ROLE: BUSINESS MODELS
Dutch consulting firm with 70 years of experience
supports private and public sector companies
www.berenschot.nl / o.ponfoort@berenschot.nl
ROLE: DESIGN & ENGINEERING
BPO supports the complete product development
process, from the first sketch, to final production.
www.bpo.nl / a.posthuma@bpo.nl
ROLE: DEMONSTRATOR
Sheer driving pleasure
www.bmw.com / frank.woellecke@bmw.de
ROLE: MANUFACTURING
EOS is the world leading manufacturer
of laser-sintering systems.
www.eos.info / joerg.lenz@eos.info
ROLE: MATERIALS
Evonik is the specialist in chemicals business
www.evonik.com / sylvia.monsheimer@evonik.com
ROLE: DESIGN, ENGINEERING AND SERVICE
Fcubic has developed a precision inkjet technology for additive manufacturing
and 3D printing of metal components
www.fcubic.com / urban.harrysson@fcubic.com
ROLE: TECHNICAL INNOVATION
Fraunhofer is Europe’s largest applicationoriented research organization
www.fraunhofer.com
ralf.becker@ipa.fraunhofer.de
damien.buchbinder@ilt.fraunhofer.de
ROLE: QUALITY ASSURANCE
Inspire is the Swiss competence centre for production
www.inspire.ethz.ch/irpd /
manfred.schmid@inspire.ethz.ch
ROLE: SERVICE PROVIDER
+90 is the “one-stop-shop” for all Rapid Prototyping,
Rapid Tooling and Rapid Manufacturing needs.
www.plus90.com / oguzhan.kudu@plus90.com
ROLE: TECHNICAL INNOVATION
TNO connects people and knowledge to create
innovations that boost the sustainable competitive
strength of industry and well-being of society
www.tno.nl / frits.feenstra@tno.nl
ROLE: DEMONSTRATOR
Eurocopter is Europe’s leading fullyintegrated aeronautical group
www.eurocopter.com / lauren.arnould@eurocopter.com
ROLE: DEMONSTRATOR
Flying-cam develops unmanned aerial systems.
www.flying-cam.com / sarah@flying-cam.com
ROLE: SERVICE PROVIDER
Hexagon is the largest independent design and
engineering house established to serve automotive
and defence industries for both local and
international OEMs and suppliers.
www.hexagonstudio.com.tr /
alper.arslan@hexagonstudio.com.tr
ROLE: MANUFACTURING & SERVICE
Materialise’ mission is to innovate product development
resulting in a better and healthier world through
its software and hardware infrastructure and
in-depth knowledge of additive manufacturing.
www.materialise.com / karel.brans@materialise.be
ROLE: DEMONSTRATOR
Siemens is the pioneer in energy efficiency, industrial
productivity, affordable and personalized healthcare
systems, and intelligent infrastructure solutions.
www.siemens.com / olaf.rehme@siemens.com
Direct Spare creates an Additive Manufacturing driven solution for companies to:
• Maximize warehousing efficiencies by
balancing spare parts’ end-of-stock
• Elongate product life time by continuously improve products with each new
and improved spare part
• Create economic and environmental
advantages by on demand on location
spare part manufacturing
By the end of the project we will have a
real-life demonstration of the production
of four spare parts with acceptable quality
using additive manufacturing.
All partners are willing to answer your
questions and to provide information about
to the project. All developments and presentations of the project can also be found
at our website: www.directspare.eu
1. DESIGN AND SIMULATION
Different design alternatives are used in this
project for aspects like mass, stress contribution,
safety and deformation. Generic tools to repair
and redesign scanned parts are developed.
More research is needed to identify problem
areas and the optimal translation from software
data to lightweight structures that perform as
good or even better than the original parts.
New methods and state of the art engineering
have been applied on test cases, including the
Gimbal case. The difficulty lies in the extraction of information to create the spare part. In
case of the gimbal the function of the product is
clear (holding the camera of a small helicopter,
enabling free movement), but the specifications
need to be determined by the user. Another
challenge is to determine the design space. First
results were promising: the stiffness of the spare
part was comparable to the stiffness of the original gimbal. More research is needed to optimally
translate data to a lightweight structure with the
same (or even better) performance, but without
adding unnecessary weight.
2. MATERIALS
Novel polymer material and novel metal powders
are developed and tested by the partners in the
consortium. The results are a good starting point
for further improvements of both the material
and the processes. The effects of gamma radiation, swelling, heat treatment and filler treatment
are studied intensively. Improved properties will
open a wide range of possible new applications
for spare parts.
DIRE
ECT SPARE PROCESS
6. TOTAL QUALITY MANAGEMENT
The proposed TQM-concept is based on the four
main aspects for additive manufacturing: equipment used, material used, production conditions
and batch characteristics. Industry standards are
developed to secure constant and comparable
production quality regardless of production location and service provider (ASTM, VDI, ISO).
3. PROCESSES
Goal is to investigate if additive manufacturing
can produce parts with the same quality as traditional processes (MIM, machining), regarding
surface finish, dimensional accuracy, material
properties and cost. One of the interesting challenges is how to optimally position the part in the
printing machine.
A possible process map for total Quality Management is shown below. Special attention is
needed for the differences between metal and
plastic powders, recycling and refreshing powders and the functionality of the part.
The case study “Front Grill” from BMW shows
that aluminium parts can be manufactured using
the DMLS process. The original size of the grill
was too big for current machines to build the part,
therefore first trails were made using a 2:1downscaled model combined with support structures.
DRAFT
5. BUSINESS MODELS
To determine the benefits of additive manufacturing for spare parts the full value chain needs
to be analysed from customer demand until use
and aftersales.
Benefits can be found in lower transportation
costs, smaller CO2 footprint and better functionality via improved design.
4. DATA MANAGEMENT AND TRACKING
Traceability and process monitoring are necessary to ensure quality. Goal is to develop a dedicated data management and tracking system
for additive manufacturing of spare parts that
incorporates Direct Spare knowledge. The data
chain will contribute to Total Quality Management by enabling traceability, data management
and constraining certain degrees of freedom.
A specific issue is the protection of intellectual
property and the prevention of illegal copying.
An online “shop” for AM spare parts will demonstrate the Direct Spareconcept and create a
link to the datamanagement system. Ordering
a spare part from the shop will automatically
create a link to the data management system.
Ideally it will support automatic functions, such
asconverting, fixing and labelling.