ACAM @ Formnext 2024: Our Exhibits

Motivation and Relevance

• VR technology can improve learning outcomes, such as retention and engagement, compared to traditional learning.
• Understanding VR’s potential in education can help educators and institutions make informed decisions about incorporating immersive technologies in training.

Motivation and Relevance

• Enabling Simulation of Larger Parts
• Long calculation times for thermomechanical simulation
• Low accuracy of distortion calculation

Motivation and Relevance

• Insufficient design guidelines for additively manufactured filigree structures and critical component areas lead to “first-time-right” approaches with high material usage
• Comprehensive engineering à How to minimally design structures to withstand process-related loads?

Motivation and Relevance

• Implementing AI models to detect and categories anomalies as well as compensate defects is still difficult and requires expertise
• The lack of standardized data formats prevents AM users and service providers from connecting and using the data

Motivation and Relevance

• Transition to sustainable energy systems requires fuel-flexible industrial burners (Hydrogen and Methane)
• Simulation based design requires manufacturing of complex geometries à additive manufacturing

Motivation and Relevance

• Would you like to train your workforce and transfer the knowledge from previous AM projects more effectively?
• What about enhancing their creativity for new products?
• Industrial Metaverse offers a scalable solution for your team to explore successfully AM-enabled product designs

Motivation and Relevance

• Additive manufacturing enables complex product designs
• Conventional CAD comes to its limits to address innovative design methods
• Designers and manufacturers of complex and variant-flexible components need automated solutions

Motivation and Relevance

• Increased demand for sustainability within the construction and building industry as one of the main consumer of the global energy demand
• Companies aiming for resource and energy efficient buildings, interested in architecturally ambitious building structure

Motivation and Relevance

• There is an increasing demand for PBF-LB/M processible high-performance nickel-based superalloys.
• Most of these alloys produce cracks and other defects during processing

Motivation and Relevance

• Complexity of Orientation Decision: The selection of component orientation presents a multifaceted challenge. It influences various, sometimes conflicting requirements.
• Impact on Design an Economics: This decision has a direct impact on both the component design and the economic viability of the process.

Motivation and Relevance

• Increased efficiency for applications requiring cryogenic temperatures using high-temperature superconductors (YBCO)
• Limited machinability of hard and brittle YBCO is an obstacle
• Additive Manufacturing for complex shaped YBCO parts

Motivation and Relevanc

• Different process parameters are needed due to varying thermal conductivity depending on a part’s geometry
• There is a need of first-time right by previously adapting process parameters in addition to in-process control of process parameters

Motivation and Relevance

• Integration of AI increases in relevance across manufacturing industries
• Importance of surface repairs increases to reduce emissions and meet climate goals

Motivation and Relevance

• Powder Bed Fusion of Metals (PBF-LB/M) enables functionally integrated hydraulic manifolds
• Potential of better carbon footprint & functionality
• High machine cost of PBF-LB/M is an obstacle

Motivation and Relevance

• Transitions of aircraft between lessees or lessor require overhaul of the aircraft cabin
• Additional cost due to lengthy component provision times
• High rate of waste material with approximately 30kg per transition

Motivation and Relevance

• Substantial portion of the intellectual property creation occurs in the design phase, when a CAD file is created
• If a CAD or build job file is sent to an external production service provider, sensitive data is shared and could be passed on or used in an unauthorized way

Motivation and Relevance

• The PBF-LB/M scan strategy includes the arrangement of scan vectors and laser parameters (e.g., power)
• The scanning strategy affects quality and productivity
• Laser parameters are already tailored to part & material, but the spatial and temporal order of scan vectors are often overlooked. Conventional strategies lead to heat peaks and distortion.

Motivation and Relevance

• Tools that are susceptible to wear can be coated in a resource-saving and cost-effective manner to prevent scrap
• Manufacturing companies in all industries use tools whose service life can be increased

Motivation and Relevance

• Individual designs are often expensive to manufacture
• Special tools or handmade processes to adopt different variations of similar yet individual products are needed
• Utilizing freedom of three-axis HS-DED can make individualization of production faster and cheaper

Motivation and Relevance

• Current 3D printers are limited by their speed and have low extrusion rates
• Nearly all usable materials are petrochemical and not eco-friendly
• Creation of support structures requires a lot of material

Motivation and Relevance

• Gripping process needs customized grippers, this causes costs in development and manufacturing
• Lack of automated process chains for the construction of grippers in the industry

Motivation and Relevance

• Filament-based technologies are characterized by a low melting rate, high material costs and low layer bonding
• Current pellet-based processes are characterized by low extrusion accuracy, high extruder weight and high extruder cost

Motivation and Relevance

• High disposal costs and low resource efficiency in maintenance and repair processes in aviation
• High demand for a more environmentally friendly and resource-efficient aviation

Motivation and Relevance

• Manufacturing systems commonly used in AM are characterized by low deposition rates or insufficient print quality
• A higher deposition rate combined with sufficient print quality would improve the competitiveness of AM

Motivation and Relevance

• Large Part Manufacturing is mostly done with expensive and complicated robot systems
• The toolpaths are the biggest influence on part quality

Motivation and Relevance

• Need for large format printed parts for tooling and other areas
• Support is inefficient for large parts
• Failed parts and support material can currently not be recycled efficiently

Motivation and Relevance

• FDM and SLS part often have poor surface quality and need to be polished before end use
• State of the art processes bring in foreign particles, have low polishing results or need a lot of manual labour

Motivation and Relevance

• FDM and SLS part often have poor surface quality and need to be polished before end use
• State of the art processes bring in foreign particles, have low polishing results or need a lot of manual labour

Motivation and Relevance

• Bamboo is a fast growing, light-weight, natural resource
• To use it in industrialized ways, automated production lines must be established
• By using AM, an individualized production is possible and adaptable for each bamboo cane