical applications and new software tools.”

Figure of a model of a bone and pelvis with lattice type titanium implant designed and manufactured at RMIT Centre for Additive Manufacturing.

Figure of a spinal Ti lattice-based disc in a model of deformed lumbar vertebrae. The disc was manufactured at RMIT Centre for Additive Manufacturing and implanted into a patient in 2015.

This year, LIA has tapped Brandt of RMIT University (Melbourne, Australia) as General Chair, along with John Hunter of LPW Technology (Pittsburgh, PA) and Prof. Minlin Zhong of Tsinghua University (Beijing, China) as Co-Chairs. Brandt brings 30 years of expertise in laser material processing to his work in additive manufacturing processes. Hunter is an expert in powder manufacture for additive manufacturing. Zhong has a wealth of experience in laser micro- and nano- fabrication and laser surface engineering. With their background and knowledge, this year’s workshop chairs have prepared an outstanding program that builds on past LAM Workshops, provides the latest updates, and peaks into the future.

The Program: AM Trends, Technologies, Applications & Something New

The LAM program will kick off with an overview of Trends in Laser Additive Manufacturing by major companies with high visibility to the state-of-the-art in additive manufacturing. The keynote presentation will be from Greg Morris discussing Accelerating the Additive Revolution. GE’s already extensive activities in AM are undergoing a period of rapid evolution as new acquisitions such as Concept Laser are integrated. A pioneer in the use of AM for medical devices, Stryker Corporation, will be represented by Marc Esformes who will speak about Additive Manufacturing of Medical Implants. Arconic (formerly Alcoa) has also been deeply involved in AM as a material provider and John Barnes will close the session presenting Arconic’s Additive Manufacturing is about the Making.

The first day sessions will continue with speakers from both academia and industry who will provide details on the building blocks of AM: materials, structures and design. To finish off the first day, the final session will focus on a new and exciting area of AM for micro- and nano- structures, and includes a talk on laser printing of graphene.

Day two will focus on technologies and applications. Wayne King of Lawrence Livermore National Laboratory (LLNL) will start the program off with a keynote on Simulation and Modeling of the Metal Powder Bed Fusion Additive Manufacturing Process. Dr. King is an expert on the transition from conventional manufacturing methods to metal additive manufacturing, and LLNL has been a leader in simulation of laser-based AM. The program will continue with the latest updates on monitoring of AM processes and beam profiling and includes talks by Fraunhofer IWS and Siemens.

World-class Networking

One of the highlights of LAM 2017 is the Exhibitor Reception, which caps off the first day of the Workshop. It provides an informal chance to interact with speakers, attendees, and also with LAM’s sponsors, including Alabama Laser, American Cladding Technologies, Inc., Fraunhofer USA, IPG Photonics Corporation, Laserline Inc., LPW Technology, Inc., Optomec,  OR Laser Technology, Inc., Polymet Corporation, Praxair Surface Technologies and TRUMPF Inc. The exhibition will include many key additive manufacturing suppliers. The Reception provides time to network, time to recharge over drinks and food, and most importantly, a chance to find solutions to your additive manufacturing challenges.

“This isn’t just a workshop,” said Jim Naugle, Marketing Director with LIA. “This is an opportunity to establish lifelong business relationships with experts in their respective fields. Our goal is for attendees to leave with more than business cards, we want them to leave with business partners.”

The Must-attend AM Event

LAM 2017 will provide attendees with depth of knowledge in the major laser-based processing technologies, as well as the latest applications and trends. This is the go-to event for laser additive manufacturing. Don’t miss out — visit www.lia.org/lam for more information and to register today. See you in Houston!

DigiFabCon Explores How Digital Fabrication Such as Laser Cutting & 3D Printing Is Changing the World

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From a mobile Humanitarian Fab Lab in refugee camps that uses laser cutting for building temporary housing to 3D Printing on the International Space Station, Digital Fabrication is changing almost every aspect of our lives.  On March 30 and 31, 2017 at the Microsoft NERD Center in Cambridge, MA, visionaries at DigiFabCon will explore the opportunities and challenges found in bringing these CAD based technologies to new, exciting arenas.  Whether for manufacturing workforce training, K – 12 education, rapid prototyping, re-designing standard products, improving surgical procedures, or fostering entrepreneurship, the tools of digital fabrication are impacting entire communities.

DigiFabCon will feature keynotes from Sherry Lassiter, Director of the Fab Foundation and Dale Dougherty, founder of Maker Media which includes MAKE: Magazine and Maker Faires.  They will give an overview of the compelling digital fabrication stories from Fab Labs and makerspaces around the world.  Dr. Neil Gershenfeld, Director of the MIT Center for Bits and Atoms, will discuss technical advances that are making digital fabrication tools accessible to “anyone who wants to make (almost) anything”.   This includes work in his lab on Machines that Make Machines, although Dr. Gershenfeld always says the impact of these tools is social, not technical!

Courtesy: DigiFabCon

 

The interactive program includes:

  • Sarah Boisvert, past President of LIA, describing a new national digital fabrication certification program for operators and technicians with a panel discussion with participants from Indian Hills Community College, the Community College of Baltimore Country, Century College and the Space Coast Fab Lab
  • David Ott explaining the International Committee for the Red Cross Humanitarian Lab project
  • Tomas Diez, from Fab Lab Barcelona, reporting on progress for self-sustainable Fab Cities
  • Andreas Bastian, of Autodesk, sharing design challenges in the Enable Community Foundation 3D Printed prosthetic hand project
  • A panel from Limitless Child International, Fab Lab Tulsa and Fab Lab San Diego on utilizing mobile fab labs to bring technology to rural and underserved areas.
  • a participatory exercise by TIES fellows examining biomimicry in design

The program includes a Fab Festival where participants can get hands-on demos in 3D Printing, laser cutting, CNC machining, CAD and much more.  Preliminary exhibitors include ShopBot Tools, the Roxbury Innovation Center, 3D Print Life, Limitless Child International, and Fab Lab Hub.  The Festival will also feature book signings by Dale Dougherty, founder of Maker Media, and Rachel Ignotofsky author of Women in Science. Generous sponsorship from Chevron, Microsoft, and ShopBot Tools keeps DigiFabCon registration to just $49.

In this, DigiFabCon’s 5th year, a pre-conference short course has been added. LEAN 101 is a hands-on workshop to introduce manufacturing managers, startup founders and entrepreneurs, and makers to methods for improving time to market, production cost and product quality through a simulated, hands-on making exercise.  Our instructors are LEAN gurus of the first rank.  Joe Rizzo, CEO of Lean is Green, previously ran factories for GE when the legendary Jack Welsh was CEO and Scott Gauvin, CEO of Macresco, focuses on creating high performing, humanistic workplaces.

For details and to register, please go to www.DigiFabCon.org.