Linked in additive manufacturing

AMAug18Features - valuechain1
AMAug18Features - valuechain1

When metal additive manufacturing specialist, Zenith Tecnica needed an ERP system that would accommodate the data generated by the 3D printing process it turned to Valuechain for the answer. Ed Hill discovers more.

Additive manufacturing processes are having a big impact on the aerospace sector, but they also create new types of data that have to be managed rigorously, especially in this tightly regulated and safety conscious industry.

New Zealand-based Zenith Tecnica specialises in the production of additive made titanium components using electron beam melting (EBM), particularly in the aerospace and medical fields.

The AS9100 Rev D certified company currently has three GE Additive/ARCAM EBM machines, one small Q10 machine with a medical certification and two large Q20 machines with an aerospace certification. It undertakes rapid prototyping and testing from CAD drawing through to production.

In 2016, one of its aerospace customers recommended the company should introduce enterprise resource planning (ERP) software to help manage the production of its parts. Zenith introduced an entry level ERP system from Tricorn Systems, however, it became clear that the system had not been developed with metal additive manufacturing in mind.

“The powder traceability was cumbersome and functionalities were limited,” explains Bruno Le Razer, Zenith's quality manager. “It didn’t cope with multiple parts in one build and multiple common operations. Build management was impossible and there were many repetitive tasks for the production of individual parts.”

Valuechain’s acquisition of Tricorn Systems prompted Zenith Tecnica to approach the new management team to see if it could develop an ERP system specifically for additive manufacturing.

“Our deep knowledge of metal additive manufacturing (either laser melting or electron beam melting) enabled us to help Valuechain develop a world class unique ERP system specifically designed for additive manufacturing. A list of requirements was provided for the main module (from quote to delivery including build management) and also for a new powder traceability module.”

The DNA benefits

The result is Valuechain’s DNAam software, which has brought a host of benefits to Zenith when it comes to managing it manufacturing data. Some of these include: the introduction of a paperless jobcard system, replaced by a web app on a tablet that can control Zenith’s AM machines and workshop area; improved powder traceability, a click of a button gives a full visual powder and build history.

Additive manufacturing processes are having a big impact on the aerospace sector

Additionally, it allows users to manage and trace any blending and splitting of powder as well as recycled powder from powder-base AM machines. Another benefit is the ability to enter and manage build files, whether they are CAD or .STL files, and trace them by assigning ID numbers. These files can be controlled by different statuses that can restrict their use in production. Additionally, they can be pushed to machine specific shared folders when a build order is raised so operators can refer to the latest issue of the build files related to that order before starting the build. Lastly, these build files can be encrypted and securely shared with partners in the supply chain.

“One of the biggest benefits of Valuchain’s DNAam to AM and EBM in particular is mass-customisation. Zenith takes orders from its largest customers where on a single purchase order there are quantities of over 100 different geometries to produce. No project is the same. This means the projects are front-heavy with a lot of data entry and programming to get the jobs underway. DNAam allows us to enter all of the data right from the RFQ stages and we never have to enter anything twice. All of the generated paperwork is templated by us so we have full control over the outputs and are able to make changes on the fly if necessary.”

From inception, jobs have a clear process that follows through the workshop and any subcontracting operations. A user has a touchscreen tablet to begin the operation, view process instructions, and sign off when complete.

“Zenith and customer procedures and specifications are linked to every step so users are only a few touches away from reading a procedure, specification, or work instruction. We’re able to see at a glance everything that is in the workshop, what stage it is up to, who did what, and how long it took. This is absolutely vital in ensuring quality procedures are followed for aerospace production and ensuring we have accurate KPIs to follow quality standards.”

DNAam captures workshop data as well as all of the subcontracting and laboratory testing data so that at the end of the process the certificate of compliance is generated automatically and no time is wasted preparing masses of paperwork.

Adding to the future

Does Le Razer think systems like Valuechain’s DNAam aid the widespread adoption of metal additive production process in aerospace manufacturing?

“Two major challenges of implementing AM parts in aviation are traceability of the powder and achieving repeatability in the process to standardise it. The trace tool allows us visualise every build in which a batch of powder has been used by clicking on it. This intuitive tool provides complete traceability which can be used to scale-up AM production, not only in aerospace but in all types of industries.

“Presently, there is still some resistance to AM when it comes to aircraft primary structure parts where the certification processes are more severe, so companies are currently certifying on a part-by-part basis. This is a long and costly certification process and makes it difficult to fully introduce AM for those parts. The aerospace industry is therefore trying to find a solution that enables it to certify the whole process instead of certifying each part made, i.e. each part made in the AM certified process will be allowed to be used.

“DNAam can aid this process due to the full integration of powder management, trace module, and build file management functionalities with the whole production process through an ERP solution. This makes it easier to demonstrate repeatability of the process and allow industries to scale up additive manufacturing.”

DNAam can also manage other additive materials and processes. Alberto Garcia, Valuechain’s technical additive manufacturing specialist comments: “In terms of wire-based technologies, the system is fully capable to operate with plastics (FDM) and soon with metal wire + arc additive manufacturing (WAAM).”

Zenith Tecnica specialises in the production of additive made titanium components using electron beam melting

Furthermore, it not only applies to different types of AM equipment, but also it allows the setup of different types of recycling systems against each machine entered in the system to ensure traceability is always maintained in the best way. It’s possible to set whether a specific machine will be using an automated powder recycling system, or if it will need a PRS operation to recover the powder from the build chamber by the operator.

DNAam also includes the industry’s need to develop and introduce new materials specific for AM purposes. It allows the utilisation of different chemical compositions and their material grade tolerances against each stock code; covering not only current AM materials, but also new materials AM specific that might be developed in the future.

He adds: “The roadmap of DNAam is to get not only more in-process real-time monitoring data through new connections to different OEMs machine APIs, but get real-time monitoring information of the batches of powders from the different locations where they are stored, as well as while they are being transported to the AM hopper to enhance control and monitoring of the process.

“The team is also working on the introduction of new types of technologies, such as WAAM or powder-blown technologies such as LENS or LDM. Moreover, the system will be able to generate intelligence through all the data stored and advise best practises for different powders and machine parameters to achieve the best possible outcome.”

http://zenithtecnica.com

https://valuechain.com

Company

Valuechain

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