Plastics News Europe - June 2018 - 12

automotive: additive manufacturing

BMW Mini dashboard personalisation

➡ Continued from page 11
In addition, BMW has an SML 500
laser-melting machine, used for small
series metal parts, or tools for moulding polymers on a Dr Boy 25 SE injection moulding machine, Plastics News
Europe has observed.
For exterior 3D printed Mini emblems, Fruhmann pointed to tests
that were needed such as exposure to
different climates, UV resistance, colour stability, high-pressure water
spray resistance and chemical resistance to e.g. ethanol and cleaning
chemicals, including those dissolving
tree resin deposits.
The characterisation of 3D printing materials is made after CO2 laser
sintering sets of 112 conventional
tensile dumbbell test bars are "printed" from powder in 16 rows of 7.
These showed mechanical properties
are critical in the Z-direction, elongation at break is the most "sensitive"
mechanical property, but with deviations within acceptable limits, while

tensile strength values do not vary
throughout the chamber.
In general, high process stability
is required throughout the entire
build-chamber in order to obtain
consistent material properties in all
parts produced in the chamber, Fruhmann stated. Moving to serial production requires close cooperation
between material and machinery
producers, as their published data
sheet properties can only be
achieved with optimisation of the
entire production process. And provision of evidence of reliable mechanical properties is not a universal
standard among additive parts producers, Fruhmann observed.
Frieda Gripp, financial director of
the "Mobility goes additive" department of Deutsche Bahn (German
Railways) showed how DB uses additive manufacturing in both plastics
and metals "to revolutionise maintenance", or, in other words, to produce prototypes, tools and, above
all, to rapidly replace replacement

Printing a Deutsche Bahn regional train headrest on a Big Rap machine

12

parts that are no longer available.
"We have sometimes waited six
months for parts in the past, or they
were no longer even available at all,"
said Gripp.
In many cases, large cost savings
can be achieved through the partial
substitution of an element in a component, instead of having to order
an entirely new complete assembly,
so "small things, great effect", Fruhmann said. It means DB needs to develop logistics contracts for the many
printed parts, but it also means additive manufacturing has "disruptive
power" on existing logistics supply
networks.
DB started additive manufacturing with just 10 parts printed in
2015, following an idea picked up
when DB visited Silicon Valley in the
US. Since then, growth has been exponential, with the number of printed parts reaching 1,000 in 2016,
2,000 in 2017 (representing 3% of
all replacement parts needed) and
15,000 expected in 2018, produced
in the 180 DB workshops in Germany, Gripp revealed.
The DB "printer farm" includes a
wide range of equipment, from
smaller Ultimaker printers costing
around €2,200 all the way through
to equipment costing as much as
€400,000. DB's 3D printing project
manager Stefanie Brickwede says
DB produces parts up to the size of
a shoe box by its powder bed [laser
sintering] process, up to the size of
a beer crate by extrusion [extruded
filaments].
On the basis of "together is better
than alone", DB maintains close contacts with 67 companies and organisations involved with 3D printing,
cross-fertilising ideas with machinery
suppliers such as EOS, SLM Solutions, Concept Laser and Ultimaker,
materials suppliers such as BASF and

june 2018



Table of Contents for the Digital Edition of Plastics News Europe - June 2018

Contents
Plastics News Europe - June 2018 - Cover1
Plastics News Europe - June 2018 - Cover2
Plastics News Europe - June 2018 - Contents
Plastics News Europe - June 2018 - 4
Plastics News Europe - June 2018 - 5
Plastics News Europe - June 2018 - 6
Plastics News Europe - June 2018 - 7
Plastics News Europe - June 2018 - 8
Plastics News Europe - June 2018 - 9
Plastics News Europe - June 2018 - 10
Plastics News Europe - June 2018 - 11
Plastics News Europe - June 2018 - 12
Plastics News Europe - June 2018 - 13
Plastics News Europe - June 2018 - 14
Plastics News Europe - June 2018 - 15
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Plastics News Europe - June 2018 - 17
Plastics News Europe - June 2018 - 18
Plastics News Europe - June 2018 - 19
Plastics News Europe - June 2018 - 20
Plastics News Europe - June 2018 - 21
Plastics News Europe - June 2018 - 22
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Plastics News Europe - June 2018 - 24
Plastics News Europe - June 2018 - 25
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Plastics News Europe - June 2018 - 27
Plastics News Europe - June 2018 - 28
Plastics News Europe - June 2018 - 29
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Plastics News Europe - June 2018 - 40
Plastics News Europe - June 2018 - 41
Plastics News Europe - June 2018 - 42
Plastics News Europe - June 2018 - Cover3
Plastics News Europe - June 2018 - Cover4
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