TCT Conference @ Formnext 2018 Agenda

To find out more about the presentations at the TCT Conference @ Formnext, please see the programme below.

Download a PDF version of the full conference 

Keynote Speakers

Additive Manufacturing is an Essential Part of the Seamless Digital Chain in Spare Parts Services of Siemens Mobility -

The business of spare parts presents a number of key challenges regardless of the industry. Whether those challenges stem from making, storing or shipping these parts, the traditional solutions often amount to time-consuming and costly difficulties. In the rail industry, these issues can take the form of discontinued parts, certification problems, and design constraints. For suppliers, certain replacement parts can either be uneconomical or impossible to manufacture, depending on the number of parts required, or the level of customisation needed. 

In this presentation, Siemens Mobility, will explore how advanced FDM additive manufacturing is enabling suppliers to increase innovation and overcome these problems. Responsible for some of the world’s most advanced rail solutions, the Siemens Mobility team is pioneering a new, distributed manufacturing network to 3D print spare parts on demand for its customers. Launched last year, this network has gone from strength to strength with FDM additive manufacturing at the heart of it. From customised, low-volume replacement internal parts to essential exterior train components, the Siemens Mobility team is pushing the boundaries of what is possible with additive manufacturing in the rail industry. 

Head of Business Support - Siemens Mobility Services
Siemens Mobility
An AM Challenge: Building on Established Use Cases while Enacting Long-Term Initiatives -

Great things are happening with AM and we truly are on the cusp of significant change and advancements. However, the allure of advanced applications, like series production, may impair success with fundamental AM applications with which you can benefit from today. Now is the time to refocus efforts on the legacy AM applications that are feasible for all; now is the time to expand those efforts while building the roadmap for grand visions and big achievements.

Founder and President
T. A. Grimm & Associates
Striking the Right Balance Between Buying Equipment and Using Service Providers for Global Companies -

Presentation Level: Beginner

The goals of zero waste and destination manufacturing, as well as design freedom, seem reachable with 3D printing and additive manufacturing. The fundamental principles of value creation, however, require heightened coordination from design engineers, management as well as vendors, suppliers, and service bureaus. Corporations also have to ask themselves when is the best time to outsource the right AM machine. Equipment, staffing, training, maintenance, and software, require significant time and money investments and the costs can add up quickly.

This presentation will assess the coordination amongst various stakeholders in AM supply chain. It will evaluate the advantages and disadvantages of using service bureaus and buying equipment. The session will also consider the financial implications associated with using service providers and in-house machines.

PGP of Additive Manufacturing
Danfoss Additive Design and Manufacturing
The Integration of AR/VR and Robotics into AM Series Production -

Presentation Level: Intermediate 

Additive manufacturing is revolutionising how parts are being designed and produced. AM technologies offer various benefits such as shorter part production time, greater flexibility in product design, lower manufacturing cost, and less material waste. As AM continues to advance, there are growing interests from various industries to adopt it. AM series production is predicted to capture part of the injection moulding sector, currently valued at $162B, and revolutionise the brick and mortar supply chain. The economics, however, do not apply to an infinite number of parts. A more cost-efficient production process requires innovative solutions. This presentation will examine why AR/VR and robotics should become a part of the AM series production process.

Head of the Technology Grant Office
NAMIC (National Additive Manufacturing Innovation Cluster)
A guideline for 3D printed (spare) parts in Oil & Gas -

In January 2018 two seamlessly aligned Joint Innovation Programs (JIPs) started, to develop a guideline and accompanying economic model to print qualified, functional metal production-ready (spare) parts, to be used in the Oil, Gas and Maritime industries. 

Currently 13 companies from 9 countries joined these programs: Equinor, BP, Rolls Royce Marine, OCAS, Ivaldi Group, TechnipFMC, Voestalpine, Aidro, Vallourec, SLM Solutions, Additive Industries, Hiptec and the Advanced Forming Research Centre of the University of Strathclyde. The JIPs are managed by DNV GL (Norway) and Berenschot (NL).The practical guideline will be available by July 2019. 

In this presentation you will learn about the set up and contents of the guideline and the way the benefits of Additive Manufacturing will be captured in this guideline. The partners in this JIP highly value the accelerated learning curve and quick design and production activities. The detailed and dynamic communication during the workshops, sharing both additive manufacturing and Oil & Gas industry expertise, are invaluable. During the presentation the expected benefits of the guideline that Equinor and BP will obtain are expressed. 

The project structure ensures a seamless link between the production of parts and the development of the guideline. Thus, the guideline is aligned with today’s additive manufacturing production set up and addresses a real life production environment, while remaining at the high quality level that industrial organisations have come to expect from the DNV-GL guidelines.

Practice Leader 3D Printing
VP Strategy,
Ivaldi Group
L'Oréal's Digital Packaging Factory: Key Wins with FFF 3D Printing -
Learn how L'Oréal uses 3D printing for the creation of functional parts, production tooling and rapid prototyping. The company's packaging factory needs to run non-stop. The presence of 3D printers on their work floor allows employees to create prototypes, functional parts and make ergonomic adaptations in no-time. Anne Debauge, Digital Director – Packaging and Development Department at L'Oréal, the leading cosmetics company explains where and how this technology results in key wins, such as a 79% cost reduction of part manufacturing. 
Digital Director - Packaging and Development Department
Additive Manufacturing of Large, Temperature-Controlled Injection Moulding Tools Using Arc Welding and Diffusion Bonding -

Presentation Level: Intermediate

The temperature control of moulding tools, in this case injection moulding, plays a critical role in the quality of manufactured plastic articles. Key parameters such as shrinkage, warpage, crystallinity, etc can be significantly influenced by the temperature control concept. Variothermal process control in particular, delivers good results in terms of flow path length and part quality. For tools in the small to medium size range, these structures can be additively generated by methods such as selective laser sintering. For large work pieces however, such as automobile bumpers or containers, the currently available manufacturing technologies reach the limits of their geometry. Up to now, it has not been possible to additively manufacture such large-format tools while generating temperature control channels at the same time. This paper presents a method of manufacturing large-scale mould tools with temperature control channels by combining the additive manufacturing techniques of arc welding and diffusion bonding with conventional processes. 

Assistant Professor
Technical University Ilmenau
Lightweight Hydraulic Manifold with Additive Manufacturing -

Presentation Level: Intermediate

Additive manufacturing is well known for its application in aeronautic, automotive and motorsport industries. Its use in fluid power sector is, however, minimal. This session will present Aidro’s metal 3D printing solutions, and their benefits, for hydraulic manufacture. It will examine the use of AM in industrial plants and mobile machinery but will also cover industries which require lightweight, hydraulic components.  The session will also evaluate Aidro’s recent research which aimed to reduce the weight and space of hydraulic components. It will discuss how the company optimised their flow performance and how they ensured the pressure’s resistance of the hydraulic system to reduce the pressure drop.

Aidro Hydraulics & 3D Printing
Implementing Design for AM Knowledge and Experience in Product Development -

Presentation Level: Intermediate

Many industrial companies are increasingly incorporating additive manufacturing processes into their frameworks. Developers, however, struggle with identifying suitable applications and design components in their product portfolio. They require knowledge about AM processes, their properties, possibilities, and restrictions.

The industry needs guidelines for different phases of product development to build AM structures. They have to be accessible to a broad public. Inspire AG developed a set of instructions to help enhance the existing AM design knowledge, applicable to various manufacturing conditions and all AM procedures.

This talk will examine the Inspire AG guidelines, focusing on Selective Laser Melting (SLM), Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM), as these processes have the most industrial relevance. The presentation will discuss Inspire AG’s aim to accelerate the implementation of AM in end products, the knowledge of AM application fields and the expansion of 3D printing processes.

Head of Design for New Technologies
Inspire AG
AMable - Support for European SME's in the Uptake of Additive Manufacturing -

AMable is a European project that aims to support SMEs in the uptake of Additive Manufacturing. Innovative ideas of functional parts often require expert knowledge to make them become reality. In this talk, Ulrich Thombansen will explain how AMable supports teams of suppliers and users with dedicated services that help and train the teams. AMable also develops technology to handle all digital information securely and trustfully. Based on the Industrial Dataspace paradigm to keep data with the data owner, files are exchanged through secured endpoint connections ad documented in the AMable Blockchain. This creates trust and traceability alike.

Research and Technology Transfer
Fraunhofer Institute for Laser Technology ILT
SLM Process Optimisation to Manufacture Small Scale and Micro Components -

Presentation Level: Intermediate

CSEM has been investigating the possibility of creating new systems, using 3D printing technology, polymer, and other conductive materials.  This session will examine how CSEM successfully integrated electrical functionalities in FFF parts with FFF deposition, ink dispensing and laser post-processing methods. The talk will present how the company manufactures small mechanical components, like watch parts or flexure-based systems, with the help of powder bed fusion processes. Sebastien Lani, Project Manager at CSEM, will also discuss the CSEM's recent developments in the design, processing, and post-processing of metal as well as future projects.

Project Manager
Pulse Laser Powder Bed Fusion; Opening New Opportunities to Control Metallurgy and Manufactured Advanced Parts -

Presentation Level: Advanced 

This session will present the latest pulse laser powder bed fusion research findings. The talk will evaluate new manufacturing opportunities offered by pulse laser and the different dynamics in the laser and material interactions. It will review a series of metal alloy systems, from conventional stainless steels to non weldable superalloys. Mathieu Brochu will also discuss how to control microstructure of the grain size, texture, and the residual stress, especially in the solidification 

McGill University
Monitoring of the Laser Re-Melting Process of Additive Manufactured Parts -

Presentation Level: Intermediate

Additively manufactured parts have many benefits. They can be produced individually with reduced time-to-market and with little or no material waste.  The dynamical properties of 3D printed components are, however, dominated by residual porosity and surface roughness. Traditional, mechanical post-processing can put mechanical stress on the part’s structures and result in erosion.  To avoid this, researchers at BIAS are exploring laser re-melting as a non-contact technique.

The researchers at BIAS believe that cw-laser can reduce the roughness of AM samples by up to 95% and to a Sa-value of 0.59 μm. This presentation will examine how to adjust the re-melting parameters to the multi-scale surface topography and achieve a smooth part. The session will assess how the re-melting process can be monitored using a high-speed camera which records the integration of single particles and clusters. The talk will also review how to improve the surface polishing methods and structures.

BIAS - Bremer Institut für angewandte Strahltechnik GmbH
The Future Start-Ups and Innovations in the AM Value Chain -

Presentation Level: Intermediate

In fast-growing industries like additive manufacturing, it is essential for corporations to develop large-scale applications and future innovations. Start-up companies are helping corporate businesses establish AM as industrial production technology. They also offer a range of new business models and methods across tooling, automation software, hardware, new materials, post-processing and more.  

This presentation will examine the start-up environment and trends in the AM value chain. It will assess high-potential start-up businesses, success stories and the methods to increase the innovative power. The session will also discuss how more established companies can learn from, and collaborate with, start-ups.

Manager of AM Activities
VCSEL-Based Preheating for LPBF -

Presentation Level: Advanced

Defect-free manufacturing of hard-to-weld materials and the reduction of process related distortions are the main challenges of Laser Powder Bed Fusion (LPBF). Research shows that the use of preheating systems can eliminate these problems. Using conventional base plate preheating methods, however, often leads to a temperature gradient across the parts and powders. The increasing build height, in return, results in a decreasing process layer temperature.

The research campus DPP- Nano, developed the approach of directly preheating the LPBF process layer, using a Vertical Cavity Surface Emitting Laser (VCSEL) module. The innovative diode laser component is capable of generating intensity distribution with an extended degree of freedom. First experimental investigations, with Inconel 718, show that the process layer can be heated up to 500°C, using the VCSEL system. Distortion measurement of test samples indicates its effectiveness.

This presentation will outline the next steps in the project like the qualification of VCSEL preheating system for hard-to-weld materials and its effects on greater build heights.

Automatic Cooling Channel Design for Injection Moulds -

Presentation Level: Advanced

The thermal design of injection moulds is an intricate process, often completed manually by its maker. Manufacturing of highly precise parts is becoming popular, and cooling channels for injection moulding are in demand right now. Institute of Plastics Processing (IKV) has developed a simulative approach for an automatic cooling channel layout. This presentation will discuss how a thermal optimization of the mould, based on quality function, and with the aim of zero warpage, was performed. Tobias Schneppe will explain how this process allowed the researchers to determine the optimal distribution temperature in the mould. The session will also evaluate how the local cooling demand of the parts, and the cooling intensity of the cooling channel design, was brought into equilibrium. The talk will also illustrate why AM technologies should be involved in the development of the thermally optimized cooling channel design.

Scientific Researcher
Institute of Plastics Processing (IKV) at RWTH Aachen University