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Direct, Mold-Less Production Systems

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Integrative Production Technology

Abstract

Additive Manufacturing (AM) technologies in general—and in particular, Selective Laser Melting (SLM)—are characterized by a fundamentally different relationship with respect to costs, lot size, and product complexity compared to conventional manufacturing processes. There is no increase of costs for small lot sizes (in contrast to mold-based technologies) and none for shape complexity either (in contrast to subtractive technologies). Thus, only the holistic development of a direct, mold-less production system that takes all relevant interdependencies along the product creation chain into account provides the full economic, ecologic and social benefits of AM technologies in future production. The following six subjects of the product creation chain were examined: (i) New business models and customer willingness to pay for AM parts are revealed. (ii) The Product Production System (PPS) was totally revised regarding the adoption of SLM technology into conventional manufacturing environment. (iii) The SLM manufacturing costs were examined regarding different machine configurations. (iv) A high-power SLM process was developed for enhancing the process productivity. (v) High manganese steel was qualified for the SLM process. (vi) Finally, two lattice structure types and a design methodology for customer parts were developed.

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Authors and Affiliations

  1. Fraunhofer Institute for Laser Technology (ILT), Steinbachstraße 15, 52074, Aachen, Germany

    Reinhart Poprawe

  2. Department of Ferrous Metallurgy (IEHK), RWTH Aachen University, Intzestr. 1, 52072, Aachen, Germany

    Wolfgang Bleck, Jan Bültmann & Ulrich Prahl

  3. Research Area Technology, Innovation, Marketing, Entrepreneurship (TIME), RWTH Aachen University, Kackertstr. 7, 52072, Aachen, Germany

    Frank Thomas Piller, Ruth Jiang, Robin Kleer & Christian Weller

  4. Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Steinbachstraße 19, 52074, Aachen, Germany

    Günther Schuh

  5. Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Steinbachstr. 53B, 52074, Aachen, Germany

    Sebastian Barg, Arne Bohl & Michael Riesener

  6. Fraunhofer Institute for Laser Technology (ILT), Steinbachstr. 15, 52074, Aachen, Germany

    Sebastian Bremen

  7. Chair for Laser Technology (LLT), RWTH Aachen University, Steinbachstr. 15, 52074, Aachen, Germany

    Christian Hinke, Simon Merkt, Johannes Schrage & Stephan Ziegler

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  1. Reinhart Poprawe
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Correspondence to Reinhart Poprawe .

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  1. Lehrstuhl für Werkzeugmaschinen, RWTH Aachen, Aachen, Nordrhein-Westfalen, Germany

    Christian Brecher

  2. RWTH Aachen, Werkzeugmaschinenlabor WZL der RWTH Aachen, Aachen, Germany

    Denis Özdemir

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Poprawe, R. et al. (2017). Direct, Mold-Less Production Systems. In: Brecher, C., Özdemir, D. (eds) Integrative Production Technology. Springer, Cham. https://doi.org/10.1007/978-3-319-47452-6_2

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