University of Paderborn, Boeing, and others form laser-based manufacturing research center
July 9, 2008--Interested in developing large-scale layer-by-layer part manufacturing processes, the University of Paderborn (Paderborn, Germany) has joined with EOS Electro Optical Systems (Krailling), Evonik Industries (Marl), MCP HEK Tooling (Luebeck), and Boeing's Berlin branch to form the Direct Manufacturing Research Center (DMRC). Others are invited to join the research effort.
An agreement was signed today by representatives of the companies and the university to further the development of direct manufacturing processes and systems--that is, the automatic layered fabrication of component parts on the basis of a computer model. The DMRC is scheduled to open in fall 2008.
The DMRC will be located at the University of Paderborn and builds on the University's expertise in mechanical engineering (mechanics, lightweight construction, particle technology, polymer technology, and mechatronics) and in chemistry (polymer materials and interface processes) as well as computer sciences. Direct manufacturing processes often consist of layer-by-layer sintering or melting of plastic or metal powders using an industrial laser; if made practical for large-scale production, they could replace ordinary milling technologies in some cases.
"Direct manufacturing offers the potential of significantly reducing parts production costs, as well as enhancing the ability to fabricate more complex and more functional component parts," said Jeff DeGrange, chairman of the board of the DMRC consortium and senior manager of direct digital manufacturing at Boeing Phantom Works, Boeing's advanced research and development organization.
While direct manufacturing technologies are already being used to develop prototypes, it has only rarely been used for the production of small runs of complex parts. Preconditions for more widespread use are technical solutions regarding quality and consistency of the production process, industrial standards, automation, and production speed.
For the DMRC, Boeing will define production process and system requirements from an aerospace standpoint; Evonik Industries will produce polymer-based standard materials as well as material solutions tailored for direct manufacturing; and EOS and MCP HEK Tooling will provide their expertise in the development of laser sinter and laser melting systems for metals and polyamides.
The four founding companies will invest a total of 2 million Euros into the DMRC over the five-year contract period., while the University of Paderborn will contribute 600,000 Euros. The DMRC explicitly invites new industry partners to join the DMRC to be able to continuously expand its research portfolio.
The German state of North Rhine-Westphalia announced today that it will invest a 1.4 million Euros to improve the University of Paderborn's research infrastructure for direct manufacturing. The funds will be used for the acquisition of equipment for the DMRC, thus establishing the basis for projects in this research area. The state of North Rhine-Westphalia also will co-invest up to 3.4 million Euros for DMRC research projects over the next five years, should the industrial partners additionally contribute the same amount of funds. The partners expect the total funding of the DMRC to reach approximately 11 million Euros over the next five years.
Research at the DMRC will be led by University of Paderborn professors and carried out by its technical staff and students. Industry staff members also will contribute and partly work on joint projects at the DMRC. Initial research will focus on improvement of the processes for laser sintering and melting technology for metal and plastic powder, as well as industry requirements for materials, training, and standards development.