Objective
1. CAD models of the benchmark parts were designed.
2. Process diagrams and parameters for density and surface roughness were determined.
* density >99%
* surface roughness Rz<40µm
3. A scanning system and a combined powder levelling and grinding unit has been developed.
4. The process strategies were implemented in the control software.
5. The consortium decided to stop the development of a automatic support generator due to insufficient common rules for support.
6. The benchmark parts were manufactured by SLPR.
7. Surface quality is partly (Rz " 30-50µm) and dimensional accuracy (<0,1mm) completely within the project objectives.
8. Benchmark parts were finished by grinding, EDM, polishing and in case of the tools fitted into a mother tool.
9. Reports on the lifetime were delivered.
10. Benchmark parts were manufactured by conventional, non-prototyping techniques like milling, drilling, EDM, etc.
11. Benchmark parts were manufactured using SLS of DTM Corp.
12. A comparison of the SLPR process to other techniques was prepared and yielded a reduction of manufacturing time up to 40%.
Aim of the project is the direct generation of tools for injection moulding (material: steel 1.4404) and diecasting (material: steel 1.2343) and of functional prototypes (material: steel 1.4404) which fulfil industrial requirements due to quality and lifetime. For the generation of these parts a new rapid manufacturing process, the Selective Laser Powder Remelting (SLPR) process will be improved with regard to density, surface roughness and form precision. The major research tasks are: development of the process layout and processing strategies for the above mentioned materials development of components (e. g. scanner system, process chamber, grinding unit) for the SLPR process generation of the tools and the prototypes directly from CAD data tests of the lifetime of the tools and the prototypes under industrial conditions and comparison with conventional manufacturing techniques Successful completion should yield cost savings for only one SME, involved in this project, for the rapid tooling sector of 45 75 kECU per year. Under the assumption that this SME represents a typical European tool manufacturing company (= 10.000 SME's in Europe) the overall cost savings in Europe can be estimated to 450 MECU. The SLPR process is also of high interest for all SME's working in the field of rapid prototyping (rp) to reduce the development time of their products. The main advantages in comparison to conventional rp technologies are: generation of complex shaped metal parts made of serial materials without post processing (e.g. infiltration, casting) Iifetime of the parts are in the range of those of short series.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology mechanical engineering manufacturing engineering
- natural sciences computer and information sciences software
- natural sciences physical sciences optics laser physics
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Coordinator
33178 BORCHEN-ALFEN
Germany
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.