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POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

As a result of 3D printing can guarantee complicated buildings and geometry, mass manufacturing of individualized merchandise appears nearer than ever. However, since requirements are considerably missing throughout course of chains, and automatic ranges of dealing with and transport processes are low, it’s solely attainable to realize horizontal and vertical AM integration in manufacturing strains on a restricted foundation. Further obstacles embrace restricted monitoring and an absence of transparency throughout the method chain, because of a non-continuous digital knowledge chain at numerous interfaces. However the potential advantages of integrating AM into meeting and collection manufacturing strains within the automotive trade are nice, which is why the POLYLINE mission was launched.

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive ComponentsWith 10.7 Mio. Euro in funding by the German Federal Ministry of Schooling and Analysis (BMBF), this “lighthouse mission” is bringing collectively 15 industrial, science, and analysis companions from throughout Germany with the shared purpose of making a digital manufacturing line for 3D printed spare and collection automotive elements.

The three-year mission formally started at a kick-off assembly of the consortium companions this spring on the Krailling headquarters of commercial 3D printing supplier EOS, which is main the mission. The opposite 14 companions are:

The BMW Group,
Grenzebach Maschinenbau GmbH,
3YOURMIND,
Additive Marking GmbH,
DyeMansion GmbH,
Bernd Olschner GmbH,
Optris,
Krumm-tec,
Paderborn College,
Fraunhofer IGCV,
Fraunhofer IML,
TU Dortmund College,
College of Augsburg, and
College of Duisburg-Essen

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

BMBF is funding POLYLINE as a part of the “Photonics Analysis Germany – Gentle with a Future” program so as to arrange AM as a strong various for collection manufacturing. The ensuing next-generation digital manufacturing line will 3D print plastic automotive elements in an goal to enrich extra conventional manufacturing strategies, like casting and machining, with high-throughput methods.

The mission is seeking to disrupt the digital and bodily manufacturing line system, and is utilizing an attention-grabbing method to take action that, in accordance with a press launch, “takes a holistic view and implements all required processes.” To succeed, the entire high quality standards and central attribute values from the CAD mannequin to the printed half have to be recorded and documented, and particular person manufacturing sub-processes, just like the selective laser sintering, cooling, and post-processing, will probably be automated and added to the manufacturing line. For the primary time, all technological parts of the SLS manufacturing chain will probably be linked because of this.

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

Schematic illustration of a laser sintering manufacturing line

Per the appliance accomplice’s necessities, the manufacturing line will probably be realized with “a excessive diploma of maturity,” and makes use of circumstances for POLYLINE will embrace giant quantities of each serial and customised elements.

Every accomplice will add its personal contribution to the POLYLINE mission. Starting with the chief, the EOS P 500 system could have real-time monitoring and automatic loading of alternate frames added to its options; the printer may also be embedded in an automated powder dealing with system. Premium automotive producer the BMW Group, already aware of 3D printing, has a large manufacturing community of 31 crops in 15 nations, and is making a catalog of necessities for the mission to ensure that the brand new line will meet automotive trade requirements. Moreover, the demonstrator line will probably be arrange close to its Additive Manufacturing Campus, and cause-and-effect relationships will probably be collectively researched.

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

Iterations of a BMW Roof Bracket made with 3D printing. (Picture: BMW Group)

Industrial course of automation specialist Grenzebach will probably be chargeable for materials move and transport between AM processes, in addition to serving to to develop automated and software program interfaces for these processes. 3YOURMIND is organising a data-driven working mannequin, which can embrace “certified digital elements inventories, orders processing, jobs and post-processing planning and execution, materials administration, and high quality management,” whereas software program options developer Additive Marking is specializing in high quality administration optimization and useful resource effectivity.

Put up-processing specialist DyeMansion will develop a course of for licensed, UV-stable automotive colours, create Trade four.Zero-ready options for cleansing and mechanical floor remedy with its PolyShot Surfacing (PSS) course of, and contribute its Print-to-Product platform’s MES connectivity. Bernd Olschner GmbH will provide its customer-specific industrial cleansing options, Optris will make quick pyrometers and particular thermal imaging cameras tailored for plastic SLS 3D printing, and air filter methods producer Krumm-tec will work to improve the guide object unpacking course of.

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

(Picture: DyeMansion)

Together with different mission companions, Paderborn College is “engaged on the horizontal course of chain for the mixing of additive manufacturing in a line course of,” whereas the Fraunhofer Institute for Casting, Composite and Processing-Expertise IGCV is creating an idea for POLYLINE manufacturing planning and management, which will probably be examined in a simulation research for scalability. The Fraunhofer Institute for Materials Move and Logistics IML will work on “the bodily concatenation of course of steps,” paying particular consideration to flexibly linking the previous guide upstream and downstream AM processes.

TU Dortmund College will assist apply deep studying, and implicit geometric modeling, for knowledge preparation and evaluation, together with on-line monitoring and high quality administration, so as to obtain sustainable automation and effectivity for the mission. The College of Augsburg’s Chair of Digital Manufacturing works to combine AM processes into present manufacturing strategies, and can apply its experience on this space to the POLYLINE mission, serving to to develop robust vertical course of chains. Lastly, the College of Duisburg-Essen will give attention to creating high quality assurance for the fabric system, and its laser sintering course of.

POLYLINE Challenge: Growing Digital Manufacturing Line for 3D Printing Spare & Sequence Automotive Components

The consortium of the POLYLINE mission (Picture: EOS GmbH)

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