Shaping the future

The 1st Munich Technology Conference (MTC) held last October, demonstrated how combining the expertise of industry, academia, government and associations contributes to advancing AM innovation.

New associations can stimulate fresh synergies. At the MTC, leading experts from industry, academia, government and associations met to discuss key trends in AM and how the combined expertise of all the participants in the value chain can be a catalyst for this technology’s advances.

As event host, Oerlikon created a platform for the participation of key industry representatives, among them GE Additive, Lufthansa, Premium AEROTEC, MTU Aero Engines, Ruag Space and Airbus. These participants shared their know-how with experts from universities, government officials and association leaders. The mutual goal was to exchange practical experiences and ideas for the future and to discuss the ways to overcome the obstacles and challenges in the increasing adoption of AM.

Popularly known as 3D printing, AM is already recognised as a promising technology that is poised to become a central building block in the future of industry. Those monitoring AM’s progress have long speculated that it would need the participation of representatives from across the fields to fulfil its potential. But until the MTC, that theory had not been given a real-world test.

Munich was chosen as the conference site because it is a technology hub and seen as one of Europe’s most innovative cities. It is also the home of Oerlikon’s Innovation and Research Centre for Additive Manufacturing, where over 35 engineers, specialists and technicians are collaborating to connect the dots between materials science, component design, production and post processing. This work is bolstered by the partnership with Technical University of Munich (TUM) and proximity to Munich-based global leading players in the aerospace, automotive and medical technology industries.

Digitalisation takes shape

Throughout history, people have used tools and machines to cut forms from stone or metal. The advent of 3D printing represents a reversal of this approach for industrial manufacturing. In the words of Prof. Dr Schleifenbaum, RWTH Aachen: “The beauty of AM is that you can directly transform an idea into reality.”

The technology empowers engineers to create objects in a manner that replicates their form as found in nature and to design those objects to fulfil a precise function. New objects can be built by adding layer upon layer of a material, whether metal, plastics, or ceramic. This positions AM technologies to drive the digitised factories of the future, which will be capable of manufacturing anything from a turbine part to a hip replacement.

As Florian Mauerer, head of Oerlikon’s Additive Manufacturing Business Unit, commented during the MTC: “AM is the most physical aspect of digitalisation.”

Equally important, AM has the capacity to significantly change the manufacturing landscape with improvements and efficiency, which in turn will open manufacturing locations in more places, regardless of local labour costs.

Reducing weight and emissions

The aerospace sector stands among the most important pioneers in applying metal additive manufacturing technology. AM is helping the industry to increase production efficiency and intelligence in a manner that boosts performance, controls emissions and promotes greater safety.

These objectives align with aerospace performance targets. As Airbus’ Jonathan Meyer noted at the MTC: “The main drivers in aerospace are CO₂ emissions targets and the ‘high value density’ of parts.” In layman’s terms, this means reducing weight, particularly in areas exposed to the highest friction.

Engineers have developed new and geometrically complex products thanks to the design flexibility offered by AM. From engine and turbine parts to cabin interior components, all of them can be made to deliver improved functionality and reduce weight.

“In a product that was manufactured for an Airbus transport plane, AM reduced the number of parts by 98%, the weight by 48%, the costs by 30% — all while keeping performance at the same level,” noted Premium AEROTEC’s Gerd Weber during at the MTC.

These advances are key to achieving greater fuel efficiency, which by extension results in reduced CO₂ emissions. And those reductions can have a significant impact on each plane’s carbon footprint: by one calculation, decreasing 500g generates a 300,000t CO₂ reduction over 30 years of the aircraft’s life.

At the MTC, a further benefit was pointed out by Michael Schreyögg, chief programme officer at MTU Aero Engines: “AM can increase airplane engine efficiency through innovative cooling designs.” Improved cooling enables engines to run at higher temperature which in turn increases engine efficiency.

Today, AM is being used for prototyping and relatively small series component production. However, the possibilities in diverse industries is immense and the potential breakthrough in mass customisation and mass production is foreseeable.

Convinced of the advantages of AM, Airbus’ Meyer said: “AM could be used excellently for low volume parts. Here it offers prototyping at a high speed, leading to faster innovation cycles. Also for higher volume parts there are a lot of benefits: Optimised parts production, more integrated structures, less supply disruption.”

True to these observations, AM’s development is poised to pave the way for new business models and opportunities across innovative value chains. New repair and replacement businesses are on the cusp of emerging. Companies like Siemens are planning to tackle design and software solutions. And these are just the developments we can predict now, while AM is still in its infancy.

Demonstrating AM solutions

Recognised as a leader in AM industrialisation, Oerlikon Group’s ambitious targets are backed by the company’s demonstrated ability to engineer surface solutions and advanced materials. Determined to provide customers with lighter, more durable and environmentally sustainable products, the company continuously invests in innovations and technologies that address these needs.

Prof. Dr Michael Süss is convinced: “Additive Manufacturing will be key to the future competitiveness of European industry.”

Oerlikon’s focus on pioneering integrated AM services and developing new materials reflects its commitment to playing a key role in raising the overall competitiveness of manufacturing in industry and in supporting customers to gain further competitive advantages.

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