Laser re-manufacturing and large-scale metal 3D printing

24 September 2020

Lindø Offshore Renewable Center
Kystvej 100
5330 Munkebo

Additive manufacturing has been appointed as one of the main drivers within the industry 4.0 race. Laser technology-based 3D printing and re-manufacturing of new and defect components are developing into a huge market for many companies worldwide both for suppliers, end-users and customers. Intensive R&D activities are carried out at universities, research centers and at private enterprises.

This seminar reveals the absolute state-of-the-art of the technology and presents some of the most in front actors in the field of laser re-manufacturing and large-scale metal 3D printing. One of the leading R&D organizations in the world will present their latest activities and development directions. Two world leading manufacturer of equipment will present typical applications and upcoming news. Further more, programming and simulation tools for 3D printing machines will be presented. A leading classification society will outline activities within quality assessment, guidelines and rules for AM/3D manufacturing.

At the seminar you will also have the opportunity to visit the new installation at FORCE Technology, LWT. With this new laser additive manufacturing and 3D metal printing equipment we are able to carry out on large components.

09:00 - 09:30 Registration and light breakfast
09:30 - 09:40 Welcome by ATV-SEMAPP
09:40 - 10:40 State-of-the art, visions and R&D developments within AM/3D manufacturing of metal components

Talu Ünal-Saewe, Fraunhofer ILT, Aachen, Germany

10:40 - 11:00 Coffee break and networking
11:00 - 11:30
Laser re-manufacturing and large-scale 3D metal printing activities at FORCE Technology

Steen Erik Nielsen, Specialist 3D Print & AM Technology, FORCE Technology, Denmark

FORCE Technology has been engaged with laser materials processing for more than 35 years. Laser surface treatment, laser cladding, inverse machining, laser re-manufacturing, additive manufacturing and latest laser 3D-printing are some of the phrases that, over time, often are denominations used in relation to basically the same technology. Laser technology-based 3D printing and re-manufacturing of new and defect components is developing into a huge market. Intensive R&D activities are carried out at universities, research centers and at private enterprises. Just recently, FORCE Technology has invested in a new installation related to mentioned technology, tailored for the handling and preparation of large scale metal components.
This presentation will cover equipment, typical applications and present activities.

Steen Erik Nielsen is M.Sc.Eng., PhD and he been engaged with laser materials processing and welding technology for approximately 40 years.
11:30 - 12:00
Equipment and systems for AM/3D metal component manufacturing

Alexander Hitzek, Project Engineer, GTV Verschleißschutz GmbH, Luckenbach, Germany

GTV is an experienced manufacturer of special machinery and provider of complete solutions in the field of thermal spraying and laser cladding.
The presentation will show the product spectrum which includes complete flexible turn-key centers for coating and 3D component production. Integrated sensors permit automatic adjustment of laser power, edge detection for near net shape cladding applications and in-situ characterization of powder flow stability. Also, the geometry of the powder stream exiting the powder nozzle can be measured. Besides benefits of these features in realized centers we will look at the capability of flexible integration into complete production lines including data mining will be shown.

Alexander Hitzek graduation as Master of Engineering in 2016 and began his work at GTV in 2016 and since 2019 his has been Project Manager.
12:00 - 13:00 Lunch
13:00 - 14:00 Tour of LWT facilities
14:00 - 14:30
Equipment and systems for AM/3D metal component manufacturing - 2

Tim Pfeuffer, Product Sales Manager, DMG MORI, Germany

DMG MORI, as global company with over 20 years of experience in the ADDITIVE MANUFACTURING of metal parts, offers two kind of technologies in this technology field. With different machine sizes in the powder nozzle (DED) and the powder bed technology (SLM) we represent different technologies for almost every application field.
This talk will give you an overview of the DMG MORI ADDITIVE MANUFACTURING product portfolio and will show you how hybrid manufacturing (milling and additive operations) and graded materials in context of our LASERTEC 3D series (powder nozzle) open up your manufacturing possibilities. Furthermore use cases and success stories for DED- and SLM applications will show the potentials and how Additive Manufacturing enables you to optimize your manufacturing process and products (e.g. reduction of lead and delivery times, improved product performances due to new designs and material changes).

Tim Pfeuffer has since 2017 been Product Sales Manager for Advanced Technologies at SAUER GmbH – A Member of DMG MORI and responsible for the sales of the LASERTEC, ULTRASONIC and ADDITIVE MANUFACTURING product portfolio in southern Germany and Nordic countries.
14:30 - 14:50 Coffee break and networking
14:50 - 15:20
Design, simulation and programming tools for 3D-printing machines

Morten Kollerup Bak, CTO, Mechatronics Innovation Lab AS, Norway

3D-printing (additive manufacturing) offers several advantages compared to other manufacturing methods, not least increased design freedom. However, efficient use still require knowledge about the specific technology to be used and the associated design rules and tools need to setup the process.
This presentation introduces tools and techniques for design and pre-processing for 3D-printing. The focus will be on metal 3D-printing using powder bed fusion and direct energy deposition with examples of both applications and software tools.

Morten K. Bak is CTO at Mechatronics Innovation Lab (NO). Morten holds a M.Sc. Mech. Eng. from Aalborg University and a Ph.D. in Mechatronics from University of Agder. Morten has long experience with research, innovation, product development, project management and technical leadership and a broad technical background within mechanical engineering and mechatronics with emphasis on robotics and additive manufacturing.
15:20 - 15:50
Quality assurance – Development of standards for AM in oil & gas and maritime sectors

Ole-Bjørn Ellingsen Moe, DNV-GL, Norway

Additive manufacturing is entering the oil&gas and maritime industries with the promise of design freedom, optimization and reduction of lead time. However, there are limited standards available for quality assurance of additive manufactured parts. Together with the industry, DNV GL develops standards and recommended practices to ensure that the industry can utilize the benefits of AM, while still operating safe.
In this presentation DNV GL will present how these standards are developed, ongoing initiatives, and present the newest addition to the AM standard portfolio.

Ole-Bjørn Moe is an engineer at the department of Materials Advisory. He has a M.Sc. in materials science, and has since 2015 been working worldwide within DNV GL. The last 3 years he has been concerned with enabling additive manufacturing for the oil&gas and maritime industries.
15:50 - 16:00 Closing remarks

Laser Re-Manufacturing and large-scale metal 3-D printing

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Registration fee

DKK 2.300 Members of ATV-SEMAPP and other collaborating organisations
DKK 2.925 Non members
DKK 975 PhD-students
DKK 200 MSc and BSc student members of ATV-SEMAPP (Membership is free of charge – register here. Early bird discount does not apply)

All prices are exclusive of 25 % VAT.

Early-bird discount of DKK 200 when registering before 24 July 2020.

The fee includes talks, breakfast, lunch and coffee breaks and access to speakers’ presentations.

Binding registration
Registration is binding, however substitutions are accepted at any time.

Questions
Please do not hesitate to contact ATV-SEMAPP by e-mailing atv-semapp@mek.dtu.dk or phoning Jytte Laursen +45 4525 4898 or Charlotte Leser +45 4525 4899.