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

21 September 2021

Lindø Port of Odense
Kystvej 100
5330 Munkebo

Additive manufacturing has become 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 within Additive Manufacturing and 3D macro steel printing at universities, research centers and private enterprises.

This seminar will present some of the leading actors in the field of laser re-manufacturing and large-scale metal 3D printing along with the absolute state-of-the-art in the technology e.g. new combination machines where AD/3D is integrated with machining of the component.

MX3D, one of the front figures in large-scale robotic wire arc additive manufacturing (WAAM), will present their latest activities and development directions within the world of large-scale metal 3D printing. GTV Verschleißschutz GmbH and DMG MORI, two leading equipment manufacturers will present typical applications in 3D metal printing. Furthermore, programming and simulation tools for 3D printing machines will be presented. Additionally, DTU will present the newest knowledge about how additive manufacturing and spray forming enables a sustainable circular ecosystem. DNV, a leading classification society, will outline activities within quality assessment, guidelines and rules for AM/3D manufacturing.

The seminar also includes a visit to the new laser additive manufacturing and 3D metal printing equipment at Force Technology, Lindø, which enables AM/3D processing on large metal components.

This seminar at Lindø will also, after a long period with very few physical meetings, give you the opportunity catch up with familiar faces from the industry and expand your network with potential new colleagues, customers, and suppliers.

Target audience
The seminar is intended for engineers working with re-manufacturing and repair of high value components within the iron & metal industry e.g. related to Energy, Power plants, Oil and gas, Tools and dies, Molds or Food processing equipment industry.

09:00 - 09:30
Registration and light breakfast
09:30 - 09:40
Welcome by ATV-SEMAPP
09:40 - 10:10
WAAM: Applying large-scale metal printing in various industries (online presentation)

Gijs van der Velden, CEO, MX3D, The Netherlands

MX3D is one of the industry leaders in large-scale Metal AM. Since 2014, they have been showcasing their technology through various projects like the MX3D Bridge, the Robot Arm and the Takenaka Connector.
In early 2021, MX3D launched a complete robotic Metal AM system called the M1. Connected with the WAAM dedicated software platform MetalXL, MX3D opens the doors to additive manufacturing for high impact industries like Oil & Gas, Maritime and Tooling.
During the presentation, the state-of-the-art of Wire Arc Additive Manufacturing (large-scale metal AM) will be discussed both from a technology as well as a business level.

Gijs van der Velden leads MX3D since the birth of the company in 2015. Until the beginning 2017 Gijs van der Velden also held the general management position at Joris Laarman Studio. This company initially developed the largescale robotic printing technique now used by MX3D and does playful research on the effect digital production will have on our physical world. Its Bone Chair (2006) is widely praised as a modern design icon. Gijs van der Velden has a master in Dutch and International Law.
10:10 - 10:40
New Processing Possibilities in Sheet Metal

Morten Kristiansen, Associate Professor, Aalborg University

Laser cutting and laser welding are well known as industrial laser processes. A range of other laser processing technologies has been matured and joint in one machine setup, which will be presented. Measurements during processing becomes important for process control and is included in the system. Here laser technologies for pre, inline and post sensing is an excellent tool and various systems and applications will be presented.

Morten Kristiansen is Associate Professor at Department of Materials and Production, Aalborg University. He works with automation of industrial processes and has for more than 10 years been focussing on laser processes.
10:40 - 11:00
Coffee and networking break
11:00 - 11:30
Laser re-manufacturing and large-scale 3D metal printing activities at FORCE Technology

Michel Honoré, 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.

Michel Honoré is Specialist in the department of AM and Laser Technology at FORCE, and holds an M.Sc.E. in physics. He has been working with industrial applications of laser processing for 15 years including 3D printing/additive manufacturing and laser safety.
11:30 - 12:00
Equipment and systems for AM/3D metal component manufacturing

Alexander Hitzek, Project Engineer, GTV Verschleißschutz GmbH, 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 the benefits of these features in realized centers, we will look at the capability of flexible integration into complete production lines including data mining.

Alexander Hitzek graduated as Master of Engineering in 2016 and began working at GTV in 2016. Since 2019, he has been Project Manager.
12:00 - 13:00
13:00 - 14:00
Tour of large scale 3D print facility, FORCE Technology
14:00 - 14:30
SLM and DED technology – potentials and use cases for metal component manufacturing

Dirk Rohde, Product Sales Manager, DMG MORI, Germany

DMG MORI, a global company with over 20 years’ experience with additive manufacturing of metal parts, offers two kinds of technologies within the field. With different machine sizes in the powder nozzle (DED) and the powder bed technology (SLM), they represent different technologies for many different applications in the field.

This talk will give an overview of the DMG MORI additive manufacturing product portfolio and show how hybrid manufacturing (milling and additive operations) and graded materials in the context of the Lasertec 3D series (powder nozzle) can open up for manufacturing possibilities.

Furthermore, case stories for DED and SLM applications will show the potential of AM and how it enables optimization of the manufacturing process and products (e.g. reduction of lead and delivery times, improved product performance due to new designs and material changes).

Dirk Rohde has been with DMG MORI since 2013. He is Product Sales Manager for “Advanced Technologies”, which include: Ultrasonic machining, Lasertec (with PowerDrill, Additive Manufacturing, Shape and PrecisionTool). He is responsible for Scandinavia, Ireland/UK and BeNeLux as well as the southwestern part of Germany.
14:30 - 14:50
Coffee and networking break
14:50 - 15:20
Circular ecosystem enabled by additive manufacturing and spray forming

Venkata Karthik Nadimpalli, Researcher, DTU Mechanical Engineering

The most common feedstock for metal Additive Manufacturing (AM) are fine metal powders that are consolidated to form a net-shape component. Metal AM components across multiple length scales are utilized in functional applications in the aerospace, tooling, biomedical and energy sectors. As the demand for metal AM powders is increasing, it is necessary to find sustainable methods for powder production. Spray forming is a molten-spray atomization process that can start with scrap and produce an ingot together with fine metal powders. Pilot studies on the fine metal powders (also called overspray) indicated the suitability of the overspray for small and large scale AM.

The presentation will focus on a circular ecosystem to convert scrap into useful ingots and powders. Two powder-based AM technologies namely laser powder bed fusion (small-scale) and direct energy deposition (large-scale) are utilized to demonstrate the application of hybrid AM using both the ingots and powders to make functional components. The components that are made primarily from the ingots can subsequently be repaired using the 1:1 compatible powders manufactured in the same production, thus vastly improving the lifetime of existing components. At the end-of-life of the components, they can be recycled straight back into the spray forming plant to produce high-quality ingots and powders, thus enabling a sustainable circular ecosystem.

Venkata K Nadimpalli holds a PhD in additive manufacturing from the University of Louisville, USA, and he has been working at DTU since 2018 in the area of metal additive manufacturing. At DTU, he serves as a technical PI on a research project titled ‘Danish Ecosystem for Recycled Powders’. He is the recipient of the Otto Mønsted Foundation MADE Award 2020 for his research.
15:20 - 15:50
Quality assurance – development of standards for AM in oil & gas and maritime sectors

Ole-Bjørn Ellingsen Moe, Senior AM Project Manager DNV, 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 develops standards and recommended practices to ensure that the industry can utilize the benefits of AM, while still operating safely.
In this presentation, DNV will present how these standards are developed, ongoing initiatives, and the newest addition to the AM standard portfolio.

Ole-Bjørn Moe holds a MSc in materials science and has been working worldwide within DNV GL since 2015. He works in the department of Materials Advisory and has been focused on enabling additive manufacturing in the oil & gas and maritime industries in the last 3 years.
15:50 - 16:00
Closing remarks

Laser re-manufacturing and large-scale metal 3D printing, 21 September 2021

  • Required on the invoice by some organisations
  • Needed for E-invoices to Danish State Organisations

Registration fee

 DKK 2,300  Members of ATV-SEMAPP or promoting organizations
 DKK 2,925  Non-members
 DKK 975  PhD students
 DKK 200  BSc and MSc students (Membership is free of charge – register here.)

All prices are exclusive of 25% VAT.

Early-bird discount of DKK 300 when registering before 1 August 2021.

Early-bird discount does not reply for BSc, MSc and PhD students.

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. Just remember to let us know who will be replacing you so we know who to expect.

If you have any questions regarding the seminar, you can write to us here. We will get back to you quickly.