On September 4, 2018, in order to create an automated production line for 3D printing of aluminum components used in the automotive and aerospace industries, the NextGenAM project established its first pilot plant in Varel, northern Germany.
Pilot production line of Premium AEROTEC in Varel, northern Germany
The pilot plant will be operated by project partner Premium AEROTEC, a subsidiary of the Airbus Group. German industrial 3D printing solution provider EOS and car manufacturer Daimler also participated in the development of the NextGenAM project.
"With this collaborative pre-development project, we have taken an important step towards the cost-effectiveness of metal 3D printing throughout the process chain," said Jasmin Eichler, future technology director of research at Daimler AG. "This project lays the foundation for the production of a larger number of parts in automobile manufacturing, and it can have the same reliability, functionality, long-term and economy as traditional production."
In 2017, Germany's Premium AEROTEC, Daimler and EOS co-sponsored the NextGenAM project to study the various stages of metal 3D printing, such as material transportation and post-processing between machines, to develop automated solutions for intelligent production plant systems.
This automation solution aims to reduce the manufacturing time and cost of current industrial metal 3D printing systems using a complex digital data collection system (ie Industry 4.0).
Dr. Tobias Abeln, chief technology officer of EOS, said: "The integration of AM systems in automated production lines is an important milestone in the widespread application of our technology in production scenarios."
EOS AEROTEC pilot production line in Varel, northern Germany
The new dedicated test facility includes the EOS M 400-4 four-laser system for industrial metal 3D printing in the center of the production line. These systems are equipped with compatible modules, including powder stations that are connected to independently set up and unpack stations.
This allows automated filling and emptying of aluminum powder material, and in addition, disassembling printed parts from the powder bed can be performed independently to increase productivity. 3D printed parts also use fully-automated guided vehicles to be transported between stations under the protection of an inert gas.
In addition, post-processing has been automated by mobile robots. The robot transports the build platform into the furnace along with the printed parts for subsequent heat treatment. The same robot will then carry them to a 3D optical measurement system for measurement to ensure accuracy. Finally, the build platform is divided into sections using a saw, and the parts are ready for further use. This simplified process can produce complex, lightweight and sturdy components.
"In this project, we have significantly reduced the production cost of each part, thereby creating economic prospects for large digital 3D printing factories," added Dr. Thomas Ehm, CEO of Premium AEROTEC.
The automated production line will be tested with production data and component reviews in the coming months.