The TCT Conference @ Formnext returns for its fifth year in Frankfurt next week. Bringing together thought-leadership, the latest research and most fascinating application studies, the four day line-up has been curated by TCT's conference team to provide a truly global overview of how advances in 3D technologies, design, and engineering, are impacting the manufacturing world. We asked our Conference Producer, Magda Brzegowy to select some of her session highlights.
Day 1: Tuesday 19th November
10:00-10:30 | Stage 1 and 2
AM in industrial production
Maximilian Meixlsperger | Head of AM Metal | BMW Group
This presentation will address the challenges of additive manufacturing (AM) technology with aspects like cost efficiency against conventional production technologies but also along the process chain and in the mindset of organisations. The keynote will show the potential of AM in the automotive industry from BMW Group’s point of view, and lead to possible approaches and necessary developments, for example, for machine manufacturers to overcome the challenges and reach the tipping point for the full industrial use. The session will also give insights into how the BMW Group as an organisation handles the challenges and how the BMW Group wants to bring AM to industrial scale production through clear specifications of requirements as well as processes and development targets.
10:30-11:00 | Stage 1 and 2
How the rail industry can benefit from AM
André Bialoscek | Head of Vehicle Physical Integration Hennigsdorf | Bombardier
The railway industry is not considered by experts as a pioneer when it comes to introducing new materials and manufacturing processes. However, in this industry, the benefits of AM can have a transformational impact on the traditional supply chain and spare part production. It is of the upmost importance to minimise time-to-market. This is exactly where AM provides its main advantages; cost-effective manufacturing from batch size 1, components in real dimensions for rapid design validation or for pre-series components, and the spare parts business. In this presentation, André Bialoscek, Head of Vehicle Physical Integration Hennigsdorf, Bombardier, will focus on a range of application examples of AM in existing accident and refurbishment vehicles, as well as new vehicle developments.
Day 2: Wednesday 20th November
14:30-15:00 | Stage 1
AM standardisation in the healthcare industry
Dr Khalid Rafi | Senior Lead, AM Program Development | ASTM
The unique characteristics of AM in making a product, introduces new possibilities to the entire healthcare sector. Despite these potential opportunities, the industry is still very cautious in adopting the technology to its fullest potential. The nuances associated with the technology and the materials used can introduce new challenges in meeting the regulatory requirements. Meeting the regulatory requirements and the wider adoption of the technology can be facilitated only through standardisation. This presentation will focus on those requirements and the current standards development initiatives to accelerate the adoption of AM in healthcare.
13:15-13:45 | Stage 2
The present state and future prospects of large-scale aluminium additive manufacture
Kwasi Ayarkwa | Research Engineer in Fusion Welding | MTC - The Manufacturing Technology Centre
Wire + arc additive manufacture (WAAM) continues to attract interest particularly in automotive and defense sectors to produce medium to large scale aluminIum components. End users and manufacturers are pushing the technology to achieve robust and stable aluminIum builds. The presented topic will review state-of-the-art of wire + arc additive manufacture processes that have been used for aluminIum components. An overview of the current challenges in processing is considered to better understand the readiness level of the technologies available.
Day 3: Thursday 21st November
15:00-15:30 | Stage 1
All quality control - Build job monitoring with near-net shape specimens
Anne Rathje | AM Process Engineer | Baker Hughes - A GE Company
Direct metal laser melting (DMLM) is of great interest regarding the fabrication of metallic components. However, production individualisation poses the challenge of assuring the quality and consistency of each single part produced, which is often achieved using mechanical witness test specimens. Witness specimens for quality control and build job monitoring require a machined surface condition. This leads to an increased effort in specimen manufacturing, as well as the application of material properties obtained from specimens with machined surfaces, which may not always reflect the mechanical properties of AM components. Within this contribution, the effect of the surface quality of tensile and Charpy impact specimens, manufactured with DMLM, is presented by comparing the mechanical and surface properties.
11:45-12:15 | Stage 2
Sensor integration in plastic and metal AM parts based on two industrial use cases
Philipp Stoll | Scientific Assistant | inspire AG, icams
This talk presents the feasibility of sensor integration, both in plastic and in metal parts, based on two industrial use cases. First, for a value manufactured with stainless steel, the integration of both temperature and position sensors during the production with selective laser melting will be shown. The second industrially relevant application presented will be a housing manufactured in PA 12 using selective laser sintering with an integrated acceleration sensor. Based on industrially relevant parts, the general potential, the benefits as well as the challenges of sensor embedding during AM will be revealed.
Day 4: Friday 22nd November
10:00-10:30 | Stage 1 and 2
3D printing at Miele
Pia Gausemeier | Head of Strategic Production Technology and Head of Information Technology - Plant Bielefeld | Miele & Cie
3D printing promises both improved functionality and cost advantages in small quantities. When implementing new technology, however, it is important to have realistic expectations. At Miele, 3D printing is positioned as a useful addition to a portfolio of manufacturing technologies. This keynote presentation will evaluate how the company uses 3D printing in its product applications now and explore what possibilities will be conceivable in the future. This talk will also discuss the organisational changes needed to take advantage of this technology, the concepts applicable to design departments, and examine scalable production concepts that have been implemented in cooperation with Ultimaker.
10:30-11:00 | Stage 1 and 2
Race to innovate: Metal AM for lightweight, highly complex race boat structures
Mark Chisnell | Technology Coordinator | INEOS TEAM UK
The America's Cup is the oldest international trophy in world sport and one that Britain has never won. INEOS Team UK was formed to challenge for the America's Cup in 2021 - the racing boat will be a 75-foot foiling monohull, built and equipped with the best of British technology. Mark Chisnell, Technology Coordinator at INEOS TEAM UK presents how Renishaw will help to optimise the design and manufacture of 3D printed metal parts, for example, the mast step for the team's test boat that connects the mast to the hull through an articulating socket. The mast step must withstand compression loads of over three tonnes caused by the rig tension required to counter the forces of the wind on the sail and mast.
Formnext takes place in Frankfurt on 19-22 November. Register for your showfloor ticket here and visit the TCT @ Formnext Conference website to register for your conference pass.
