"The industrialization and digitalization of additive manufacturing (AM) for automotive series processes has succeeded". Twelve project partners are proud to announce that IDAM (Industrialization and Digitalization of Additive Manufacturing) has succeeded in two respects. The consortium of SMEs, large companies and research institutions started three years ago with the common goal of revolutionizing metallic 3D printing in the field of automotive series production. A digitally networked, fully automated 3D printing production line was set up at two locations and prepared for automotive series production. From now on, at the BMW Group sites in Munich and at GKN Powder Metallurgy in Bonn, at least 50,000 components can be produced cost-efficiently per year in the production of identical parts and more than 10,000 individual and spare parts using 3D printing via the Laser Powder Bed Fusion process (LPBF). Thanks to the modular design of the blueprint for this line, the annual quantity can be scaled up as required.
In just three years - from concept sketch to fully integrated production line
Launched in 2019, driverless transport systems (AGVs) now transfer the mobile build chambers of the 3D printers between the modules of the IDAM production lines fully automatically. The machine ballet is orchestrated by a central control unit in which all data from the individual line modules converge on a digital level. The digital twin generated in this way monitors all relevant production data at all times - for maximum productivity and quality.
Innovative concepts for the automatic generation of 3D print build data have been developed. Fully automated modules transport the processed metal powder and prepare it. In addition, the finished components are automatically post-processed in specially designed stations. Comprehensive quality assurance measures have been implemented along these lines. For example, sensors are used in the laser melting process to monitor and ensure the quality of the finished parts.
Networked production lines require closely networked project partners
The implementation of the lines required interdisciplinary expertise. It enabled digitalization, automation - in mechanical and plant engineering - in component design and in the field of metallic 3D printing to be realized. The Fraunhofer Institute for Laser Technology ILT in Aachen supported the project with its many years of experience in the field of additive manufacturing technologies. The project partners quickly realized that "off-the-shelf" solutions would not meet the ambitious project goals and the associated productivity and quality requirements of the automotive industry. As a result, the majority of the modules had to be completely redeveloped on a digital and physical level. In addition, successful operation of the IDAM lines is only possible through close networking of the individual modules - the same was demanded of the project partners. From owner-managed SMEs to large companies, a spirit characterized by a common striving for success was established from the very first day of the project: learning from each other, developing innovative solutions together and bringing out the individual strengths of each partner in the best possible way - these were the keys to success for IDAM.
