• The joint project of Premium AEROTEC, EOS and Daimler demonstrates the great potential of production of replacement parts and mass production of parts
• Truck parts have begun additive manufacturing and are currently evaluating the potential to provide more 3D printed parts for traditional and electric vehicles
• The manufacturing cost of parts can be reduced by up to 50%
• Industry 4.0 in Farrell, Germany: Fully automated production processes and continuous data links are managed by the control center
• From data preparation to quality control, an integrated, scalable process chain covers the entire process
The NextGenAM (Next Generation Additive Manufacturing) project was launched in May 2017 and is a pilot production line for a new generation of automated "additive manufacturing" processes jointly developed by partners Premium AEROTEC, EOS and Daimler. The project's prospects were optimistic from the beginning and have now been successful.
3D printing, also known as "additive manufacturing" (AM), is becoming more and more interesting as a complement or replacement to traditional manufacturing techniques. It is called "additive", because in the process of technology implementation, layers of material are superimposed, and then they are solidified by energy. In addition to plastics and ceramics, 3D printing technology can also produce metal parts.
The pilot project aims to develop a new generation of all-digital production lines that will enable the production of aluminum components for the automotive and aerospace sectors, and to make the cost-effectiveness significantly higher than currently achievable. The "Next Generation Additive Manufacturing" project has achieved certain results: As far as the overall production process of Premium AEROTEC is concerned, compared with existing 3D printing systems, manufacturing costs can be reduced by up to 50%.
"In the aircraft industry, Premium AEROTEC is already a pioneer in the field of international metal 3D printing. Our goal now is to continue to advance at this stage of professionalism and apply the technology to other industries." Thomas Ehm, Chairman of the Executive Board of Premium AEROTEC "Therefore, the success of the 'Next Generation Additive Manufacturing' project is an important part of our strategy."
Capacity will further increase
A continuous 3D data link with integrated quality management makes this production system one of the first examples of future Industry 4.0 benchmarks. The manufacturing process is fully scalable: production lines can be easily replicated to expand the plant's capacity. With this number rising, further substantial savings are expected in the future. Today, the pilot equipment has been able to automate the production of parts and achieve quality standards for mass production.
The components required by Daimler are already manufactured on the Premium AEROTEC new technology production line. For example, the truck division is already using truck diesel engine mounts from Premium AEROTEC as the first replacement parts.
Truck and bus replacement parts
The 3D printing process is very useful in the field of replacement parts. Because when there is a problem with the tool or for some replacement parts that are not used often, compared to the traditional sand or die casting process, 3D printing can make the parts cheaper and more profitable. Currently, Daimler Bus's 3D Printing Capability Center is reviewing print requests for the first batch of 3D printed aluminum bus replacement parts. An analysis team in the field of passenger cars is also considering potential applications for this technology.
Small parts mass production and opportunities for development
"Additive manufacturing is also suitable for the smallest batch production of new cars (limited editions). The systematic development of 3D printing-specific parts means that production costs can be further reduced and quality can be continuously optimized." Daimler is responsible for future technology According to Jasmin Eichler, "3D printing also has special significance in the development of automotive technology. Compared with traditional production processes, additive manufacturing can usually produce a smaller number of products more economically and faster."
3D printing is also suitable for internal combustion engine vehicles and electric vehicles, such as battery-mounted cooling circuit integrated substrates in electric vehicles.
Based on high product quality
The pilot plant is based on high product quality: the aerospace sector also mandates the use of high-strength aluminum / magnesium / rhenium alloys (also known as Scalmalloy®).
The classic material often used in the automotive industry is aluminum alloy (AlSi10Mg), whose performance has been continuously improved in pilot projects. Compared with the beginning of the cooperation two years ago, the material strength and the quality of completion have been significantly improved.
Looking to the future: 3D printing has good prospects as a production method
All quality checks have now passed and the results are exciting, and the project is preparing for the review in accordance with VDA 6.3 industry standards. This is one of the prerequisites for Daimler to choose a 3D printing supplier for mass production of its parts. In the future, the automation of the entire additive manufacturing production chain will make it possible to produce larger quantities of parts with the same reliability, functionality, durability and economic benefits as traditional manufacturing components. The components of the new car can be optimized for 3D printing at the design stage, which brings more advantages in terms of cost. The lightweight advantages brought by 3D printing are also of particular interest to electric vehicles. For replacement parts, the 3D printed "on-demand" production feature can help save storage costs. This vision Daimler is also known as "digital inventory", in other words, centralized digital manufacturing data allows 3D printing of replacement parts to be dispersed and used in different places to produce replacement parts.
As a result, 3D printing, as a complementary, versatile and relatively young production method, is being further developed in the automotive and aerospace fields.
Project partners
Premium AEROTEC is the world's first component manufacturer to provide titanium alloy 3D printed parts for Airbus aircraft production. The company is a global aerospace leader whose core business is developing and manufacturing aircraft structures made of metal and carbon fiber composite materials. The company has plants in Augsburg, Bremen, Nordenham and Farrell, Germany. Premium AEROTEC is responsible for the entire production process in a joint project.
EOS is a global technology leader in 3D printing for the metal and polymer materials industry. Established in 1989, EOS is an independent company that provides comprehensive additive manufacturing solutions as a pioneer and innovator. EOS 'solution portfolio including system, material and process parameters helps customers to establish a decisive competitive advantage in product quality, achieve sustainable production, and obtain long-term economic benefits. In the joint project, EOS is responsible for providing all 3D printing technologies and related software solutions, as well as a control center that connects and manages the production chain.
Daimler contributed to the project's large-scale mass production experience. In this project, Daimler's research department and advanced development department cooperate closely, and the scope of cooperation includes parts samples, algorithm robustness and digitization of parts data throughout the production process. Testing of component samples and standardized manufacturing practices for 3D printing are also the responsibility of the automaker. In addition, it is also responsible for monitoring verification and certification according to the standards for mass production in VDA 6.3.