Formnext magazine EN - Fon Mag
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
02/2021 EN
fon formnext magazine
Foundries: Fittings: Aerospace:
A forward-think Grohe 3D-prints How the satel
ing concept in faucets for lite industry is
3D-printedmolds the luxury set using AM
» Page 08 » Page 14 » Page 16 by
formnext magazine · Issue 02/2021 [ 03 ] formnext magazine · Issue 02/2021
EDITORIAL
H
umankind has always been driven bulk of the population is very likely to be
to come up with new develop- inoculated by the end of the summer at
ments and make new discoveries. the latest.
For a prime example, look no further than The resulting upswing in the general
the latest NASA mission to Mars, where mood is also evident in the feedback
the helicopter Ingenuity recently rose we’ve received from exhibitors regarding
from the surface of the red planet. Past this year’s Formnext. We already have
If you
journeys of discovery might not have almost every key player on board, along
made it quite that far, but were no less with an entire array of small and midsize
spectacular: Around 3,400 years ago, the companies – many of them first-time
famed Greek hero Odysseus experienced exhibitors from various countries. With
compromise so much adventure, hardship, and revela-
tion on his travels from Troy back home
that Homer’s account of his story (the
more than 55 percent of our exhibitors
set to arrive from outside of Germany on
16–19 November, it’s clear that Formnext
bold decisions
Iliad) went on to become an international 2021 will draw attendees from all corners
bestseller. of the world.
Since the people of the ancient world As the organizers behind this event,
had decidedly less digital processing we will nevertheless continue to keep a
you lose. power at their disposal to plan for every
eventuality of their trips, they sought out
the wisdom of an oracle. The ruins of the
close eye on the ongoing development of
the pandemic and adjust our concept.
Meanwhile, we plan to heed the famous
most well-known temple where travelers inscription at the temple in Delphi –
could solicit such advice can still be »know thyself« – by leveraging the expe-
found in Delphi today. An oracle’s cryptic rience we have gained from these chal-
prophecies offered clues as to how wars lenging times to forge ahead with new
would end and whether entire civiliza- vigor. After all, the team behind Formnext
tions would survive. and the entire AM industry still have a
Due to the coronavirus pandemic, long and thrilling journey ahead of us.
we’ve essentially been on an uncertain
journey of our own for more than a year
now. At this point, we wouldn’t be above
consulting an oracle ourselves given the
choppy waters we find ourselves naviga-
ting as trade fair organizers. Sincerely, Sascha F. Wenzler
Still, there are plenty of signs that Vice President Formnext
augur a return to the fertile economic
terrain we’d grown accustomed to. Vac-
cination efforts are picking up speed in
Cover: Gienanth Group
many countries, especially in Israel, the
United Kingdom, and the United States.
Some international companies want to
start allowing business travel again as
[ Jonas Brennwald, Co-CEO Grohe AG and Leader Lixil Emena ] soon as May. Here in Central Europe, the
formnext magazine · Issue 02/2021 [ 04 ] [ 05 ] formnext magazine · Issue 02/2021
CONTENTS FORMNEXT NEWS
12
16
14
REAL-LIFE ENCOUNTERS AND FRESH NEW COLORS
Following a year in which trade fairs Formnext-team is counting on a positive trend, A NEW LOOK FOR FORMNEXT
08 all across the world went almost enti-
rely digital, Formnext 2021 now pro
which should enable more people to undertake
business trips as the year progresses.
At the heart of Formnext’s new key visual is
a sphere made up of lots of lines, all of which
interlace and merge to create an intricate
mises to combine such elements with AS MUCH FLEXIBILITY AS POSSIBLE whole – a nod to the intelligent design that is
a return to real-life encounters in a To provide Formnext’s exhibitors with as only made possible by additive manufacturing.
08 » T HINGS ARE STARTING
TO GET ROLLING «
05 FORMNEXT NEWS
»R
eal-life encounters and
hybrid concept. To symbolize progress
and new beginnings Formnext is laun-
much flexibility as possible in their planning,
both the related deadlines and the event’s
The slogan »Where ideas take shape« is there-
fore reflected in the visual language of the new
» 3D-printed molds: a forward- fresh new colors ching a brand-new key visual. general terms and conditions have been adjus- design. The new look also puts the spotlight on
ted. Exhibitors can, for example, cancel their Formnext’s key objective of bringing the whole
thinking concept for foundries
bookings free of charge until the end of June. world and all the process steps involved in
06 NEWS In light of the current situation, Formnext 2021 innovative manufacturing together in one place,
12
T
TAPPING INTO NEW » Lithoz · Nikon · he event will enable the world of additive is also offering modified, turnkey booth con- in order to identify new potential for industrial
Trumpf · Wohlers manufacturing to finally come together cepts that make planning an entire trade-fair production.
MARKETS again in Frankfurt on 16 – 19 November appearance a simple affair without any major Formnext’s existing color scheme provided
» Automotive supplier Burgmaier 2021 »The feedback we’ve received from exhibi- additional effort. the foundation for the blue-green color palette,
hoping to tap into new markets
with AM
20 TRENDS
» Hansgrohe / EOS · Holo ·
tors, attendees, and the exhibitor advisory
board has made it clear that a genuine in-person
In terms of its subject matter, Formnext will
continue to focus on the entire process chain
although the new colors are fresher and more
modern. The blue stands for an event that can
SLM Solutions · Makerbot event is essential to this industry. Everyone involved in industrial 3D printing. »An array o f be relied on and is associated with technology,
is longing to visit some real booths and have highly innovative companies from the various innovation, and communication. And the fact
14 LUXURY DESIGNS FOR some face-to-face conversations,« reports sectors of this industry can’t wait to present that Formnext is a modern, forward-looking
OASES OF WELLNESS
»G
rohe marks two years of 3D-
22 OUTSIDE THE BOX
» In pecunia veritas
Sascha F. Wenzler, Vice President of Formnext
at Mesago Messe Frankfurt GmbH.
their latest developments to our audience in
person,« Wenzler says.
platform is reflected in the fresh new shade of
green.
Since the health and safety of all attendees To offer a counterpart to the in-person event
printing exclusive faucets remains priority one, the plans for Formnext for the very first time, the Formnext Digital Days
2021 are being made on the basis of a health are being planned two weeks later (30 Novem-
concept that at minimum meets the correspon- ber – 1 December 2021). These two days are to
16 OUT OF THIS WORLD
» S pace series, part II: The role of
ding legal requirements. The overall event
concept will also be adapted to reflect the
provide an intriguing digital platform, especially
for attendees and exhibitors who can’t make it to FURTHER INFORMATION:
AM in satellite construction latest developments in the pandemic. Here, the Frankfurt in November due to travel restrictions. » formnext.com
formnext magazine · Issue 02/2021 [ 06 ] [ 07 ] formnext magazine · Issue 02/2021
NEWS NEWS
LOWERING THE ENTRY-LEVEL FOR NICKEL-BASE ALLOYS, WINNERS, LOSERS, AND INTERESTING FIELDS FOR THE FUTURE
3D PRINTING CERAMICS STEELS,TITANIUM AND
ALUMINIUM
T
he Wohlers Report analyzes the conse-
115,2
quences of the pandemic for the AM
L
ithoz, a specialist for ceramic 3D printing, industry and predicts a continued high
T
has launched its 3D printer Cerafab Lab rumpf GmbH & Co. KG, Germany, recently growth rate. Although the AM industry was Trend in turnover in the
L30 which has been developed for those unveiled its new Truprint 3000 metal Addi- another sector hit particularly hard by the global AM industry
new to ceramic 3D printing and is suited to tive Manufacturing machine. The medi- Covid-19 pandemic, it remains on track for
shop floors, research purposes and small-se- um-format machine uses Laser Beam Powder growth. That is the conclusion of the recently
ries production, as Lithoz reports. The new Bed Fusion (PBF-LB) technology to produce parts published Wohlers Report 2021. The 375-page 18
machine will enable more companies to adopt with a diameter of up to 300 mm and a height of report published by Wohlers Associates found
16
3D printing as a manufacturing technique a nd up to 400 mm. It can reportedly handle all industry expansion of 7.5% to nearly $12.8
drive the growth of this technology. weldable materials including steels, nickel-base billion in 2020. However, compared to average
14
According to Lithoz, the new Cerafab L30 alloys, titanium and aluminium. Klaus Parey, annual growth of 27.4% over the previous 10
contains the full manufacturing power of the Managing Director of Trumpf Additive Manufac- years, this growth was down considerably.
12
Cerafab 7500, Lithoz’s original 3D printer. turing, stated, »We’ve improved key aspects of At the same time, the pandemic also pro-
The new entry-level machine also enables the the TruPrint 3000 to tailor it even more closely to duced winners and losers within the AM
10
development and use of own materials, making the quality requirements, certifications and industry: In the first half of 2020, smaller AM
it well-suited for use in research and labs. production processes of various industries.« companies and service providers in particular 8
Founded in 2011, the Austrian company has The new AM machine can be equipped with were the ones who suffered, while opportuni-
an export share of almost 100 percent, employs a second 500-watt laser that is said to almost ties for investments and acquisitions rose 6
more than 80 employees and, since 2017, has a double its productivity and to facilitate the move from the second half of 2020 onwards. The
subsidiary in the USA. into mass production. latter was reflected in large acquisitions such 4
Trumpf also has transformed the movement as those involving Origin (bought in December
of inert gas. The way in which it flows through 2020 for around $100 million by Stratasys), 3D 2
the machine from back to front is now steadier Hubs (bought in January 2021 for $280 million
and more uniform which, according to Trumpf by Protolabs), and Envisiontec (bought in
NEW GROWTH AREA FOR NIKON improves the quality of additively manufactured February 2021 for $300 million by Desktop
93 96 99 02 05 08 11 14 17 20 30
parts. In addition, the new machine concept Metal).
allows the operator to remove excess powder »The growth we saw in 2020 was surpri-
N
ikon Corporation has acquired majority »Morf3D has proven leadership in metal from the part while it is still inside the machine. sing. We expected it to be much worse,« Terry industrial manufacturing and generate $640 nents, where the combination of metal and
ownership of Californian AM startup additive technology, a strong innovation pipe- Previous models required the operator to take Wohlers explains in an interview with Formnext billion in revenue.« Exactly when, however, plastic is proving extremely useful and is now,
Morf3D Inc. Founded in 2015, the young line and highly specialized aerospace manufac the part out and remove the powder at a sepa- magazine. He gives an optimistic forecast for remains to be seen. thanks to the development of new manufactu-
company is headquartered in El Segundo and turing qualifications. It also brings a team of rate station. The new machine is designed to the years ahead: »We believe the AM industry The highly dynamic nature of the AM mar- ring methods, becoming a reality, says Wohlers.
Infographic: feedbackmedia.de, Source: Wohlers Associates, Inc.
specializes in metal components for the experts accustomed to partnering with custo- process the powder in a shielded environment, will begin to recover this year, with much stron- ketalso comes from the continuing develop- 3D printing of medicines is also a very young
aerospace sector, using AM technology to mers to achieve their unique requirements. using inert gas to prevent the powder from ger growth next year. We predict the market ment of innovative technologies, which means field; designing tablets in a certain way can
produce aluminum and titanium components This combination is well aligned with Nikon’s becoming contaminated during the build. A will grow to $17.7 billion in 2022.« This would new, pioneering additive manufacturing tech- make them more effective and tailored to each
for Boeing helicopters and satellites, for vision for accelerating industrialization of AM crucial advantage for sensitive industries such imply a return to annual growth rates of more nologies are still being developed every year. specific patient, which opens the door to new
example. The size of the investment has not through innovation,« said Yuichi Shibazaki, as medical device manufacturing notes Trumpf. than 20%. According to Wohlers, many of these innovative treatments.
been officially released, although the industry Corporate Vice President and General Manager Wohlers sees no end to the AM industry’s startups do not sell machines, materials, or 3D printing of food (3DPF) has already
estimate is around $90 million. of Nikon’s N ext Generation Project Division. continued remarkable growth in years to come software, but produce parts as a service. This is been a reality for several years, albeit cur-
International technology group Nikon was Purchasing this stake in Morf3D, which either: By 2030, sales of AM products and mostly because the barriers to entry are relati- rently as a niche application. However, many
founded in 1917 and is internationally ren Boeing itself has invested in in recent years via services are expected to rise to $115.2 billion. vely low: If you have a machine, a website, and different research projects are currently
owned as a pioneer of optical technologies, its venture capital arm Boeing HorizonX Ventu- This corresponds to a roughly tenfold increase the relevant knowhow, you can make a start in underway. For example, creating meat substi-
Photos: Lithoz, Trumpf
but recently was forced to announce its res, could also open the door to the satellite from the current level. Overall, the AM indust- this business. tutes (from proteins or living cells) via 3D
camera business has been ailing due to the market for Nikon (see feature starting on page ry’s share of the total global economy (cur- The Wohlers Report singles out 3D printing printing is one way of getting involved in the
pandemic. In the interest of tapping into new 16). Japanese competitor Canon set a prece- rently $80 trillion) and global industrial produc- of food, medicines, and electronics as particu- trend toward sustainable nutrition. The
growth areas such as materials processing dent for this move when it built a small Earth tion ($12.8 trillion) is still quite manageable. larly interesting fields for the future of the AM authors of the Wohlers Report therefore anti-
technologies, Nikon established its Next Gene- observation satellite and had it launched into But Wohlers is right that the AM industry »will industry. For the electronics sector, 3D printing cipate significant market growth as advances
ration Project Division in July 2019. space back in 2017. eventually account for a 5% share of global is a revolutionary way of producing compo- are made over time.
formnext magazine · Issue 02/2021 [ 08 ] [ 09 ] formnext magazine · Issue 02/2021
»THINGS ARE STARTING
TO GET ROLLING«
Text: Thomas Masuch
Gienanth Group GmbH
Founded as the »Hammerwerk« in Eisenberg (western Germany)
in 1735, Gienanth is now one of the longest-standing
companies in Germany. One of its locations in Bavaria even
dates all the way back to the year 1449. Gienanth has since
evolved into an international corporate group that employs
some 1,800 people and generates around €250 million in
turnover each year. Its products and solutions include highly
complex cylinder crankcases and cylinder heads designed
for heavy-duty engines with between 1,000 and 15,000
horsepower. Among other settings, these engines see use in
power generators, locomotives, and ships.
The gradual electrification of the automotive industry is impacting many sectors, but perhaps nowhere are the effects
being felt as strongly as in the foundry industry. At the moment, more than half of the metal components cast in Germany
are built into road vehicles, but many of them will no longer be needed in future electric vehicles. Of course, e-mobility
does present new business opportunities in this regard. However: »There won’t be enough alternative business to go
around in the foundry industry in the years ahead,« predicts Simon Geib, head of project management and business
development at Gienanth Group GmbH. This is why Gienanth, which boasts a centuries-long history in the aptly named
town of Eisenberg (western Germany), has already adapted its strategy to the new challenges ahead – and could thus be
blazing a trail for its entire industry. The 3D printing of sand molds plays a key role in its approach.
T
he drivetrains of electric cars require only molds and cores1 with a focus on new compo-
At left: around half the parts of vehicles that nent designs and smaller lot sizes.
Gienanth has been casting
run on conventional combustion engines.
iron since 1735.
Above: »As e-mobility continues to gain significance, MORE EFFICIENT COMBUSTION
Sand cores are traditionally you’re going to see more and more excess Elsewhere, Gienanth recently provided
manufactured using a core
shooting machine. capacity in this regard,« Geib reveals. »That metal casting support to the Austrian engine
makes for a very challenging future – especially developer AVL List GmbH in a research project
for foundries that mainly supply the automotive to make heavy-duty engines even more effi-
industry.« On the one hand, he believes this cient. The two partners wanted to optimize the
trend hasn’t yet arrived in the marketplace, and combustion of these units – many of which
that the spare parts trade will mitigate its weigh tons and see use in naval and power-
effects to some extent in the coming years. generation operations – by achieving higher
»Over the long term, however, there’s going to levels of ignition pressure with diesel, natural
be a kind of natural selection in the casting gas, and alternative fuels. Besides increasing
market, and companies that only supply parts efficiency, this reduces consumption, and
for combustion engines will inevitably leave.« emissions and operating costs along with it.
Founded all the way back in 1735, the What might sound simple enough involved
Gienanth Group now does 20-25 percent of its some profound technological challenges:
business in the automotive sector, which Increasing ignition pressure beyond the maxi-
means the impact of this development has mum allowed by the current state of the art
been rather moderate. It has nevertheless puts a great deal more stress on an engine,
»
Photos: Gienanth
already realigned its strategy to prioritize pro- and in particular on its cylinder head. If the
ducts that aren’t connected to the drivetrains
of combustion vehicles. At the same time,
Gienanth’s iron casting division is exploring 1
I n metal casting, a core is the part of a mold
the possibilities afforded by 3D-printed sand that prevents metal from filling the entire mold
formnext magazine · Issue 02/2021 [ 10 ] [ 11 ] formnext magazine · Issue 02/2021
cores produced the conventional way. »This combustion engines for some time. Meanwhile, Geib says was almost never the case in the
means 3D printing can be a useful addition in we handled a number of major orders last past. After all, larger series were (and still are)
the production of large quantities,« Geib affirms. year that showed us there’s a lot of momentum more profitable most of the time. Geib reports
in e-mobility.« In one example, voxeljet has that this is another area where mindsets are
»A LOT OF MOMENTUM IN 3D-printed molds for body components on behalf changing, however, and 3D printing could play
ELECTRIC VEHICLES« of larger manufacturers of electric vehicles. a more prominent role going forward. As for
Meanwhile, the quantity at which 3D-prin- Ederer suspects these molds were initially used other applications in the casting industry, Geib
ted sand cores make economic sense appears in the production of smaller lot sizes before and Benjamin Heil believe additive manufactu-
This innovative cylinder
head is designed to make to be constantly rising thanks to the develop- being replaced by die casting tools. ring has potential in the ongoing pursuit of
heavy-duty engines more ment of new 3D printers. Small series (meaning greater environmental awareness and energy
efficient.
those of less than 1,000 units) and very small PRESSURE TO OPTIMIZE PROMPTING A efficiency, which is what has led to more pres-
series (less than 20 units) have become the CHANGE IN MINDSETS sure to optimize things like heavy-duty engines.
norm for service providers like voxeljet in Back at Gienanth, the people in charge They say this is changing the way people think
recent years, but CEO Ingo Ederer could ima- can foresee their new cylinder heads being about design and manufacturing processes, as
gine six-figure amounts being produced in a manufactured with the help of 3D-printed sand well. »The development cycles in these indust-
cost-effective manner. »That would require cores – assuming the tests currently being ries are relatively long, though: For heavy-duty
things like automated unpacking solutions, conducted yield positive results, of course. If engines, they’re several times longer than for
though,« he says. they do, a small production series will be the utility vehicles or passenger cars,« Geib exp-
At voxeljet, Bavaria’s pioneer in 3D sand next step. Depending on the number of cylin- lains. »Still, things are starting to get rolling.«
printing, the upheaval brought on by the elec- ders at hand, up to 24 cylinder heads can be
trification of the automotive industry is already screwed onto a heavy-duty engine one by one.
having a tangible impact. »We’re definitely Corresponding demand is on the rise with regard
seeing a decline – or at least a shift – in orders to both new engines and replacement parts.
from the automobile industry,« Ederer reports. The megatrend toward customization –
FURTHER INFORMATION:
Binder Jetting engine’s design is not modified, its useful life JUST A FEW MINUTES »We’ve already been noticing a significant and thus to relatively small lot sizes – is also » fon-mag.com
For further information on
this procedure, check out
will be considerably shorter. To counteract this For the casting experts at Gienanth, lot reduction in requests from projects involving evident in the casting industry, which Simon » gienanth.com
the AM Field Guide at issue, the research project devised a new type sizes in the single digits are rare; indeed, it
formnext.com/amfieldguide of cylinder head with much better cooling usually deals in quantities that are many times
properties and improved stability. greater. The group, which generates around
The cylinder head features reduced thick- €250 million in annual turnover, produces more
ness and narrower conduits that optimize the than 15 million brake parts each year. Accor-
flow of coolant and are thus capable of disper- ding to Geib, this gives Gienanth a sizable share
sing more heat. This innovative design, which of the corresponding market in Europe.
AVL has since patented, used to be »techni For mass production purposes, the sand
cally impossible to realize in this way, but it cores used in making the aforementioned cylin-
can now be done by 3D-printing sand cores,« der heads will be manufactured using core
explains Benjamin Heil, head of hand-molded shooting machines. Depending on the design in
casting projects at Gienanth. Heil has thus question, this takes between three and seven
grown to appreciate 3D printing as a »tool that minutes. The production time on a 3D printer
takes engineering to the next level«. is much, much longer, but the traditional
With AVL heading up this research project, method requires tools that are very complicated
Gienanth handled the development of the cast to manufacture and can cost several hundred
and the actual production of 10 cylinder heads. thousand euros. As a result, 3D-printed sand
Some of the challenges involved had to do with cores can be much more cost-effective when
achieving a very precise level of surface quality – dealing with small lot sizes. That said, time is a
and removing all the sand residue from the factor: While 3D-printed cores can be made
cast pieces. available in a matter of days, assembling the
Gienanth acquired the casting molds and tools for a core shooting machine sometimes
cores it needed to form liquid iron at over takes several months.
1,370 degrees Celsius from the service provider The use of 3D-printed sand cores in pro-
voxeljet. For the moment, the Eisenberg-based duction processes nevertheless remains rather
company is not planning to run its own marginal, which Gienanth’s experts mainly
3D-printing equipment. »Placing orders with attribute to the »considerably higher costs
service providers gives us flexibility with compared to traditional manufacturing«. At the Cast and finished engine
regard to sizes and unit quantities,« Simon same time, it is possible to incorporate 3D-prin- blocks
Geib points out. ted sand cores into mold consisting of other
formnext magazine · Issue 02/2021 [ 12 ] [ 13 ] formnext magazine · Issue 02/2021
Burgmaier Technologies GmbH + Co KG
Headquartered in Allmendingen (near Ulm), Germany,
Burgmaier is one of the leading manufacturers of precision
components. It employs over 800 people in development,
TAPPING INTO NEW
construction design, production, assembly, and quality
assurance at four plants in Germany, France, and Slovakia.
According to the company’s own figures, around 350,000
parts roll off the line at these facilities every day. In
Text: Thomas Masuch
MARKETS
statistical terms, every European automobile contains an
average of five Burgmaier components.
PARTNERS ON EQUAL FOOTING
In establishing its own AM operations,
Burgmaier was always looking to find custo-
mers in other companies and industries outside
of automotive supply. It has since discovered
that along with manufacturing knowledge,
many clients need guidance with regard to
As if struggling with the coronavirus pandemic weren’t enough, the traditional development. »A good portion of our customers
Photo, page 12:
automobile industry had to contend with the transformation to alternative drive already have AM expertise, but are searching
Burgmaier is combining its
for a production partner that will discuss their
experience in milling with systems in 2020. This transition is also putting automotive suppliers under con-
its new additive expertise. developments with them on equal footing – and
Top photo, page 13: siderable pressure to respond. Burgmaier, however – a family-owned company ask some critical questions, as well,« Krauß
Metal components on a
powder bed
based in Allmendingen (southwest Germany) that employs around 800 people – »AM IS THE RIGHT STEP FORWARD« market. Well-known for its versatile properties explains. He also points to other customers
Bottom photo, page 13: already began setting the wheels in motion to leverage new technologies like A businessman by training, Krauß leads a in metal cutting, this material has already who want to incorporate the advantages of AM
A nozzle support manu
factured using both additive additive manufacturing and tap into further markets two years ago. team of five employees that includes two passed the test in a wide variety of applica- into their products despite having just gotten
and subtractive methods application engineers. »Still, I like putting the tions in the automotive sector, mechanical started with the technology themselves. In
mask and lab coat on myself now and then to engineering, and the manufacture of tools and these cases, Burgmaier works with them on
lend a hand in our AM operations,« he reveals. clamping devices. Burgmaier purchases the developing designs for components. Krauß says
Although just 36 years old, Krauß is the most powder required, but developed the production the company rarely handles just the 3D printing
senior member of his dynamic AM department, parameters itself. »At a thickness of 50 micro- of parts designed for AM. »We typically only
which reports directly to managing partner meters, we’re producing components with a do that when the production process is difficult
Karl-Hugo Schick. »Burgmaier’s ownership group density of up to 99.9 percent,« Krauß proudly or post-processing is required,« he reports.
is convinced that additive manufacturing tech- states. At the same time, the heat treatment
nology is the right step forward in leading the cycles involved can be fine-tuned to make this
C
ompared to the 280 machining centers in cessing. It’s here that the company sees one of company into the next generation,« Krauß case-hardening steel rigid and wear-resistant
use at Burgmaier’s four plants, the com- its particular strengths: Since its foundation in says, citing the family-run company’s flat hier- on the outside, while the inside remains tensile
pany’s single powder bed unit is defini- 1931, Burgmaier has amassed decades of exper archy as a further advantage that »enables us rather than brittle.
tely playing more of a minor role. Ken Krauß, ience in cutting and surface treatment. to operate with agility and flexibility«. Since additive manufacturing doesn’t begin
who has been heading up the AM division at Through AM, it is now also reaching out to While AM is a key aspect of Burgmaier’s and end with 3D printers, Krauß and his team
Burgmaier for two years now, nonetheless new customer groups outside of the automo- future technological plans, it has set some have adopted the same quality standards Burg-
reports that this twin-laser SLM 280 is already tive industry – manufacturers of cutting tools, specific short-term business goals in this field, maier maintains in series production, but adap-
producing series of more than a thousand for instance. With 16MnCr5, a material the as well. Krauß reports that his department was ted some aspects to the particularities of AM
components in a dedicated AM environment. company has certified specifically for additive already expected to turn a profit in 2020 before (which deals in much smaller production runs).
To continue ramping up these production runs manufacturing, it is 3D-printing things like the coronavirus set it back a year. Among other things, they conduct inspections
over the long term, Krauß and his colleagues mounts for the sharp working edges found in of their process and make use of test pieces.
are also taking a look at additive technologies milling and turning machines. The cooling BURGMAIER’S FUTURE ACE IN THE HOLE: Burgmaier also provides measurement reports
beyond powder bed fusion. channels Burgmaier is integrating into these A NEW MATERIAL when requested by its customers, some of
Outside of Burgmaier’s neatly isolated AM mounts are more efficient at dispersing pro- Luckily, Burgmaier has used the pandemic whom have also audited the company’s AM
operations, dozens of milling and turning machi- cess heat. Meanwhile, the company’s product as an opportunity to lay the foundation for its operations themselves. Here, Krauß undersco-
nes send plenty of metal shavings flying as they portfolio now includes 3D-printed grippers, as next big push. In completing its internal certifi- res the special attention Burgmaier pays to
Photos: Burgmaier
produce thousands of parts every day. »We’re well. Here, AM produces rougher surfaces that cation of the aforementioned material 16MnCr5 quality assurance. »For AM start-ups in parti-
advancing into a new production environment offer improved hold. Krauß also sees a great for selective laser melting in the summer of cular, it’s a subject that can really sneak up on
with additive manufacturing,« Krauß says, refer- deal of potential in gearwheels, which are 2020, the company achieved a significant you,« he points out. A long-standing organiza-
FURTHER INFORMATION:
ring to the application-oriented way in which used in many industries and are highly compa- technological advancement – one it believes tion like his, on the other hand, can take » fon-mag.com
Burgmaier closely combines AM with post-pro- tible with additive manufacturing. gives it a unique selling proposition in the AM advantage of its decades of related experience. » burgmaier.com
formnext magazine · Issue 02/2021 [ 14 ] [ 15 ] formnext magazine · Issue 02/2021
Photo, page 14:
The Atrio Icon 3D
Left photo, page 15:
The Grohe Allure Brilliant
LUXURY DESIGNS FOR
Top-right photo, page 15:
At the Norwegian restaurant
Under, patrons can wash their
hands at 3D-printed faucets.
Text: Thomas Masuch
OASES OF WELLNESS
Bottom-right photo, page 15:
Thorsten Schollenberger,
Grohe's head of industrial
engineering
They’re elegant, exclusive, puristic in
their design – and definitely not for
everyone’s budget: In the Allure Brilliant
and Atrio Icon 3D, the bathroom fixture
manufacturer Grohe AG has added
3D-printed faucets to its product range
for the first time over the past two
years. These luxury items, which weigh
in at around €12,000 apiece, are made
already come up with a plan to slash the pro- larly important in ensuring a high-quality pro- tion they attract and the considerable value
at Grohe’s main production site in duction time needed to 3D-print a faucet from duct with a flawless surface – and one that they offer in terms of marketing. Grohe has
Hemer, Germany, and represent just the the current 52 hours to just over 12. There’s still could be made a great deal more efficient at gained a good deal of expertise and experience
first step in the company’s additive quite a difference between that and conventio- Grohe. »Grinding and drilling still involves a lot in additive manufacturing, as well.
journey. nal manufacturing, though: Using low-pressure of manual work, which can be time-consuming Meanwhile, its 3D-printed faucets represent
casting, Grohe’s plant in Hemer produces brass and isn’t a good fit for high-end production,« Grohe’s response to a trend it has observed in
fixtures every 10 to 15 minutes. he points out. which the bathroom is no longer viewed as
For the Atrio and Allure Brilliant Icon 3D, Meanwhile, Grohe is currently only using closed-off space meant solely for hygiene pur
the company’s designers envisioned a much one of its Trumpf machines to 3D-print faucets. poses, but an »oasis of wellness« that integrates
smaller production volume. Thanks to additive The other is producing tool inserts with confor- seamlessly into the rest of the home. Another
manufacturing, the faucets’ internal water mal cooling elements made of brass. Grohe has future trend Grohe has identified – and one that
channels are considerably narrower, which secured a patent on the AM production of this is playing an increasingly significant role for
opens the door to elegant designs that wouldn’t material, which features a high degree of ther- this subsidiary of Japan’s Lixil group – has to do
be possible with standard methods. By selling mal conductivity. Having passed a round of with customization. So far, this aspect has been
G
rohe AG prefers not to reveal how many stainless-steel water faucets are at the very top more 3D-printed fixtures, Schollenberger also initial tests, its new tool inserts for injection evident in the demand for a wider variety of
Grohe 3D-printed faucets it has already sold, of the line. The new owners of these eye- wants to achieve better capacity utilization in molding machines are now proving their ability colors in bathrooms, for example. According to
Grohe is a brand known around the world for its compre
but does say it hopes to increase the catching items are similarly exclusive: The Atrio AM production at the Hemer facility, which can to stand up to long-term operations at Grohe’s Schollenberger, Grohe wants to continue follow
hensive bathroom solutions and kitchen fixtures. Grohe AG
employs a total of more than 6,500 employees in 150 coun number in the future. To that end, head of Icon 3D can be found, for example, at the wor- currently turn out 400 water faucets per year. Porta Westfalica plant, where they are already ing this trend with its 3D-printed fixtures. In the
tries around the world – 2,600 of them in Germany. Since industrial engineering Thorsten Schollenberger ld’s largest underwater restaurant, Under, facilitating more efficient production. »The future, he can see the company offering basic
2014, the company has belonged to the brand portfolio
of Lixil, a Japanese manufacturer of water- and housing- wants to make the company’s additive manu- which resides below the frigid tides off the »NOT A GOOD FIT FOR HIGH-END conformal cooling aspect enabled us to reduce versions of certain products that can then be
related technologies. facturing operations much more efficient, southern coast of Norway. Grohe has also sold PRODUCTION « cycle times by 20 percent,« says a pleased customized. Customers will thus be able to put
which should ultimately reduce the price of these fixtures to numerous private individuals Grohe’s AM department is based around two Thorsten Schollenberger. »With the brass tools, the finishing touches on their fixtures themsel-
these refined fixtures. At the same time, with an eye for design, but Schollenberg would Trumpf TruPrint 3000 units and a four-person we’re now around 50 percent faster.« ves or with the help of a designer.
Schollenberger also wants to keep an eye out still like to find a lot more customers for them. team that works on design, machine operations,
Powder Bed Fusion for other products that could be compatible He says the production costs need to be signifi- and post-processing. After being 3D-printed, THE »WELLNESS OASIS « TREND
Photos: Grohe
For further information on
this procedure, check out with 3D printing. cantly reduced to make that possible. »We’ve components go straight to post-processing, Despite the rather modest contribution they
the AM Field Guide at Grohe’s product categories include ever- got to bring the costs down; otherwise we can’t where their support structures are removed and make to Grohe’s bottom line, these elegant
FURTHER INFORMATION:
formnext.com/amfieldguide
ything from moderately priced appointments to make these products accessible to a larger the fixtures are ground, drilled, and polished. 3D-printed fixtures have already left their mark » fon-mag.com
the premium segment, and its 3D-printed, target market,« Schollenberg affirms. He has Schollenberger describes this step as particu- on the company – thanks in part to the atten- » g rohe.com
formnext magazine · Issue 02/2021 [ 16 ] [ 17 ] formnext magazine · Issue 02/2021
A
irbus Defence and Space is currently 2015, before installing additively manufactured industry or even in aviation. After all, we can-
manufacturing two Hotbird satellites parts in 45 other communications satellites in not repair a faulty part or recall a product,« said
OUT OF
for its customer Eutelsat, which will be 2017. Today, all Thales Alenia Space communi- Mulser. »This means that the manufacturing
fitted with a total of 500 3D-printed compo- cations satellites use 3D-printed antenna bra- process must be stable and consistently deliver
nents. These parts are made from an alumi ckets and reflector sleeves. reproducible results.« This excludes the possi-
Text: Thomas Masuch
THIS WORLD
num-silicon-magnesium alloy (AlSi10Mg) and bility of developing the process over time, a
produced by certified partners using the sel PURCHASED FROM SERVICE PROVIDERS »learning by doing« approach, so to speak.
ective laser melting (SLM) process. »There are Both OHB System AG and Airbus Defence Engineers at OHB System therefore work with
more than 100 different waveguide designs, and Space purchase their 3D-printed compo- fixed process parameters that have been veri-
together with other network designs. The nents from suppliers, but only once they have fied in advance and use these as a basis for
waveguides conduct the RF signals around »gone through a complete supplier and qualifi deciding where additive manufacturing could
the spacecraft. The components come in sizes cation process,« according to Neal. OHB Sys- be a suitable production method, then desig-
ranging from about 100 mm [4"] to about tem decided four years ago to purchase ning components accordingly. »By now we have
300 mm [12"],« explained Andrew Neal, an 3D-printed parts solely from suppliers – the a very clear picture of which applications this
expert in additive layer manufacturing at Airbus same approach the company takes to most of works for,« according to Mulser.
in Portsmouth, UK, when he spoke to Formnext the other parts and components it uses to make
Magazine. its satellites. »We want to be able to rely on A PRETTY ROBUST SECTOR SO FAR
Aerospace company OHB System AG has service providers having stable processes,« said With its extraordinarily complex technology
also been engaged in additive manufacturing Mulser. And the engineer considers established and long development times, satellite produc-
for more than six years now. »At first, it was a companies in particular to be at an advantage tion has actually been a pretty robust sector in
development project. Now we are at the stage here, »because it’s not so easy to just catch up the past. Although the market did fluctuate
Meteosat Third Generation (MTG) weather
satellite orbiting the Earth of not only replacing existing components, but on years of experience.« OHB System turns to depending on what was happening with certain
optimizing them in a really targeted way,« said external partners for quality assurance too, major projects, it showed quite steady sing-
Marco Mulser, a technology manager for addi- »although we choose specifically which tech- le-digit growth overall. In the years 2014 to
tive manufacturing at OHB. Next year, after nology and which type of quality inspection 2018, satellite production revenues stood at
several years of development, the first metallic is used.« $16.2 billion (source: Satellite Industry Associa-
AM part installed by OHB System will launch tion, SIA), with more than half that amount
into space. RELIABILITY IS A PRIORITY attributable to the USA. According to the SIA,
AM has also been high on the agenda for Generally speaking, the satellite production 62.4 percent of global satellite production in
another industry heavyweight, Thales Alenia industry has extremely high demands when it 2019 took place in the USA. (See SIA chart.)
Space, for years now. The French company built comes to reliability, which means redundant Overall, satellite production makes only a
a 3D-printed aluminum antenna into the Turk- solutions are sometimes required. »Our job is small contribution to the entire satellite sector
menAlem communications satellite way back in very different to working in the automotive of the aerospace industry. According to Bryce- »
At left:
3D concept of a cleat for
connecting sandwich panels
At right:
Integration of an MTG
satellite in the OHB System
AG cleanroom
Photos: Airbus Defence and Space, OHB System AG
It is as if additive manufacturing was tailormade for the satellite construction industry, which is all about very small
quantities, complex designs, and a quest to reduce weight: all demands that suit additive manufacturing to a T. No won-
der, then, that satellites containing 3D-printed components have already been orbiting the earth for several years now.
In this second part of our »AM in the Space Industry« series, we look behind the scenes to find out how widespread AM
is in satellite construction at the moment, what market potential it has, what trends are driving the industry, and what
challenges satellite manufacturers and their service providers still face.
formnext magazine · Issue 02/2021 [ 18 ] [ 19 ] formnext magazine · Issue 02/2021
a few ounces on a large satellite does not really
Satellite Manufacturing
$12.5 B have much impact on its overall weight. No, Airbus Defence and Space
$12.5 B (5%) where additive manufacturing actually offers a Airbus Defence and Space is a division of the Airbus Group,
which generates revenues of around 10 billion euros and
great advantage is in the design process.
Launch Industry TOTAL TURNOVER has approximately 34,000 employees. Its business areas
$4.7 B Improvements can be made to individual com- cover military aviation and space systems, as well as sensors
$4.9 B (2%) and communications technology. It is headquartered in
SatelliteServices ponents much more easily and quickly than to Taufkirchen near Munich.
$123 B (45%) milled parts, for example, which significantly
reduces development time and costs. Mulser OHB System AG
OHB System AG is one of Europe’s three leading aerospace
also appreciated the opportunity »to practice companies. The systems provider belongs to the listed high-
integral construction, that is, to integrate diffe-
$7.8 B
tech group OHB SE, where around 2,900 specialists and
executives work on key European space programs. With
rent functions into one component and thus two locations in Bremen and Munich and around 40 years
save on joining and assembly steps.« of experience, OHB System AG specializes in high-tech
Airbus expert Neal also highlighted this solutions for space travel. These include low-orbiting and
Shares of satellite manu
geostationary satellites for Earth observation, navigation,
facturing accounted for by bonus of faster production: »We have speeded
$271 B
telecommunications, science, and space exploration, as well
the United States and the
rest of the world (2019)
things up considerably compared to existing as systems for manned space flight, aerial reconnaissance,
and process control systems.
conventional waveguides. On average, we have
TOTAL TURNOVER halved the time it takes to produce waveguides
with AM.« Where a little over two years were
spent working on the initial AM components, sector that is offered by additive manufactu-
1.900 now the processes have been industrialized at
Airbus Defence and Space it takes just a matter
ring. »This includes, for example, establishing
lattice structures in the components and for-
IN OPERATION of months. ging ahead with functional integration.« Airbus
expert Andrew Neal also considered additive
THE CHALLENGE OF EXTREMELY CLEAN manufacturing to be vitally important for satel-
SURFACES lite production in the coming years. On the one
In order to reap the benefit of these faster hand, »the technology can now also be used as
Ground Equipment
8.900
times, incredibly stringent demands must be the basis for adjusting the payload.« And, as
$130.3 B (48%) met, especially in postprocessing. As an well as providing new ways to speed things up,
SATELLITES example of this, Neal referred to the smooth additive manufacturing enables production and
Turnover by sector in the
IN SPACE surface that waveguides need to have in order assembly costs to be lowered even further.
global satellite industry to achieve the required RF power. »Satellites »Because, on average, one AM component will
(2019) are assembled in a cleanroom, the surfaces replace a part that was previously made up of
must be clinically clean,« added Mulser. This five separate components.«
means even the tiniest powder residues need to
be removed, which requires scrupulous
cleaning, especially of internal surfaces.
But the additively manufactured compo-
tech, this satellite sector generated revenues of Starlink satellites into orbit. But despite its TREND TOWARD SMALLER SATELLITES Infographic: feedbackmedia.de, Source: Satellite Industry Association, SIA IT'S ALL ABOUT TIME nents also need to have technical characteri-
$217 billion in 2019, but that figure also inclu- large number of satellites, Starlink has not In addition to Starlink, the trend toward ever Generally speaking, it is the contracting stics that meet the very particular requirements
des ground equipment, TV, mobile services, and significantly increased the volume of the smaller satellites is giving the industry a boost entities, i.e., satellite operators such as ESA, of space travel. These include the huge loads
launch services. exclusive satellite construction market. That’s too. Fired up by new applications in agriculture, Eutelsat, or Telesat, which determine a satellite's encountered during lift-off and the enormous
Some 8,900 satellites have been launched because, with estimated m anufacturing costs energy, civil defense, or oil and gas, for example, performance requirements. Manufacturers such temperature fluctuations that occur when satel-
into space since 1957, with 5,000 still orbiting of $250,000 to $500,000 per unit, the 260 kg the market for small satellites weighing under as OHB System or Airbus Defence and Space lites or parts thereof are illuminated by the sun
the Earth and 1,900 of those still operational. [570 lb] Starlink satellites are positioned 500 kg [1,000 lb] is expected to grow strongly in develop the design, equip the satellites with the or situated in the shade. OHB System, for
Having ushered in a new era of rocket toward the lower end of the market’s price the coming years. Allied Market Research ana- necessary instruments and software, and, if instance, has developed connecting elements
engineering, Elon Musk and SpaceX are now range. Other satellites, such as those used in lysts predict that this sector will grow from necessary, take care of other services such as called cleats, which connect two sandwich
set to do the same for the satellite industry: Earth observation, are competing in a whole $3.6 billion in 2018 to $15.7 billion by 2026, an the journey into space or mission control. panels and compensate for thermal deforma-
The Starlink project, which aims to bring high- other weight class due to their size alone. annual increase of about 20 percent. Contribu- Contrary to popular belief, the main benefit tions, to deal with this issue. »Their structural
speed broadband internet even to rural areas One of the largest satellites ever launched was ting to this growth will be the Lightspeed project of additive manufacturing in satellite construc- design means these cleats can only be manu-
(for a fee), has launched 1,318 satellites into the TerreStar-1 back in 2009, which weighs by Canadian satellite operator Telesat, which tion does not always take the form of reduced factured additively,« explained Mulser.
the Earth’s orbit at an altitude of around 6,910 kg [15,230 lb] and has solar panels with intends to launch a fleet of 298 satellites, each weight – at least at present. »We won't say no
FURTHER INFORMATION:
270 km [168 miles] since May 2019 (data cor- a span of 32 m [105 ft]. According to estimates weighing 700 – 750 kg [1,543 – 1,653 lb], into to that benefit. But satellite weight has already OUTLOOK: FIVE BECOME ONE
» fon-mag.com
rect as of March 24, 2021). This led to SpaceX from satellite phone provider Globalcom, a orbit around the Earth over the next few years – been optimized, and the number of components For Marco Mulser, stable manufacturing
becoming the world’s largest satellite operator typical weather satellite costs around Thales Alenia Space was awarded the contract that can be further optimized by additive manu- processes are the key to unlocking all the » ohb-system.de
very quickly indeed. One Falcon 9 delivers 60 $290 million. for this work in February 2021. facturing is limited,« explained Mulser. Saving future potential for the satellite construction » airbus.com/space.htmlformnext magazine · Issue 02/2021 [ 20 ] [ 21 ] formnext magazine · Issue 02/2021
TRENDS TRENDS
A SHOWER THAT EVEN DOGS WILL ENJOY FIRST AM COMPONENT OF A NOSE LANDING GEAR OF A BIZJET
I I
t’s not unusual for man’s best friend to dis- Hansgrohe began making the Furly prototype So this special shower head will be hours of n a joint project, Safran Landing Systems and
like the shower. But what if it were possible and the first batch of 5,000 units on an EOS P fun for both owner and furry friend alike! SLM Solutions tested Selective Laser Melting
to clean dogs that are afraid of water simply 396 3D printer. for the first time to produce a component of
by stroking them? EOS worked with Hansgrohe, Thanks to the AM-optimized design, there a nose landing gear for a bizjet. The joint objec-
a fittings and shower specialist based in Ger- was no need for any complex welding of indivi- tive of the project is to demonstrate the feasibi-
many’s Black Forest, to come up with an inter- dual parts. Only the switchover valve for chan- lity to produce a main fitting by Selective Laser
nally tested, sellable product in just five and ging the jets, which was based on an in-house Melting process. The component was therefore
a half months: a shower designed specifically large-batch product, is installed separately. Dog redesigned for metal-based a dditive manufac
for dogs. owners can use the switchover valve to choose turing allowing time saving in the whole process,
As far as the Furly canine shower head was whether the water will flow out of the shower and weight reduction about 15 percent of the
concerned, there were two major issues to head nubs gently or as a powerful, compact jet. component. Due to the stringent requirements
solve: First, to make the relationship between of this component, which is one of the parts
dog and owner even better. And second, the that transfers the loads from the wheel to the
product in question had to be brought from idea aircraft structure and is retracted after take-off,
to series production within a tight timeframe Safran selected a titanium alloy with excellent
and with a keen eye on cost. So the project mechanical properties that is naturally resistant
came with requirements that are really more to corrosion and does not require any surface
familiar in the field of IT startups, but which treatment. The component was produced on an
also form part of the Hansgrohe think tank’s SLM800 system.
arsenal: be agile, test fast, identify errors fast,
learn fast.
Hansgrohe and EOS worked closely to
gether to obtain the drinking water certification
needed for the material used in additive manu- FROM THE WORKSHOP TO THE DESERT
facturing (AM): EOS submitted the powdered
material PA 2200 and the relevant extracts from
W
EOS’s very own patented recipe to several ith off-road legend Nani Roma the
laboratories. Once approval had been granted, Bahrain Raid Xtreme Team (BRX)
finished 5th in this year’s Dakar Rally
with – also supported by the mobile use of 3D
printing. The BRX team, led by the company
Prodrive, produced more than 30 car parts for
BIG PLANS THAT ARE VERY COOL the Hunter T1 race car from nylon carbon fiber.
To do so, the team had a Makerkbot 3D printer
installed in its service truck.
C
alifornian company Holo recently laun- formance computers, electric vehicles, RF anten- This year Dakar Rally took place over two
ched its PureForm platform, which is set nae, or heat exchangers, for example. Stainless weeks, with stages covering hundreds of miles
to produce high-resolution components steel is also set to be added to the material across Saudi Arabia. With two Method X 3D
from pure copper. Soon enough, thousands of portfolio soon, which would open up even more printers, the BRX team was able to engineer
components per month will be manufactured applications. some parts at the factory in the UK as well as
Photos: SLM Solutions, Makerbot
on this platform at Holo’s newly opened 1,900 m2 Holo has developed a sinter-based platform on site at the Rally. »We printed remotely in
[20,500 sq ft] production facility in the Bay for additive manufacturing using high-resolu the middle of nowhere; literally where you can’t
Area. The young company is focusing on selling tion imaging technology and a backend process see traces of civilization«, reported Paul Doe,
Photos: EOS, Holo
3D-printed components, not 3D printers them- based on the Vat Photopolymerisation (VPP). chief engineer at Prodrive.
selves, and thus lowering the barriers to adop- The company, which was founded as a spinout The BRX team 3D-printed over 30 parts on »There are quite a bit of parts in the car, such start to struggle, forcing us to revert to alumi
tion in this technological field. of Autodesk along with other AM companies, is the Hunter T1, including a mount for a suspen- as the engine bays and wheel side near the num which is costly. In this case, we were able
By using pure copper, Holo is able to backed by top-tier Silicon Valley investors such sion position sensor and a sculpted nozzle brakes, where the environments reach up to to print parts in nylon carbon fiber which is
concentrate on cooling solutions for high-per- as Prelude Ventures and Lightspeed. mount for the cockpit’s fire suppression system. 120°C and where traditional FDM materials able to reach very high temperatures«, said Doe.You can also read
