Industrialized Additive Manufacturing

Power of eco-system partnerships

Bangalore – January 18, 2023
International Seminar on Manufacturing Technologies
Martin Gehringer Heinz-Ingo Schneider
Senior Business Development Manager Additive Manufacturing Senior Key Expert for Additive Manufacturing

Unrestricted | © Siemens 2023 | FINAL (V4) | International seminar on manufacturing technologies 2023
Businesses and Services of Siemens AG

Industrial Business
Smart Siemens Portfolio Siemens
Infrastructure Mobility Healthineers1 Companies Advanta

Factory Automation
• PLC Controllers (SIMATIC)
Services
• Engineering SW
• HMI, IPCs Financial Services Real Estate Global Business Services
Motion Control
• CNC Controller (SINUMERIK
• Drive systems
• Motors Siemens Digital Industries
Industrial Software provides solutions for
• PLM Software
industrial Additive
• Manufacturing Operations Manufacturing
• Industrial IoT and Low-Code

1 Publicly listed subsidiary of Siemens; Siemens’ share in Siemens Healthineers: 75%

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Industrial AM technologies are covered by Siemens Digital Industries solutions
These are developed further in collaboration with customers and partners

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We industrialize Additive Manufacturing to empower our customers to create,
make and use additive applications at scale
Utilize full data traceability with integrated
security and digital rights management

Realize first-time-right printing

empowered by digital twins

Improve machine quality and efficiency

by using industrial automation
Increase efficiency by seamlessly integrated
software and data consistency

Expand business opportunities by Speed up the way to industrialized additive Ramp-up and scale production with automated
connecting to AM Network manufacturing with value-add services post-processing and handling

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Industrializing
Planar AM technologies

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Application

End-to-End software and machine

control solution for Laser Powder Bed
Fusion (L-PBF)
Partners

Software development Machine builder

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Simplified machine control structure
Machine Control Software as a central link

General machine control NX NX NX

Siemens Build Proc. AM Modeling

automation
SIMATIC Build Job Preparation
systems HMI
WinCC Unified
included Machine RTC6
Control DLL
• SIMATIC PLC S7-1500F Software
Scanlab Laser
RTC6
with OPC UA connectivity
Standard IOs
• SIMATIC IPC427E
as platform for HMI and
Failsafe IOs Scan
AixPath Machine Control SIMATIC
System
Software PLC Controller
S7-1500 not implemented yet
Servodrives
• SIMATIC WinCC Unified
visualization software in M2M, MES, SCADA
Heat control
TIA Portal as HMI

Laser and Scanner Control

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AM Part description
Paving stone mold

Component designation
Paving stone mold

Purpose
Generate a texture on a concrete block

Material
EN 1.7131 (16MnCr5) Chromium Steel

Why AM as a method to produce it

With AM (L-PBF) complex shape elements can be
realized. This makes it possible to adapt the surface
structure of a paving stone individually to specific
requirements like slip resistance
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AM Machine description
Reichenbacher AMS 400
Basics

Build volume (XYZ) 400x400x500 mm

Laser type Yb-Fiber laser, 1000 W
Focus diameter 80 – 500 µm
Layer thickness 20 – 120 µm
Modularity

Heated build platform up to 200° C

Heated feed platform up to 200° C
Heated printing chamber up to 200° C
Heated feeding chamber up to 200° C
IR lamps up to 1,5 kW
Inert gas supply Nitrogen or Argon
Materials

Metals : 16CrMn5, Stainless Steel 316L*, Stainless Steel 17-4PH*, AlSi10Mg*, In718* | Plastics : PA12 (black)*
* in build process development
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Part design

Using
NX Modeling
to efficiently generate
the surface structure

Using
NX DfAM
to check printability

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Build job preparation
Build tray setup

Part
Positioning
• Direct use of native
CAD geometry
• Make use of
reference sets and
print coordinate
systems defined in
the modeling
environment
• Adopt part for
printing in
associative relation
to the original part

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Build job preparation
Support generation

Support features
• Integrated support
structures
• Automatic generation of
support structures
• Embedded CAD for
designing custom supports
• Associative design changes
across NX workflow are
recognized: "Regenerate
supports" feature
• Patterning parts and
supports

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Build job definition
Build Processor Configuration
Profile Library
enables full control on
build strategies per
material
• Build Order Profile
Specify build order

• Part Profile
Specify scan strategy and
process settings for parts

• Solid Support Profile

Specify scan strategy and
process settings for solid supports

• Non-Solid Support
Profile
Specify scan strategy and
process settings for non-
solid supports

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Build job definition
Build Strategy

Build strategy
assignment
• Use pre-defined
profiles for setting
build tray and part
Defaults
• Selective overwriting
of profiles per part
enables full flexibility

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Build Job Generation
Job validation

Build Job
Analysis
• Full access to scan
paths for all layers
after build job
generation
• Scroll through all
layers or select one
specific layer
• Check individual scan
strategy settings
• Review individual
sequences

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Machine Control Software framework as orchestrating element
Paving the way to efficiently control a L-PBF system

Challenges for an Machine Control Software

AM machine builder (MCSW) meets these challenges
• AM Machine control architecture is distributed • MCSW manages the dataflow
between general machine controller (typically a • Synchronizes HMI, PLC and scan controller
PLC controller) and a scan controller (typically a • Reduces the integration effort for a machine builder
realtime control board) significantly
• Build job file (build processor Output) provides a
full recipe to execute a build job for both machine
controller and scan controller
• Dataflow from build processor to controller
platforms needs to be established
• Different control architecture components need to
be synchronized and served in the right manner

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Machine Control Software framework as orchestrating element
Scanner and laser integration

Key features and highlights

• Support leading brands of scan controllers
• Connection via scan controller specific API
• Sets process parameters like laser power, laser speed,
laser delays or skywriting
• Enables the calibration of scanner systems
• Monitors laser status
• Prepares and load the command lists into the scan controller
• Enables layer-wise build job execution
• Monitors status of scan controller for PLC and HMI

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Machine operation
Human Machine Interface

User Interface generated with WinCC Unified HMI control for MCSW

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Machine operation
Job execution

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Industrializing
Multi-Axis AM technologies

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 Directed Energy Deposition
Multi axes AM Technologies for Metals

DED

AM Material Wire Powder

Electron Kinetic
Energy Source Arc/ Plasma Laser Plasma Laser
Beam Energy

WAAM WLAM EBAM PTA LMD Cold Gas

Method Wire Arc Additive Wire Laser Additive Electron Beam Additive Plasma
Laser Metal Deposition Spraying
Manufacturing Manufacturing Manufacturing Transferred ARC

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SINUMERIK ONE
ONE Controller for AM Technology and Machining

• High performance in AM processes and

machining
• Control of machine tools and robot systems
• Realization of high precision and jerk free tool SINUMERIK
path movements
ONE
• Complete machine programming in TIA portal
• Virtual programming and commissioning of NX RUN MyVirtual Machine

SINUMERIK ONE (SIMIT, MCD, Create My Virtual

Machine)
• Optimal NX CAM alignment NCU 1740 NCU 1750 / 1760

• Open architecture for customer specific functions

• Display of machine status
• Process monitoring PPU 1740

• Closed loop control functions

Open architecture for monitoring Scalable controller types for
• Scalability in soft and hardware and closed loop control special AM application

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Digital Enterprise for AM

Digital world Seamless digital chain for AM

NX CAM
NX CAD Run My Virtual Machine
NX MCD Simulation tools
SIMIT Plant Simulation
Create My Virtual Machine 
 • G-Code machine program
• Machine Design • Technology simulation
• Programming • Tool path optimization
• Virtual Commissioning AM AM • Production planning
Machine Production
Machine Builder Machine User
AM machine with Stable AM and production
SINUMERIK ONE process with monitoring
and closed loop functions

Performance
Real world

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USE CASE Rocket Nozzle – MT Aerospace

PBF

DED
Development Focus
• Capability
• High building rate
• Scalability to large geometries
• Robust process
Design of generic Cryogenic engine Ariane 6,
nozzle Upper Stage

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Siemens NX CAM – Connection between the virtual and real world
DED NX CAM preparation for fuel injection channel

NX CAM
Preparation
• Toolpath generation
• Freeform Additive
Thin wall with Merge
functionality
• Machine Simulation with
NX / Run MyVirtual
Machine
• Machine program
generation

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DED Manufacturing of Fuel Injection Module

Machine
BeAM Modulo 400
• equipped with
SINUMERIK ONE
• enables the
manufacturing of
double walled rocket
thrust nozzle in five
axis mode.

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AddUP BeAM Modulo 400 in Siemens AM Experience Center
Working on Process Monitoring and Process Control

Siemens
Analyze My Workpiece/ Toolpath

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AddUP BeAM Modulo 400 in Siemens AM Experience Center
Working on Process Monitoring and Process Control

Siemens
Analyze My Workpiece/ Toolpath

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AddUP BeAM Modulo 400 in Siemens AM Experience Center
Working on Process Monitoring and Process Control

Siemens
Analyze My Workpiece/ Toolpath

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Digital World
Preparing the DED process to generate the Rocket Nozzle

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Edge based monitoring and data analyzing with Analyze MyWorkpiece/ Toolpath

DED process rocket nozzle Toolpath analyses of DED (LMD) manufacturing process of rocket nozzle
on Modulo 400
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Parameters of DED (LMD) for process monitoring and control

Temperature distribution in
Powder feeding LMD head
process  constant Monitoring systems on
M base of
Sinumerik • SINUMERIK ONE
controller
• Edge
Nozzle distance, layer
1 thickness • MindSphere

Melt pool dimension

Laser Power (Width control)

Axis Quality evaluation on base

Temperature
drives distribution in part of process parameters

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High process stability on base of closed loop control for LMD

Closed loop motion control

• Machine with SINUMERIK controller
• Measurement of nozzle distance Movie DED Closed Loop Layer Thickness Control
by OCT Sensor from Precitec
• Control algorithm running on SINUMERIK

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Siemens is collaborating with a large number of customer, partners and institutes

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 Contact
Siemens AG

Martin Gehringer Heinz-Ingo Schneider

[email protected] [email protected]

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