Periodic Reporting for period 1 - 3DTTool (Next Generation of Cutting Tools Using Additive Manufacturing Technology I, Phase 1)
Berichtszeitraum: 2016-06-01 bis 2016-09-30
Thürmer aims to develop both kinds of taps with the latest additive manufacturing (also mentioned as 3D-printing). The technology enables producing complex geometry suitable for highly functional structures. On machine taps, the technical break-through is the innovative cooling and lubricating channels and nozzles that deliver the cutting fluid to the cutting edges, where it is need the most. The importance is not only the economic benefits resulted by the increased cutting speed and tool life, but also the minimized consumption of cutting fluid, which significantly reduces the impact to the environment and worker’s health.
AM is one of the core enabling technology that will upgrade the manufacturing industry towards high-performance, functionality, and environmentally friendly production. The machine tool industry is the sector that has broad impact on other sectors, such as consumer products, general machines, and transportation. We expect the success of the project to disseminate the knowledge and experience of AM adoption to a spectrum of industries, thus maintaining the competitiveness of the European manufacturing industry.
The development of 3D-printed machine taps aims to achieve:
• 100% increase of tool life,
• 20% increase of cutting speed,
• reduced power consumption during material removal,
• reduction of cutting fluid consumption significantly compared to conventional flood cooling
• The goal is a serial production of 200.000 tools/year by 2023.
The study presents the end-users’ benefits as a value proposition, in aspects of productivity, machine down-time, and cutting fluid reduction. The case study performed at Nissens A/S quantifies these benefits, confirming a 10 times returned value by investing high-quality taps. Together with the environmental advantages and the mass customization possibility, the total value proposed gives sufficient space for the AM-induced extra cost. The study also provides a comprehensive estimation of the eventual production cost, which is under the prices of existing high-end tools.
In the technical assessment, the intellectual property and competitor analysis exposes an accessible path towards the expected performances under the protection of our patent. Moreover, it presents an in-depths investigation of the current status of metal AM technology with focus on material properties, design tools, and existing AM products. The operational assessment and supply chain addresses the key issues of lead time, inventory, and the selection of suppliers. Due to the large investment of an in-house AM facility, the operational assessment also considers the time the purchase takes place during the business development.
At the end, the study outlines the financial prospect, product launch strategy, future business model, and a prospect of Phase 2 development plan.
The knowledge generated by the projects are directly transferred to Thürmer’s 3D printing platform where the focus is on learning (teaching) and co-creating. The learning platform focuses on creating awareness, visibility and talent creation within in the scope of additive manufacturing. The co-creating platform focuses sharing the capabilities and processes that are needed for full scale adoption of industrial additive manufacturing as production option for Danish Industry with focus on SME’s
Currently Thürmer is working with two universities and numerous engineering programs focusing on industrial additive manufacturing.
Thürmer expects the success of the project to disseminate the knowledge and experience of AM adoption to a spectrum of industries, thus maintaining the competitiveness of the European manufacturing industry.