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Workshop: Design for Additive Manufacturing Presented by Réseau Québec-3D, CME Canada Makes & McGill University

March 21, 2018 at McGill University SOLD OUT!Réseau Québec – 3D (RQ3D)

This half-day workshop will feature presentation from some of Canada’s leading experts in additive manufacturing (AM) and offer the chance to network with some of Canada’s AM professionals. The workshop’s goal is to help industry personnel  understand one of the most important components of AM, designing for additive manufacturing DfAM.

Additive Manufacturing is changing your sector whether you like it or not, be ready!

It is no secret that AM is disrupting key sectors of Canada’s economy and Réseau Québec-3D and Canada Makes are working together to bring you the expertise and knowledge needed to help understand how you can use this powerful new technology to your advantage and be ready to adapt.

As usual, networking will be a primary focus of this workshop so we plan on including breaks and a networking lunch so you can ask questions face-to-face. Experts from Altair, Renishaw, Expanse Microtechnologies and the CRIQ will offer insightful discussions in their area of expertise. We look forward to seeing you there!

Sign up now as seating is limited.

Click here to register

Date: March 21, 2018
Time: 8 a.m. – 1:30 p.m.
Location: McGill University
Macdonald Engineering Building, Room 267
817 Sherbrooke Street West McGill University,
Montreal, Quebec H3A 0C3
Cost: 
$25 Réseau Québec-3D & CME Canada Makes Members
$50 Non-Members

Agenda:

Time Topic Speaker
8:00 – 9:00 a.m. Registration and Networking coffee  
9:00 – 9:30 a.m. Welcome Remarks & DfAM Fiona Zhao, McGill University
9:30 – 10:00 a.m. Design for Additive Manufacturing Ross Myher, Altair Canada
10:00 – 10:30 a.m. Impact of new AM capability and adoption method/point Félix-Etienne Delorme, Renishaw
10:30 – 10:45 a.m. Networking Break
10:45 – 11:15 a.m. Révision de la conception pour la fabrication additive, étude de cas Denis Lépine, CRIQ
11:15 – 11:45 a.m. Pushing Limits in Design for AM through Smart use of uCT James Hinebaugh,  Expanse Microtechnologies
11:45 – 12:00 p.m. Special announcement – Finalists Canada Makes 3D Challenge Frank Defalco, Canada Makes
12:00 – 1:30 p.m. Networking lunch
1:30 – 2:30 p.m. Canada Makes’ Additive Manufacturing Advisory Board (AMAB) AGM Note: Only AMAB members

Contact information:
Frank Defalco, Manager Canada Makes
Frank.defalco@cme-mec.ca

Design for additive manufacturing: Guidelines & case studies for metal AM

The Government of Canada recently commissioned the Fraunhofer Institute to deliver a report ‘Design for Additive Manufacturing (AM) – Guidelines and Case Studies for Metal AM’. The goal of the report is the help Canadian companies and researchers take advantage of existing knowledge in metal AM.

The report is based on seven components each tailored to the specific needs of the chosen AM technology. It identifies leading edge industrial applications and trends associated with the design for AM and limitations related to current AM technologies. The evaluation of the seven case studies highlights general design principles to take best advantage of the powder bed based additive manufacturing techniques Laser Beam Melting (LBM) and Electron Beam Melting (EBM).

1. Bionic Wheel Carrier of Electric Vehicle – Automotive / Motorsports

2. Main Gearbox Bracket – Aerospace

3. Calibration Tool for Extrusion Process –  Energy

4. Heat Exchanger – Energy

5. Miniature Heat Exchanger / Cooler – Not limited to specific industry

6. Functionally integrated Implant – Medical

7. Functionally integrated Tooling Segment – Tooling

Compared to conventional manufacturing methods additive manufacturing technologies provide unique opportunities and freedom in design, resulting in a high degree of product individualisation. Building parts layer by layer without using any tooling, moulds or dies enables the design and manufacturing of very complex component geometry, such as lattice structures or free formed surfaces and organic shapes.

Hinge assembly manufactured in one shot with LBM (Source: Fraunhofer IWU)

Design attributes like undercuts are no longer a limitation and with the aid of topology optimisation the component geometry can be tailored to the specific needs of application. In addition to it, features and functionalities can be incorporated into a part just during the manufacturing process in one shot and assemblies consisting of many components can be reduced to a single part. Even the assembling of different parts during primary shaping with AM technologies is possible, which has already been demonstrated for components like bearings, chains, hinges.

Moreover, the design optimisation and material characterisation are analysed. Finally, there are given overall conclusions with focus on AM-specific design optimisation, main flaws and weaknesses of the considered metal AM processes as well as aspects of AM commercialisation.

Example for topology optimisation – skateboard axle mounting, manufactured with LBM (Source: Fraunhofer IWU)

Skateboard Truck (Titanium) , LBM design demonstrator with topology optimisation and graded lattice structures (Source: Philipp Manger)

This is a small sample of what is available in this comprehensive report. We invite you to download this report and take full advantage of the know-how on offer.

Download the full report here.

Calgary’s Cassidy Silbernagel repeats as winner of Design for Additive Manufacturing Challenge 2017

Cassidy

Cassidy Silbernagel

Last month Canada Makes reported on the finalists for the Additive World Design for Additive Manufacturing Challenge 2017 and we are pleased to announce that Cassidy Silbernagel once again won in the students’ category.

“I’m honoured to be selected a second time as the winner in the student category,” said Silbernagel. “This  competition offered the opportunity to show that additive manufacturing (AM) can take old designs, such as a carburetor, and make them new again with added benefit and features like part reduction, decreased size and weight, and improved performance.”

On Wednesday March 15, the Jury announced the two winners of the Additive World Design for Additive Manufacturing Challenge 2017. From a group of 76 contestants, both professionals and students, 3 finalists were selected per category. The two winners selected best achieved the goal of making a new design or redesign an existing product for additive manufacturing.

Sealer Arm

Lareka Confectionery Equipment’s Sealer Arm

The ‘Chocolate Shock Prevention Team’ of Lareka Confectionery Equipment from The Netherlands won in the professionals’ category with their redesigned ‘Sealer Arm’ for a chocolate bar packaging line. The redesigned and 3D printed sealer arm successfully combined a substantial increase in the quality of chocolate packaging because of better temperature regulation with a reduction of 50 parts.

Cassidy Silbernagel, representing the University of Nottingham, won with redesigned carburetor including integrated moving parts, floats, lightweight internal lattice structures and optimized design to reduce the number of support structures.

Cassidy said, “software like the University’s FLatt Pack for lattice generation is speeding up the workflow from idea to creation is becoming easier and quicker and greatly decreases development time for new products. The use of these new software options is crucial to new AM design creation.”

Cassidy Silbernagel's redesigned carburetor

Cassidy Silbernagel’s redesigned carburetor

“Although AM is an amazing technology,” stated Cassidy. “It isn’t a magic hammer that solves all manufacturing needs. It is just one of many tools in a designer’s tool chest that can be utilized, but first designers need to know that they have this tool, and they need to know how to use it. I’m happy to see that this competition along with organizations like Canada Makes and Additive Industries are helping teach designers this fact, and I’m proud to also aid in this educational goal.”

Canada Makes salutes the winners and all contestants. Challenges like Design for Additive Manufacturing Challenge helps showcase the vast potential of Additive Manufacturing for industry.

A graduate of Mechanical Engineering at the University of Calgary, Cassidy is in the UK currently pursuing a PhD at the University of Nottingham. He is researching the possibility of using AM in electric motors, specifically using AM to create coils/windings using a conductive metal like copper or aluminum and an insulating material like ceramic.

Last years’ winning design was an innovative electric motor casing to fit into an existing crankshaft case of a regular motorcycle enabling electrification. Silbernagel’s design reduced eight parts to one lightweight component and integrated room for heat transfer and well-rounded wiring tunnels.

Motor casing

Cassidy’s 2016 winning design Electric motor casing

For this years’ contest designers were asked to tailor their designs, to eliminate manufacturing difficulties, reduce the number of parts, minimize assembly or lower logistics costs, often combined. Designs were submitted from all over the world including the US, the Netherlands, Germany, UK, Spain, India, Russia and Italy representing different sectors, advanced food processing, the aeronautics industry, automotive as well as high-tech.

About Design for Additive Manufacturing Challenge
In order to grow the number of examples and inspire many other industries to develop dedicated applications for industrial 3D printing, Additive Industries has launched the Additive World Design for Additive Manufacturing Challenge. Competing in two categories, both professionals and students were encouraged to redesign an existing conventional part of a machine or product for 3D printing.

Partners in the Design for Additive Manufacturing Challenge are leading CAE technology provider (e.g. Topology Optimization) – Altair Engineering and consumer 3D printer manufacturer Ultimaker. Contestants are to be supported by Additive Industries’ AddLab team in topology optimisation during the design process. Winners in both categories take home the latest Ultimaker 2+ 3D printer and Autodesk’s NetFabb software. All finalists receive a licence of Altair’s Inspire software and Autodesk Fusion 360 and award winning designs will be printed in metal by AddLab.

About Canada Makes

Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

 

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