Additive manufacturing: competitiveness and economy

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MAPAL Fabrik für Präzisionswerkzeuge Dr. Kress KG

External reamers made using AM

ETMM: Mapal uses additive construction for external reamers. What advantages does that have in practice?

Dr. Sellmer: For these rotating tools, the weight and imbalances determine the performance characteristics due to the mass inertia. External reamers manufactured additively can be roughly 50% or more lighter. In particular, they can be made with cavities, which we call balancing profiles. That permits lower imbalances, higher speeds, higher precision and greater economy. This is based on a honeycomb structure which facilitates lightweight construction and balancing potential. In general, we assume that we can also optimize the honeycomb structure bionically. FEM analyses allow us to optimize these honeycomb structures to increase the rotating potentials. Our patent for solutions like this gave us the foundation we needed. But that is not the end of the story. Process-appropriate design allows us to implement new ideas constantly as a "work-in-progress".

ETMM: When did you start using additive manufacturing?

Dr. Sellmer: First, we explored the market on the supply side and evaluated the different system concepts for our applications. We soon found that all of the concepts would enable us to change our previous machining environment. And in just 12 months after choosing the Concept Laser technology, we put the first series-ready products on the table, in spring 2014. Our boss, Dr. Dieter Kress, is so impressed that he often carries an additive part to show visitors these minor miracles.

ETMM: Why Concept Laser?

Dr. Sellmer: When making decisions like this, there is a lot to think about as, fundamentally, all three main providers offer good solutions on the hardware side. However, there are certain nuances in the details which can be important. We soon found that Concept Laser has a special approach to topology. In the exploratory negotiations, Concept Laser also focused on our applications and showed us how additive manufacturing is currently used by other processing companies. That meant that we soon knew everything a user needs to know. Concept Laser offers open parameter intervention. That was also an important point for us in the R&D department, enabling us to make specific developments. In my opinion, the M1 cusing system is designed very customer-specifically and easy to operate. It's not an "off the rack" system, it's highly customized with a few soft factors. Our cooperation is one between equal partners.

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