The industrialisation and digitalisation of additive manufacturing (AM) for automotive series processes has been prosperous.
A undertaking consortium funded by the German Federal Ministry of Education and Investigate (BMBF) and led by the BMW Team was introduced 3 years back, with smaller and mid-sized enterprises, huge providers and analysis institutes. The typical goal was to revolutionise steel 3D printing in normal output of cars and trucks.
The 12 associates of the consortium presented the prosperous implementation of the IDAM (Industrialisation and Digitalisation of Additive Manufacturing) job at the BMW Team Additive Manufacturing Campus in Oberschleißheim, where a digitally related, entirely automatic 3D printing manufacturing line has been set up and prepared for automotive common production. An additional line is located at the company GKN Powder Metallurgy in Bonn.
Around 50,000 elements per 12 months can be created price tag-correctly in common aspect output, as nicely as far more than 10,000 person and new areas, by means of 3D printing working with Laser Powder Mattress Fusion (LPBF): The starting up material, metallic powder, is remelted with a laser, layer by layer, at the site the place the solid part requirements to be designed at every single level. Applying this 3D printing procedure signifies specified applications are no for a longer period required and new layout choices can be realised – which enormously will increase overall flexibility.
Acquiring started out out from a notion outline in 2019, fully automated driverless transport techniques (FTS) now carry the 3D printers’ cellular make chambers between modules in the IDAM output lines. The equipment are orchestrated by a central control unit that consolidates all production facts from unique line modules to assure optimum productiveness and high quality.
About the training course of the project, modern concepts were formulated for automatic technology of 3D printing construction knowledge. Thoroughly automatic modules now transportation the processed metal powder to workstations in which they get ready the substance independently. Post-processing of the manufactured elements takes position at specifically developed stations that are also absolutely automated. The excellent of the components is best priority. Excellent assurance of the finished sections will take location in-line, during the laser melting course of action, employing sensors. This contains examining emissions from the molten pool with a CMOS digicam and pyrometer. AI algorithms are employed to correlate the info collected with true ingredient good quality. This signifies process deviations can previously be determined in the course of generation and component high quality evaluated.
Successful implementation of the undertaking referred to as on the abilities of all challenge partners. This was the only way to realize digitalisation and automation in mechanical and plant engineering, in ingredient style and design and in the spot of metal 3D printing.
“From the pretty very first working day of the venture, you could truly feel the crew spirit amid the associates. Learning from a person an additional, developing revolutionary remedies together and making the ideal use of every single partner’s person strengths – individuals ended up crucial to productive industrialisation and digitalisation of additive manufacturing,” according to Felix Haeckel, consortium leader and BMW Group task manager.
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Video Timeline
:00 – IDAM-line: 24/7 manufacturing
3:35 – Pickup of the managing robot via Computerized Guided Cars (AGV)
14:08 – Set up course of action of Laser Powder Mattress Fusion Device
35:44 – Depowdering establish position
1:48:11 – Concluded construct work and portion separation
1:59:59 – Intelligent interim storage
2:05:34 – Plant exterior
