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Written by Adam Trumpour, Concept Designer at Pratt & Whitney Canada, Owner and Rocket Propulsion Researcher at AT Aerospace, and founder and president of Launch Canada (www.launchcanada.org).
“Rocket Science”. 50 years after those first footsteps on the Moon, this phrase is still immediately evocative of something almost unimaginably challenging: something demanding of the most uncompromising skill and excellence. Here in Canada, we have had our space technology niches that we excel in, but true “rocket science”, that is to say the engineering of the vehicles that enable access to space and the propulsion systems that power them, has not been among them.
Yet over the last several years, a remarkable thing has been happening. Internationally, entrepreneurial companies such as SpaceX, Blue Origin, Virgin and Rocket Lab have been rising to prominence and disrupting the space launch industry, leveraging new ideas about how to build an aerospace company, new manufacturing technologies, small, nimble teams and a mindset more traditionally associated with Silicon Valley than aerospace. They’re building and launching rockets for lower cost than ever before and disrupting an industry that was once the domain of global superpowers and massive prime contractors. One such company, Rocket Lab, is even doing this in New Zealand, a nation with a population less than the Greater Toronto Area and almost no established aerospace industry. Clearly the landscape has shifted.
Unfortunately, Canada has been slow to catch on. For far too long, we’ve been held back by a very self-limiting mindset that says “we’re too small; we need to stick to what we’ve always done”. This is the very sort of attitude that causes us to fail to recognize new opportunities, fail to perceive that the world is changing around us, and fail to respond to that change.
Yet under the radar to most Canadians, a rapidly growing movement has sprung up right across the country. It’s being driven by students and grassroots innovators (and a smattering of professionals as well) who are inspired by what they see happening elsewhere at innovative companies like SpaceX and the vast potential and opportunity it represents, and are no longer satisfied with being told that they can’t do that here.
Where just a few years ago there was almost nothing, today there are around 20 university rocket teams right across the country, representing nearly 1000 active students. All are building sophisticated vehicles and pushing the technological envelope in everything from advanced composite structures and supersonic aerodynamics to liquid rocket propulsion and additively manufactured high performance rocket engines. And they are dominating at major international competitions. At the world’s largest student rocket competition, the Spaceport America Cup in New Mexico, Canadian teams regularly take home the top awards in spite of making up less than 15% of the entrants in the competition. What’s more, this level of excellence has been consistent. Talk about punching above our weight – all this in an area of space technology and cutting-edge manufacturing that, supposedly, “we don’t do here”!
Building on this demonstrated passion and exceptional talent, four Canadian teams are even participating in the Base 11 Space Challenge, a $1 million US competition to become the first university team to successfully design, build and launch a liquid-propellant rocket all the way to space: 100 km altitude. This is by far the most advanced, most challenging student design competition ever undertaken, and this past June, two of those Canadian teams placed in the top 5 in North America in the design phase of the competition, as voted by judges from industry leaders like SpaceX and Blue Origin.
Yet there remains a serious disconnect. In spite of all this raw passion and demonstrated world-class talent, there have been few avenues of support for them in their home country. Canada has not yet caught on to the incredible potential they represent, and they frequently don’t even have the opportunity to launch their more advanced rockets here. Far too often, they are forced to either abandon their passion, or leave the country to pursue opportunities abroad. We are losing some of our brightest, most talented and motivated individuals due to a lack of support and opportunity.
When there is this much raw passion and demonstrated talent, yet virtually no support to help it thrive, it points to a serious disconnect. We want to consider ourselves a nation of innovators, but innovation does not happen in a vacuum. It emerges most reliably when you have an ecosystem that is conducive to it, that cultivates opportunities to develop practical skills and supports those with the passion and talent to do great things.
As I write this, work is underway to create the inaugural Launch Canada rocket innovation challenge (www.launchcanada.org) , the first-ever major Canadian rocket competition that aims to finally give Canada’s student rocketeers an outlet to pursue their activities here in Canada, take them to the next level, learn, collaborate and compete. At the same time it will provide a highly visible showcase of the kind of Canadian engineering excellence that they’ve been repeatedly demonstrating internationally but until now has been largely unseen at home. Major emphases of this competition will be design, development and testing of novel rocket-related technologies and components, and entrepreneurial thinking about the potential applications and business cases.
Collaboration and partnership are key pillars of this initiative: bringing together these students with professionals from industry, government and the investment community who can give them guidance and support; and creating win-win situations for everyone involved. And central to this is advanced manufacturing.
Rocketry, whether amateur or professional, is at its core an exercise in high-skill advanced manufacturing optimized for weight and cost. Additive manufacturing, advanced composites, exotic materials and joining processes combine with conventional machining and fabricating to enable the amazing feats of cutting-edge rocket companies like SpaceX. Metal additive manufacturing processes, for example, have become key enablers for complex liquid rocket engine designs that operate at extremes of temperature and pressure, and lightweight fluid controls for these systems. Helping Canada’s students and rocket innovators to access and leverage these processes will enable them to turn their passion and ingenuity into real hardware, build the skills that will help them become tomorrow’s leaders in Canadian industry, and even lay the groundwork for new aerospace technologies and companies.
At the same time, students and amateurs fueled by passion for the technology have the freedom to pursue genuinely novel designs and concepts with higher technical risk than traditional aerospace companies would be willing to assume, and at far lower cost than a company could achieve. While this risk has been a major roadblock to the adoption of novel manufacturing techniques like additive in cutting-edge aerospace applications, student rocketeers are able to fully embrace it and provide the kind of real-world testing, hardware demonstration and manufacturing process qualification in the most demanding of applications that can help refine manufacturing processes and accelerate their adoption in industry. After all, 3D printing a complex part is one thing, but proving that part in the extreme environment of a rocket engine is a vastly more effective demonstration of the process.
We’re creating Launch Canada because we’ve seen the talent and the potential of these grassroots rocketeers, but to truly unleash it, we need your help. We have skilled, driven young “rocket scientists” across this country who believe in what they’re doing and where they can take it. It’s high time we as a nation started supporting them and showing them that we truly believe in their potential to achieve amazing things, right here in Canada.
If supporting and tapping into this extraordinary and rapidly growing rocket science talent and helping to grow this nascent new high-tech industrial segment sounds intriguing; if you share in our belief in the limitless potential of Canadian talent and our excitement in helping it to thrive, I invite you to get in touch and help us #LaunchTheNorth!
Canada Makes is a division of Canadian Manufacturers & Exporters (CME), currently delivering a federal program that supports manufacturing advancement initiatives. Burloak Technologies Inc. of Oakville Ontario is the Additive Manufacturing (AM) division of SAMUEL. MDA, a Maxar company, has operations across Canada, including in Ste-Anne-de-Bellevue, Quebec, which develops and manufactures satellite antennas and communications subsystems. These three organizations recently partnered to produce 3D-printed titanium and aluminum parts for satellite antenna applications. The projects they undertook validate that AM technology provides accelerated and cost-effective solutions for making space parts. One advantage is that AM allows designers to consolidate into “one item” a sub-assembly that would traditionally be comprised of multiple parts (including part flanges, fasteners and assembly effort for putting them together). Consequently, the single piece allows for smaller packages, mass savings and designs that could not otherwise be conceptualized with the limitations of conventional/computer numerical control (CNC) manufacturing technologies.
Canada Makes enabled, with funding from the National Research Council (NRC) through its Metal Additive Demonstration program, the manufacturing development and build of the following two parts at Burloak Technologies:
For the Titanium Antenna Hold Down and Release Mechanism (HRM) bracket, the approach was to take a conventionally/CNC-machined part and build it using AM techniques without making any changes to the design. The goal was first to ascertain if it was indeed printable, and to also measure the time and cost savings of AM compared to conventional/CNC machining approach.
For the Aluminum Quad-Antenna, the objectives were to minimize wall thickness to make the part as compact and as light as possible, to obtain as-printed smooth walls to minimize RF losses, and to establish compensation techniques to cancel-out the 1G sagging effect of unsupported 45° ceilings during printing.
Through this Canada Makes initiative, MDA and Burloak were able to successfully prove that AM of the titanium HRM bracket resulted in cost and schedule savings in the order of 40%. Similarly, MDA and Burloak successfully proved that the aluminum Quad-Antenna was printable with smooth surfaces (64 micro-inch), thin walls (as low as 0.012”) and with the ability to compensate for the 1G effect on 45° unsupported ceilings.
“This is yet another example of how additive manufacturing is transforming how satellite parts are being manufactured,” said Eric Amyotte, MDA Vice President, Antennas and Electronic Products. “These parts were 3D printed by Burloak and then tested by MDA. Canada Makes is definitely helping to fast-track the acceptance of AM for space application.”
“One of the objectives of the Canada Makes program is to stimulate the Canadian additive manufacturing industry, and the two highlighted successful projects definitely promote the use of AM,” said John Rodic, Program Manager at Canada Makes.
The Metal Additive Manufacturing Demonstration Program is delivered by Canada Makes through funding by the NRC’s Industrial Research Assistance Program (IRAP). The program is designed to increase Canadian industry’s awareness and assist in their understanding of the advantages of metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide guidance to participating companies with respect to the advantages, business opportunities, cost savings and efficiencies of AM.
MDA is an internationally-recognized leader in space robotics, space sensors, satellite payloads, antennas and subsystems, surveillance and intelligence systems, defence and maritime systems, and geospatial radar imagery. MDA’s extensive space expertise and heritage translates into mission-critical defence and commercial applications that include multi-platform command, control and surveillance systems, aeronautical information systems, land administration systems and terrestrial robotics. MDA is also a leading supplier of actionable mission-critical information and insights derived from multiple data sources. Founded in 1969, MDA is recognized as one of Canada’s most successful technology ventures with locations in Richmond, Ottawa, Brampton, Montreal, Halifax and the United Kingdom. MDA is a Maxar company (TSX: MAXR) (NYSE: MAXR). For more information visit www.mdacorporation.com and www.maxar.com.
A leader in the additive manufacturing industry, Burloak Technologies provides engineering and designs for additive manufacturing, materials development, high precision CNC machining, post-processing and metrology. Burloak is a supplier to leading aerospace, space and energy companies and is registered to AS9100D, ISO9001 and is Canada Controlled Goods Approved. Burloak Technologies is a division of Samuel. For more information, visit www.burloaktech.com.
Founded in 1855, Samuel, Son & Co. is a family-owned and operated integrated network of metal manufacturing, processing and distribution divisions. With over 5,000 employees and 100+ facilities, Samuel provides seamless access to metals, industrial products and related value-added services. Supporting over 40,000 customers, we leverage our industry expertise, breadth of experience and the passion of our people to help drive success for North American business – one customer at a time. For more information, visit www.samuel.com.
SUBMISSION DEADLINE: FEBRUARY 22, 2019 – CLOSED
Canada Makes is again offering its Pan-Canadian 3D Printing Design Challenge for postsecondary students enrolled in a Canadian college or university. Winners to be announced in the Spring of 2019.
Last year’s challenge was “Design solutions for a sustainable future” and is again this year. Five finalist from last year’s challenge each received $1,000 for their design. Learn more about the designs at Canada Makes announces finalists for its 3D Challenge.
The adoption of digital manufacturing technologies such as 3D printing requires new approaches to skills and training focused on building experiential and collaborative learning. To foster this objective, the Canada Makes 3D Challenge will challenge university/college teams to design a part and compete for a full one-year paid internship from a Burloak Technologies and cash prizes.
Theme: Design solutions for a sustainable future
Description: Additive manufacturing is empowering new ways to re-think design and fabrication through innovative materials, optimized structures and enhanced functionality. There is currently a drive to think about how our society is changing in the wake of population growth and sustainability concerns. Canada Makes invites student designers to participate in the 3D Design Competition with a focus on creating innovative tools or products that reduce our environmental footprint using additive manufacturing in tandem with conventional manufacturing approaches.
Such examples include (and are not limited to):
- lightweight structures or new designs of automotive or aerospace components that reduce overall weight and fuel consumption
- innovative components that optimize fuel or energy consumption
- energy harvesting devices with innovative features
- multi-purpose objects that simplify everyday life and reduce waste
- wearable tools or objects that enhance mobility efficiency and reduce waste
Phase I – Students who wish to participate must pre-register by November 30, 2018 indicating their intent to submit a final design.
Phase II – Participants will submit a design based on the provided criteria. These designs will be analyzed and evaluated via simulation with the top finalists announced, recognized and awarded their cash prize. Deadline for submissions is February 22, 2019.
Phase III – The top five finalists will have their design fabricated and tested, and will be invited to either make a live or video presentation and have a chance at more prizes including a chance at a one-year paid internship at Burloak Technologies.
The Student/Team (no more than 3 students per team) will submit the following by February 22, 2019:
- Cover sheet
- 150 word description/summary
- STL files and source files from any CAD program
- An image of the current product design (if applicable) and a detailed description of the changes
- Business case (800 word):
- Justification of the product redesign, value added as measured by reduced
- Time to produce
- Cost impact
- Energy consumption or renewable energy generation
- Reduced materials
- Promoting green design
- Participants should define the unmet need in society or explain the waste in current solutions
- Precisely what is being proposed
- Why it is am improvement over existing products
Judges will choose the top 5 finalists and Canada Makes will arrange to fabricate their designs to be showcased at a final event in the spring of 2019. The finalist/teams will receive a cash prize and a chance at a one-year paid internships at Burloak Technologies.
Submitted designs will be evaluated via simulation, and the top five designs will be selected for fabrication and testing based on the required criteria. The winning entries will best satisfy all of the performance criteria.
The Panel will be part of the McGill AM event “Top Business Applications for Additive Manufacturing” February 27, 2019
This coming February 27 is the additive manufacturing event “Top Business Applications of Additive Manufacturing” at McGill in Montreal. Réseau Québec-3D (RQ3D), Canada Makes and McGill University partner for this industry focused event designed to help companies adopt one of the main pillars of Industry 4.0: 3D Printing / Additive Manufacturing.
Last week we discussed one of the featured panels “3D Printing and Lightweight Robotic End Of Arm Tooling (EOAT),” and how it is now being used in a number of fields for manufacturing of end devices. This week we’ll have a look at the other featured panel for the day “Machining Challenges in an Additive World.”
Once again we bring in some of Canada’s leading experts on the topic metal additive and machining, the panel will be moderated by Moderator Fabian Sanchez of Siemens and includes panelists; Christian Desravines, Usinage Multiconcept, Éric Thibault, Bell Helicopter and Jared Kozub of Precision ADM.
This panel will be a good opportunity learn about best practices, the advantages and challenges companies are facing in adopting AM.
Discussion will focus on what impacts is AM having on machining and how do the technologies complement each other.
Panelist intend to talk about the importance of the design in the integration of AM through machining and offer a better knowledge of the technology and understand how we can design for AM.
Design for AM is an item that companies are struggling with (Topology optimization, part growth vs shape and loads, distortion due to metal shrinkage, surface finish, etc). Be ready to hear questions about what help AM companies can provide to end-users and the challenges to certify an aircraft part and more.
Join us on February 27 at McGill for this great opportunity to meet and learn from leading practitioners of 3D Printing and join the 4th Industrial revolution. View the agenda
*REGISTRATION FOR THIS EVENT IS NOW CLOSED
We have asked a number of Canadian experts in Additive Manufacturing to provide us with their views on the year by answering some questions. Additive Manufacturing – Year in review – 2018
As we approach the end of the year and look back, we see that a lot has happened in the world of Additive Manufacturing. To help bring the year into perspective, we have asked a number of Canadian experts in Additive Manufacturing to provide us with their views on the year by answering some questions.
- What trends have you seen this past year in AM?
- Any announcements from the past year that grabbed your attention?
- What is one thing from the past year that has you hopeful for Canada’s AM industry and what opportunities exist for Canada going forward in AM?
- What apprehensions do you have and what are some upcoming challenges?
- Any words of advice for those looking to use AM in the coming year?
These questions have been answered by (in alphabetical order):
- Peter Adams, President & CEO of Burloak Technologies Inc
- Dr. Mathieu Brochu, Associate Professor at McGill University
- Gilles Desharnais, President of Axis Prototypes Inc.
- Dr. Philippe Dupuis, President & Co-founder of Creadditive Solutions 3D
- Martin Petrak, Co-Founder & CEO of Precision ADM
- Cassidy Silbernagel, Expert in AM and Design, future PhD graduate
- Dr. Ehsan Toyserkani, Professor at the University of Waterloo
- Dr. Tonya Wolfe, Senior Research Engineer at InnoTech Alberta
Canada Makes would like to thank our contributors for taking the time to share their expertise.
What trends have you seen this past year in AM?
From my perspective,adoption of AM for series production has been the main trend in 2018. It seems that reliable, repeatable and affordable mass production is eventually on the horizon by AM processes. Hardware speed and quality improvements, reliable software and a larger pool of materials adopted for AM are some of the main eye-catching trends in 2018.
Major meaningful initiatives for full adoption of AM to the automotive industry have been surfaced. Thanks to the first point mentioned above.
The last year has been a turning point in AM here in Alberta from a perspective of AM being a technology for other industries in other countries to one that should be implemented in current practice now. There seems to be more designers using a desktop printer for visualization and prototyping purposes, so the growth into production will be an inevitable next step.
We have noted that AM is now a mainstream event at conferences and tradeshows both in Canada and internationally. It is no longer a small dispersion of companies but now has its own dedicated halls and conference streams.
The technology is reaching to more remote areas and enabling local ideation and manufacturing. However, risk of adopting premature technology is crippling the competitiveness of the local industries. Perhaps there is an overabundance of new technology and companies are anxious in deciding what areas are best for their growth?
Metal is king. FDM leads the way for Polymers… HP is now delivering and aggressively pushing MultiJet Fusion.
In the metal world, big industrial players have joined the field and are making their mark – Trumpf, DMG Mori, AddUp (Michelin-Five), GE are adding a layer of seriousness to the Powder Bed market. The “prototyping” manufacturers (EOS, 3D Systems, SLM, Renishaw), are now being challenged by companies that have experience in making robust industrial machines that can reproduce the same quality.
The metal presence at FormNext was impressive and the marketing investment by the metal players showed the seriousness that they put into this market.
There is also a big trend of powder metallurgy being used as a source of additive manufacturing of metal. People like BASF, DeskTop Metal, MarkForged, XJet, HP are bringing to market solutions that rely on the science of powder metallurgy to facilitate 3D Printing. Now, there are serious challenges associated to the powder metallurgy process that is causing challenges for these solutions, namely the challenge of the part shrinkage during the post processing which can alter dimensions of the parts. Most if not all of the manufacturers are investing into the post-process and software to resolve this issue, however, to date, the solutions are not stable and universally applicable. There is progress however, and these processes could significantly impact the cost of metal 3D Printing components.
On the Polymer side, HP Multijet Fusion seems to have finally ironed out the kinks in their systems and can now ship systems that are relatively stable. HP’s aggressive marketing appears to be generating results as the number of systems being shipped is growing.
For Thermoplastics, the continued advanced on the FDM front are apparent. More and more materials are being offered with most of the big engineered plastic players now present in the field… BASF, Covestro, DSM, Dupont, etc. In addition, numerous small production houses with their own recipes is increasing the scope of the offering. On the machine side, the low bar has been set for years, and now we are seeing a growing number of high temperature solution, and also, the growing availability of large format FDM printing.
It seems that the industry is moving away from printing cool trinkets and toys as a way to showcase the technology, and rather highlighting solutions to problems which the technology can help solve. This is a much better way to help change the mindset from the idea that 3D printing is just for making cool little plasticy things. The power of Additive Manufacturing comes from it’s potential applications, which requires a different mindset. Part of this shift requires seeing the solutions others have come up with, and that is much better done with actual plastic fixtures for tooling rather than Yoda figurines and toy boats.
As you know, I am only involved in metal AM. Some key aspects that I found interesting, but that can all be summarized under “pushing the boundaries of AM”. I believe the race to launch AM platform has slowed down, but strengthening of what is existing has occurred. We are seeing more automation of system (fully integrated systems), where human intervention is reduced and performance optimization is increased. The field has now pushed the boundary of maximum built angle with new and innovative laser raster path, we are seeing several attempts at increasing the built speed, with multi-lasers, new recoaters, attempts to increase the powder layer thicknesses, etc. New intergrated systems with built and sinter platform integrated, etc. All these developments will definitely contributes to bring AM closer to mainstream manufacturing.
Metal additive manufacturing applications are on the rise with a growing demand for metals like Titanium, Inconel and Stainless Steel.
Consolidation of AM equipment offerings by industry giants continued to dominate the discussion in 2018. Large manufacturers such as Stratasys jumping into the metal additive manufacturing space, following GE Additive’s new investments in metal technologies is exciting as it validates many experts’ opinion that the massive adoption of metal AM is right around the corner.
At Burloak we see customers moving from a tire kicking phase of evaluation into full blown qualifications of programs. This seems to be driven by several factors including – better understanding of the material performance – Better standards definition – the availability of multilaser AM systems which are lowering the cost of manufacture – A much more serious approach to identifying suitable applications and finally that the machine platforms are becoming more robust.
Any announcements from the past year that grabbed your attention?
Health Canada publishing a draft guidance document for the use of AM to produce Class III and IV medical devices paves the way to broader acceptance of this game-changing technology in the medical field for Canada. This announcement followed the CRIQ’s major investment in a medical additive manufacturing center in Quebec City and Renishaw’s opening of the ADEISS center in London, Ontario which all point towards Canada setting itself up to become a global competitor in manufacturing medical devices using AM.
Nothing in particular, but its more the sum of all the new opportunities, that now once integrated, makes AM even more concrete. The points discussed above.
On The machines side I would say that EOS announcement of the laser array system which will lower cycle times to fractions of todays systems for plastic builds signals where the industry is heading. Several of the major metals groups finally brought their multi laser technologies to market and there have been multiple developments on the post processing side which we like.
With respect to the AM supply chain I would say that there have been a number of very large announcements that signal a shift in the market. Burloak Technologies a division of Samuel announced its $104M AMCE in Oakville, Ontario. Carpenter Technologies announced a new large scale technology centre along with the acquisition of LPW. Oerlikon continued to roll out its $300M+ investment in its AM supply chain. Siemens opened its new Material Solutions technology centre in the UK with approx. $70M of investment and Voestalpine continued to open AM focused facilities.
I found it interesting that all of these announcements had similar themes with respect to what the industry perceives is needed to be successful in additive production parts manufacture in that all of the companies focused not just on AM machinery, but rather on the whole value proposition from design through manufacture, heat treatment, machining and materials qualification as part of the service. We certainly believe that these levels of investment are really the minimum to deliver certified production parts.
Canada has its very first Metal AM machine innovator and supplier: Nanogrande, that officially unveiled the MPL-1, the world’s first nanoscale metal particle 3D printer at Fabtech 2018 in Atlanta.
HP’ announcement that they will go into metal additive with a binder jetting – powder metallurgy type solution.
Burloak (Samuel) commitment to their new center.
One that stands out is the TRUMPF announcement of using a green laser in a production machine and that their new printer will allow pre-heat temperatures of up to 500°C. If these two things were in the same machine, it would allow almost any material to be printed because the energy from green lasers is better absorbed by almost all metals including pure copper and aluminium, and the high pre-heat temperature reduces the thermal differential from meltpool to solid, thus reducing the internal stresses in a part, and may allow for crack suseptable materials such as nickel super-alloys to be better processed.
We are very proud of Onstream Technologies using AM in pipeline applications. They are a success story of design and implementation of AM technology to improve their products.
We have also noted that large number of collaborations that are occurring in AM outside of Canada between sectors and types of organizations. The need to work cross-disciplinary has been realized and will strengthen adoption. This is happening in Ontario, Quebec and the Maritimes, but has yet to be formalized in Western Canada.
Companies such as Ethiad and Navantia are fully adopting the technology on a variety of scales. I am not aware of Canadian companies fully adopting the technology yet throughout their practice or having an AM business unit. In Alberta, large companies do not yet understand where AM can be integrated into their processes, but change is starting.
I think the diagram Digital Alloys put out recently showing all the metal AM processes is telling of where we are in metal AM. There is a lot going on and we need to be cognizant that no one technology will solve all problems. There is also a lot of work to do to decide which processes meet a company’s manufacturing needs. For example, understanding tolerances in AM is not yet fully understood, but is critical for adoption into AM.
- BMW’s Additive Manufacturing Campus
- Carbon+ Adidas collaboration
What is one thing from the past year that has you hopeful for Canada’s AM industry and what opportunities exist for Canada going forward in AM?
I am hopeful the superclusters and the initiation of the HI-AM will be a supportive role for AM in Canada. The trade issues that have evolved recently have initiated discussions regarding reshoring manufacturing. We have a number of unique industries that will benefit from adoption of AM (energy, agriculture and marine). These industries need some time to redevelop their designs to take advantage of additive manufacturing.
I am an avid supporter for women in technology and manufacturing. AM makes manufacturing more accessible to bright, creative people. We have initiated an Alberta Additive Manufacturing Network, with the goal to make the technology accessible and at a lower risk. The number of participants will quickly grow over the next year.
GE Additive is being a phenomenal evangelist to the Additive Industry with their remarkable case studies for part consolidation as a driver to their manufacturing future. With this, GE is working with Canadian manufacturers allowing these opportunities from south of the border to stimulate the Canadian AM market.
We have seen significant investments in AM capability and capacity in Canada in 2018. There is great opportunity for Canadian companies large or small to become global leaders in the Additive Manufacturing value and supply chains. With Canada’s strong natural resource base, AM capacity and capability, as well as manufactured product export track record, I feel Canada will continue to be highly competitive in AM well into the future.
The above announcements have changed the pace of AM in Canada, both academically and industrially. Canada can be a leader in R&D and also AM adoption to different industries such as aerospace and automotive.
The discussion around AM is starting to shift from the verticals it has been typically constrained to (aerospace, for example) towards other sectors which were once thought of as more conservative and less promising. The automotive, energy as well as oil and gas sectors are increasingly joining the bandwagon for AM adoption, and we at Creadditive are seeing a lot of interest from the construction sector in exploring disruptive technologies which could help them address the challenges that are typical of labour-intensive and extremely complex multi-discipline projects. In terms of opportunity, Canada is a very natural-resource rich country, and has a very strong position in metal powder manufacturing with companies such as AP&C, Tekna, Pyrogenesis and Equispheres, so I hope we can learn from these success stories and build an AM material processing infrastructure around our organic materials resources such as petroleum-based plastics and bio-plastic from wood products for both western and eastern Canada.
Obviously you would expect me to say that the Burloak Additive Manufacturing Centre of Excellence was the major announcement that I believe puts Canada in a lead position. Beyond that, I think the continued adoption by academia is critical and very welcome although I do think that we need to be careful that these academic centres focus remains on R & D and education and not competing with industry as this will kill investment by the private sector. Another noteworthy event was the major expansions undertaken in Canada by AP& C and Equispheres.
I’m excited about Canada’s Innovation Supercluster Initiative and hope that it will help grow Canada’s AM sector, because right now it is very small and young compared to what is happening in Europe and the US. At the same time, this opens up great possibilities for growth and adoption in Canada for the technology.
To me, Canada is a raw material supplier and a end user of the technology. Massive investments in metal powder production is occurring to offer a wide variety of high quality products to the market. We are also seeing the number of printing bureau and OEM increasing the number of machine, testing the products, learning the technology. The important footsteps for a healthy AM adoption is on-going.
What apprehensions do you have and what are some upcoming challenges?
Although the level of misconception about the potential of AM has been reduced over the last few years, it is still a big challenge to control public and industry expectation. This may create negative impression if the technology readiness level will not be able to fulfil unrealistic conceptions that are wrongly disseminated in industry and public.
Other worry is the low momentum in the adoption of new materials to the portfolio of metal AM. For instance, more than 1,000 ferrous alloys are commercially available for conventional manufacturing such as casting, machining and forming; however, only a handful number of ferrous alloys have been verified for AM systems and limited production by original equipment manufacturers. Customization and validation of AM metal powders and introducing them to the market usually takes years of research and development. This may simply undermine the current momentum in AM
The biggest challenge for AM in the coming years will be the attraction and retention of skilled labour. The education network in Canada is strong and well versed in AM, but will most likely struggle to produce enough talent to compensate for the shortage. Companies will need to invest in training employees on the job instead of relying on a previously built skill-set. This type of training will also put pressure on the too-few equipment hours available in the marketplace already. In this sense, the challenge will be to create a model and ecosystem where academia can open the doors to laboratories and classrooms for industry and to create continuing education opportunities to reskill factory workers with skills in traditional manufacturing towards the technical skills required for AM.
I believe cost remains the main challenge. Cost with the capital “C”. Anything that will bring down the cost is a challenge to be solved if AM is to be mainstream and not only for smaller hi-end products. We have to keep in mind that the competing technologies are also getting technological improvements, it’s a ferocious competition. Talent is another key aspects, but numerous schools with various education level are tackling this issue.
We think that the industry leading OEM’s may try to commoditize the market too soon and that this would lead to investment shortfalls and the industry would not reach its potential. The powder supply chain may not be ready to meet the scale up although investments by AP&C, Carpenter, Praxair, Equispheres etc. make provides some comfort.
I am concerned about risk averse company culture and the fear of ‘being first’. We need to support retraining in the areas of mechatronics, design for additive, digital twins and data analytics. It will be very challenging to hire people with these skill sets for the foreseeable future, so they will need to be developed internally.
The lack of investment in capital infrastructure compared to other jurisdictions is concerning. It will be challenging to compete with limited resources.
My apprehension is the long term viability of Powder Bed with its significant overhead associated with supports.
I’m worried about the adoption level of AM in Canada. There is so much potential for it’s use, but Canada seems to be lagging behind the rest of the world when it comes to adoption. Before there can be any meaningful growth in this area in Canada, individuals and companies need to be aware of what AM can do for them, which means a lot of education is required for this awareness. However, Europe gained this awareness a decade ago and are showing massive growth in this area, and Canada is playing catch-up. If Canada doesn’t rapidly adopt this technology, they will miss out on some potentially huge opportunities.
Any words of advice for those looking to use AM in the coming year?
I would say that you need to understand your motivation for trying AM and that you find a potential partner who can not only guide you through the process, but can demonstrate their technical competence and ability to scale with you to production.
Jump in and see what others are doing in the rest of the world with AM. Then try and find the experts who can help guide you in the journey to adopt AM. Realise that AM may not solve all of your problems, and it may not be the best solution, but on the otherhand, it could do all those things. It’s potential reaches beyond just prototypes and proof-of-concept. It can be used as actual end-use products, or help make those end-use products faster and cheaper.
Go before its too late. However, one need to understand that starting in AM is not as easy as it looks, and lots of efforts must be put down downstream of the first order is completed. AM is a fascinating field, but integrating all these multi-disciplinary field under one technology remains a challenge. Who would have thought we would go to the moon… and we did. Who would have thought 3D printing would be mainstream at one point in time, and it will happen.
There is opportunity for those who can provide design for AM solutions. However, the human element is more important than ever before. We need to collaborate, challenge assumptions and share ideas. AM cannot be done simply by uploading a drawing to the cloud and receiving the part in the mail a few days later. The best solutions are found by collaborative convergence.
Most engineers are still thinking linearly and need strategies to think organically. This process takes time and there are several failures leading to the final successful design. Companies need to support this process.
Start small but start now. Additive manufacturing is going to proliferate at high speed in industrial spaces as the business cases for AM gain traction and attention. The key issue will be to know when and how AM can provide an edge by adding value to a product or workflow, instead of trying to use this tool to directly replace other manufacturing processes where competition is fierce. In this case, incremental adoption can outperform complete workflow rework by ensuring the best process is chosen on its own merits, not due to its novelty or to its disruptive quality. Remember: “The early bird gets the worm, but the second mouse gets the cheese”!
I would recommend that those companies that are looking to adopt AM start to have dialogue with key AM players in Canada (e.g., Canada Makes, Burloak, HI-AM, MSAM, etc.). This will minimize the risk of their investment. These groups emphasis strengthening collaborative interactions between academic researchers, the Canadian manufacturing industry, industrial organizations, government researchers, and international collaborators by addressing complex technical issues associated with metal AM.
My best advise to most organization and companies interested in AM is to invest in knowledge and formal training in Design for Additive Manufacturing. Keep an eye on new software developments that will make it easier to go from design to print in the near future.
On October 24th, Canada Makes successfully concluded the forth Canada Makes Additive Manufacturing (AM) Forum at the University of Waterloo. The event was highlighted by leading international and national AM experts who shared their knowledge and insight in this emerging technology. Many in attendance requested the presentations see below for links to the ones available.
See more about the event at LEADING AM EXPERTS SHOWCASED AT CANADA MAKES FORUM
Below are the presentations that we have permission to share with the public. Note: Some may have modified the content.
|Names of presenter||Biographies and links to presentations|
Fraunhofer Institute for Machine Tools and Forming Technology IWU,
Group Manager AM Applications
|Presentation: Laser Beam Melting drives efficiency of tooling applications
Mathias Gebauer studied mechanical engineering with a specialization in production engineering at the University of Applied Sciences in Dresden. He started his career as a casting technologist for a medium-sized automotive supplier in the field of light metal low-pressure sand casting. His responsibilities included technological support for prototype and small-series components as well as cooperation in innovation management. For more than nine years Mr. Gebauer has been working as a research associate at the Fraunhofer Institute for Machine Tools and Forming Technology IWU. At the Dresden branch, Mr. Gebauer works as a group manager in the department “Additive Manufacturing”, where he is responsible for the acquisition, planning and implementation of research and development projects regarding AM for tooling and the technological development of the laser beam melting process. Mr. Gebauer has been involved in additive manufacturing for more than twelve years.
|Cassidy Silbernagel||Presentation: How Additive Manufacturing has shaped the automotive sector and is driving it into the future
Cassidy has been active with 3D printing since 2010 and is about to complete an additive manufacturing PhD in the UK. He has worked for several years prior to his PhD as a mechanical design engineer and has helped develop electric motors for motorcycles and generators for wind turbines. He is researching how additive manufacturing can be used to help create electric motors. He is a two time winner in the student category of the Additive World Design Challenge in 2016 and 2017.
|Dylan Yazbeck, Lab Supervisor at Jesse Garant Metrology Center||Presentation: CT Scanning
Dylan Yazbeck is the lab supervisor at Jesse Garant Metrology Center. He started his Computer Tomography career working as a data analyst, focusing on scanning and analysing client products. The countless hours working in this role working with thousands of unique products allows him to oversee lab operation and work closely with clients establishing specific procedures on a project basis. The creation of new CT procedures at the company has allowed ISO9001: 2015 and AS9100 certification. The opportunity to continuously improve and learn within the CT industry matching procedure with client expectation and requirement makes Dylan excited to continue his role.
|Ed Bernard, Director of Research & Development at Crest Mold Technologies Inc||Speaking notes: Panel Conformal Cooling – Facts vs Myths and Overcoming Obstacles
Ed Bernard has over 40 years of experience in the Moldmaking Industry, having received numerous awards and accolades for innovative achievements and leadership within the manufacturing sector, and is currently the Chair of the Research & Development Committee and Director of the Moldmaking Cluster Collaboration Network of the Canadian Association of Moldmakers as well as the Manager of Scientific Research & Experimental Development at Crest Mold Technology Inc. where he has been experimenting with various different types of advanced manufacturing, essential to conformal thermal systems, for the application of cyclic process thermodynamics.
|Steve Slusher, Executive, AddWorks Manufacturing Development Leader (GE)||Speaking notes: Prototyping to Production
As an Executive leader within our AddWorks organization, Steve Slusher is leading a team of design and manufacturing engineers along with data scientist whom partner with our customers to industrialize their additive manufacturing process. In this role he championed the upgrades of the M2 product line and brought analytics to the forefront to improve both machine and product repeatability. Steve has been with GE for 16 years with roles in design, test and certification. He has led teams on several GE Aviation Commercial product lines. Since joining GE Additive a year and a half ago Steve has established a multi-regional team to industrialize the existing laser and electron beam product line and the surrounding processes. The team has worked with both internal and external customers to help them advance their additive journey into piece part production.
|C. Annette Langhammer, Director of Advanced Engineering NMC Dynaplas, Toronto||Presentation: Conformal Cooling in Automotive/Mobility
BA Econ, York; Toolmaker Ticket Magna; 30 yrs primarily Magna/Decoma; NMC Dynaplas – Technical Captive Injection Molder; focusing on assisting customers migrate to high performing thermoplastic materials including lightweighting, design flexibility, recyclability, performance improvements.
|Mathieu Fagnan, Pratt & Whitney Canada||Presentation: Additive Manufacturing at Pratt & Whitney Canada
Mathieu has been involved with technology since his teens, welding bicycle frames in his parents shed. He fueled his passion for making stuff by completing a technical degree in industrial engineering that saw him entered the world of composites manufacturing, mostly in process optimization for helicopters components. Still hungry for knowledge, he completed a bachelor in Mechanical Engineering and moved toward faster moving vehicles, contributing in core design, supply chain technical support and manufacturing equipment technology for turbine engines at Pratt & Whitney Canada. Mathieu now leads the deployment of Additive Manufacturing Technologies at P&WC. With his team, Mathieu is taking over the challenge of building the whole design system to incorporate AM to the P&WC toolbox of qualified manufacturing processes.
|Roger Eybel, Materials and Processes Group Leader/Safran Expert
Safran Landing Systems
|Presentation: Safran Helicopter Engines process for AM combustion parts
Roger Eybel is a graduate of Queen’s University (Canada) in Metallurgical Engineering (1986). Mr. Eybel has been with Safran approximately 29 years and is presently a senior Safran Expert (Senior Technical Fellow). His work on emerging technology projects has included new alloy development (i.e. AF1410, AerMet 100, beta titaniums, etc.), new coatings, metal matrix composites, solid state welding and now additive manufacturing. Mr. Eybel has long been involved in SAE metals committees which have included AMEC, ASEC, P17,B, D, E, F,G and additive manufacturing, and presently a sponsor of three AMS documents.
|François Charron-Doucet, Director of Quality Control and Scientific Director at Groupe AGÉCO||Presentation: Greening the Aerospace Supply Chain
Mr. Charron-Doucet is Director of Quality Control and Scientific Director at Groupe AGÉCO. François Charron-Doucet received a diploma in engineering physics in 2004 (École Polytechnique de Montreal), and obtained his Master’s degree in 2007 from the same university with a thesis on greenhouse gas project quantification using Life Cycle Assessment. He held a position at the CIRAIG, Interuniversity Research Centre in Life Cycle Analysis, from 2007 to 2010 as research associate and as scientific director at Quantis Canada (now Groupe AGECO) from 2010 to 2015. He is a CSA Group Certified GHG Verifier and a recognized verifier for several North American and European environmental product declaration programs, including the International EPD System (Sweden) and CSA (Canada). He is member of the CAC/ISO/TC207/SC3 – Environmental Labelling Canadian mirror committee.
|Thomas A. Houle, Director, LUMEX NA for Matsuura USA||Presentation: Conformal Cooling LUMEX NA for Matsuura
Thomas Houle is an experienced Manufacturing Professional with a demonstrated history of success in the tooling and plastics industry. He is skilled in new product development, Program Management, Sales and Business development, new Technology adoption and Manufacturing systems and experienced with in-mold sensing and monitoring to measure mold and part performance. Houle has 27 years of continuing experience in the injection mold and molding industry developing turn-key projects for customers all around the globe. In his role as Director, LUMEX NA for Matsuura USA, Tom leverages his experience in operational excellence and continues to develop a cutting-edge, innovative U.S. presence for Matsuura’s Hybrid AM Manufacturing solution. He inspires a culture of continuous improvement by defining goals, developing strategies, implementing systems and measuring performance results for the LUMEX product.
Agent de recherche et développement
|Presentation: Additive Manufacturing at the CRIQ and recent Initiatives
Olivier Marcotte holds a master’s degree in mechanical engineering. He has held the position of research and development officer at the Center de recherche industrielle du Québec (CRIQ) since 2009. As such, he participated in the establishment of a metal additive manufacturing laboratory for industrial applications in 2014. This laboratory aims to familiarize Quebec companies with this technology of the future by providing access to the equipment and expertise of CRIQ staff. For close to 2 years, he has been working on the development of a new additive manufacturing laboratory that will be dedicated to the medical applications of 3D printing. This laboratory, created in partnership with a group of local hospitals, will aim to develop new applications of 3D printing in the medical field, be it patient-specific metal implants, cutting guides, anatomical models or other applications of interest.
Thank you once again to our Sponsors:
On October 24th, Canada Makes forth Additive Manufacturing Forum successfully concluded by bringing Canadian and international AM experts together under one roof at the University of Waterloo. The level of discourse featured during the day in booth the networking and presentations signals Canada has taken big steps towards developing world-class Additive Manufacturing (AM) capabilities.
The event kicked off with Germany’s Mathias Gebauer from Fraunhofer IWU who gave a great presentation covering some of the fascinating things they are doing. His presentation was highlighted by topics such as embedding thermocouple sensors directly into SLM parts while the SLM part is being built, selectively removing powder from a SLM build and replacing it with a second material in paste form which is then processed to become solid.
Following this was Cassidy Silbernagel, one of Canada’s rising stars in AM, who reviewed Design for AM guidelines as well as presenting a past, present and future look at AM in the automotive industry.
After some networking with leading AM companies taking part in this years Canada Makes Scrum was the panel on conformal cooling. The panel, moderated by Ed Bernard of Crest Mold and including panelists Wes Byleveld of Exco Engineering, Annette Langhammer of NMC Dynaplas and Tom Houle from Matsuura Machinery, who discussed the work that is happening with plastic and metal dies in Canada, which is currently saving a lot of money to manufacturers in terms of reduced cycle times, scrap reduction, and increased machine up-time due to more robust and reliable processes. Listening to this session one can certainly believe that Conformal cooling is Canada’s entry into seeing success with AM technology.
Also presenting were Dylan Yazbeck who gave us a glimpse into the world of computed tomography for AM parts. He was followed by one of the day’s keynote speakers, Peter Adams CEO & President Burloak Technologies, who shared some of the challenges faced in the emerging AM market and what Burloak Technologies is currently working on in the aerospace industry. He also gave us a peak at their new 60,000 sq foot facility and described how some of the 100 million plus investment by Samuel &Sons will be used.
One of the highlights of the day was to hear a great panel moderated by Mark Kirby of Renishaw Canada and included panelists Roger Eybel of Safran Safran Landing Systems, Mathieu Fagnan of Pratt & Whitney Canada as well as Steve Slusher from AddWorks. They discussed the some of the challenges faced by the Aerospace setor in adopting AM.
Finishing off the day were presentations from François Charron-Doucet on positive environmental impacts, which the AM industry can take advantage of, as well as updates in the medical field from Martin Petrak from Precision ADM and Olivier Marcotte of the CRIQ.
Overall, it was a great day with plenty of high-level networking and information sharing from all of those in attendance.
Stay tuned for our next event!
Canada Makes is pleased to welcome DMG MORI Canada as its newest Leadership level partner. A global leader in machine tool manufacturing, DMG MORI offers a unique product range of metal additive manufacturing machines, including powder bed Selective Laser Melting (SLM) and Laser Deposition Welding on the LASERTEC 3D systems.
“Including the world-class DMG MORI in the Canada Makes network is a big plus for us,” said Frank Defalco, Manager Canada Makes. “The capabilities offered by combining their different process chains available for additive is truly inspiring and I look forward to working with DMG MORI in bringing innovation solutions to Canadian industry.”
DMG MORI has successfully performed on the additive manufacturing machine market for over five years with the laser deposition welding and metal-cutting machining with the LASERTEC 3D hybrid series. In addition to establishing and expanding the digital process chain DMG MORI has also developed a full-line in additive manufacturing. While the LASERTEC 65 3D is geared solely towards laser deposition welding as a complement to existing machining on the shop floor, the LASERTEC 30 SLM 2nd Generation with its new Stealth design expands the portfolio to include powder bed using selective laser melting.
Thanks to the combination of additive manufacturing technologies with conventional CNC machines DMG MORI has realized four individual needs-based process chains.
On January 26, 2016, Canada Makes lead a trade mission to Germany and we were lucky to have a full day tour of the DMG MORI open house at DECKEL MAHO Pfronten to see the latest innovations and groundbreaking technologies on offer. Learn more here http://canadamakes.ca/dmg-mori-technology-for-the-future/
The DMG MORI group is a global manufacturing leader of CNC machine tools. The product range includes high-tech turning and milling machines, as well as Advanced Technologies, such as ULTRASONIC, LASERTEC, ADDITIVE MANUFACTURING, automation and complete technology solutions for the Automotive, Aerospace, Die & Mold and Medical industries. The APP-based control and operating software (CELOS) and innovative products of Software Solutions enable DMG MORI to shape the future for Industry 4.0. DMG MORI also supports its customers with a wide range of training, repair, maintenance and spare part services covering the entire machine life cycle. As a ‘Global One Company’ with over 12,000 employees, DMG MORI is present in 79 countries around the world. A total of 157 international locations are in direct contact with customers. https://ca-en.dmgmori.com