EPP manufacturing evolution: Using SLM techniques, advance EPP manufacturing shape complexity possibilities and create efficiencies that reduce industry production costs by 16%

Project Information

SLM-Tools

Grant agreement ID: 836131

DOI

10.3030/836131

Project closed

EC signature date 3 December 2018

Start date 1 January 2019

End date 31 March 2019

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 71 429,00

EU contribution

€ 50 000,00

Coordinated by

OVERATH EPP GMBH
Germany

Periodic Reporting for period 1 - SLM-Tools (EPP manufacturing evolution: Using SLM techniques, advance EPP manufacturing shape complexity possibilities and create efficiencies that reduce industry production costs by 16%)

Reporting period: 2019-01-01 to 2019-03-31

Summary of the context and overall objectives of the project

Today, driven by the EC’s strict regulations and rising fuel prices, by 2021, automotive manufacturers are tasked with reducing their vehicle fleets CO2 emissions. To achieve this, every possible measure to reduce every gram of CO2 is being explored and invested in to ensure regulatory compliance as well as safeguard profits. OEM demand for weight and costs reductions is driving designers to seek the most versatile materials available to satisfy performance, durability, safety as well as design flexibility needs. As such, the role of lightweight materials such as EPP is expanding into more and more applications. Components made from lightweight EPP improve over-all fuel economy by replacing heavier parts traditionally made from metal and plastic. These components also capitalise on the energy absorbing properties of EPP in order to make automobiles safer in the event of a collision.

Although the material has fantastic benefits, todays EPP has limitations. Primarily, these are its high energy and water usage costs to manufacture the moulds as well as the limited shape complexity versatility. However, SLM Tools overcomes these barriers, thus creating new application opportunities and increasing design freedom whilst reducing part manufacturing costs significantly.

SLM Tools is a globally unique concept that takes advantage of the design freedom of 3D printing in the form of conformal cooling in the EPP moulding industry. In using SLM technology, uniquely complex spatial structures can be produced by melting and sintering start material to build up moulds cavities layer by layer. By using beams in this way, any three-dimensional geometries can be generated to include undercuts, i.e. work-pieces that are impossible to produce using conventional mechanical or casting production methods.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During our Phase 1 Feasibility Study we have completed a market potential assessment to assess the SLM Tools target market sectors opportunity and analysed the data to identify the most accessible routes to market. This has produced market potential information for our initial target markets. We have also planned our route to commercialisation.

Also, within the Feasibility Study, we have prepared for a Phase 2 project by preparing a Phase 2 work plan, Gantt, list of deliverables and a project budget. This plan has enabled the development of our strategic business plan that will be utilised to enable us to reach these new markets.

Having undertaken this Feasibility Study, we are now confident that the SLM Tools technology is commercially viable. Therefore, we are proceeding with our plans to reach market as soon as possible. In order to achieve this, we shall submit a Horizon 2020 Phase 2 application to enable us to complete the technology development to increase capability, to complete commercial trials to gain market reference and continue our current route for commercialisation.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

PROGRESS BEYOND STATE-OF-THE-ART.

Improved end-product: SLM technology enables the construction a completely new generation of innovative tools with multiple cavities (mould inserts) that is only possible with SLM technology. This offers many advantages for the manufacturing processes of moulded foam parts, including new design methods and systems. Further, in using SLM Tools moulds, EPP components have improved surface quality over traditional techniques to offer an excellent finished product.

Production cost saving: When used for EPP mould production, SLM Tools has the following effects:
• Reduction of energy consumption by 70%
• Increase plant output by 100%
• Reduction of tool weight by almost 50%
• Tool lifetime increased by 500%
• Reduction of cooling water consumption by almost 90%
• Reduction of the cycle time by 67%
• Redesigned surfaces and absolute design freedom
• Tool cost per part 4x cheaper (from 7.5c down to 1.8c)


EXPECTED RESULTS.

Our principle objective is to develop SLM Tools technology to TRL9 and prove that SLM Tools can 1) produce complex structures for mass-production cost-effectively in large series, increasing EPP production by 100%; and 2) reduce energy usage by 70% and water usage by <90% (and the associated CO2). In all, we target to prove costs are reduced by 16%. To achieve and evidence this, during the intended Phase 2 project, we plan to action the following technical and commercial objectives:
• Scaling from TRL6 to an efficient production environment validated by extensive testing.
• Automation of design processes; extension of toolmaking to larger or more complex tools.
• Productivity increase of SLM technology; process-reliable conception for SLM tools.
• Production-ready design and production processes for SLM mould foam production tools.
• Attend commercialisation events to demonstrate results and increase market awareness.
• Protect IP in the target market locations, mainly with patents.
• Scale-up for SLM Tools market entry.

As we progress SLM Tools to TRL9, we will increase marketing activity to generate our first sales in 2022.


IMPACTS.

Beyond the economic benefits that cheaper and increased complexity moulding will bring to Europe, there are also significant water, materials, energy and CO2 savings. Should SLM Tools become industry standard and replace the entire inventory of EPP and EPS moulded foam machines, the theoretical savings volumes in mould manufacturing are estimated at:
• 555 million m3 water
• 15,048 million kWh energy
• 3,036 million m3 CO2

Further to this, in production of EPP, further savings can be realised of:
• 25,080 tons material saved and their related manufacturing impacts
• 3,080m kWh energy
• 154 million m3 CO2

SLM Tools production process

How SLM cavities are produced