EOSTATE Base and EOSTATE Everywhere

EOSTATE - Key overview of all production-related data

As a quality assurance instrument, EOSTATE monitors the progress of the construction of multiple products across multiple interlinked laser sintering machines and provides an overview of production-related data. EOSTATE is a multifunctional tool for Additive Manufacturing (AM) with EOS systems. Status, control and reporting software can be used to monitor production on several interlinked systems at the same time. EOSTATE evaluates data saved on the machines, prepares it in a clear format and provides a key overview of all production-related information at all times.

EOSTATE is modular in structure and can be adapted flexibly to the different requirements of users and end customers. The basic version contains the Basic Module and EOSTATE can be extended to include the optional components Quality Assurance (QA), Controlling, Machine Park Management (MPM). These modules make processes transparent and therefore controllable.

The process software of a laser sinter machine continuously logs important process data in a database on the machine's computer. A Data Base Management System (DBMS) that runs on every machine computer manages this data. EOSTATE establishes a network connection to the DBMS and thus enables direct access to all data that logs the process software in the database.

EOSTATE filters this data according to the given criteria, manages, saves and exports machine data, creates statistics and enables extensive reporting. The software also allows a machine to be monitored by webcam.

EOSTATE Everywhere - Real-time Monitoring for your EOS Systems

EOSTATE Everywhere is the next step towards a user friendly machine park monitoring. Real-time information on Machine Park Status and access to current sensor values and pictures.

EOSTATE Monitoring Suite – Real-Time Monitoring for Industrial 3D Printing

Multi-monitoring tool for quality assurance and process development

Binding quality standards apply in many industries, and particularly in large-scale manufacturing for the aerospace sector. For that reason, reliable quality control and quality assurance systems for the innovative technology of industrial metal 3D printing are of huge significance.

With the EOSTATE monitoring suite EOS offers customers a modular, comprehensive hard- and software solution that captures all production- and quality-relevant data in real time. EOSTATE comprises four different monitoring modules: System and Laser, PowderBed, MeltPool and Exposure OT (optical tomography).

 

With EOSTATE Exposure OT, EOS is the only manufacturer of DMLS systems offering its customers a quality assurance tool that incorporates optical tomography. It enables complete build processes to be permanently monitored, resulting in high cost-cutting potential through non-destructive examination via CT scans.

EOSCONNECT - Industrial Grade Connectivity

Industry 4.0 means to fully integrate industrial 3D printing into manufacturing processes, enabling a highly flexible production and increased efficiency.

And with EOSCONNECT, all the machine and production data collected can be made usable on a live basis. To enable this, EOS offers an open interface capable of providing integration either into intelligent EOS applications providing productivity increase or to be used by third party applications. This way we lay the foundation for companies to truly integrate additive manufacturing in industrial production environments.

Stages of digital integration

Stages of digital integration

The factory of the future is digital: EOS solutions for industrial 3D printing enable a highly flexible and efficient production. (Source: EOS)

 

Product details

EOS solutions are highly connective to on premise MES/ERP solutions but also serve upcoming digital marketplaces and IoT platforms. EOSCONNECT will be the most advanced gate opener to gain flexibility and increase productivity. Machine and production data can be gathered and made available in near real-time. EOS even offers an intuitive app to visualize the data in a dashboard. This is the next step towards a comprehensive and user-friendly machine park surveillance.

This high connectivity enables two beneficial outcomes: Companies gain a seamless handover of production data into their CAQ systems (Computer Aided Quality) for secure traceability, helping them to validate their processes for production. They also can benefit from transparency with visualization and readout of real-time production KPIs. In the end, the connectivity helps businesses to improve their productivity.

Data Preparation and Process Software for Additive Manufacturing

EOSPRINT 2: New generation of job and process management software

It is an intuitive, open and productive CAM tool for EOS systems that enables to assign and to optimize build parameters for your CAD data. Now available for EOS M 290, EOS M 400 and EOS M 400-4.

 

  • Be more productive with the new plane segmentation and significantly increase speed.
  • New exposure patterns and parameters enable unseen part quality at lowest cost per part.
  • Open EOS ParameterEditor module allows even greater freedom for application-specific parameter optimization.
  • Workflow-based user interface reflecting the AM CAM process makes it intuitive and quick to learn.
  • An easy and safe part production with the automatic geometry and position-driven dosage quantity of material.
Up-to-Date Version: PSW 3.8 - Flexibility with Open Parameters

The process software (PSW) controls the EOS System. An option of the PSW is the EOS ParameterEditor which allows the exposure parameters to be changed for each specific material. The new software update PSW 3.8 allows to optimize various previously preset process parameters to suit the special requirements of different parts. These extended setting options allows to adapt the parameters in steps to the requirements in order to increase the productivity of the system, to save costs or to improve the quality of the parts.

Data Preparation Software

The prerequisite for the correct progress of the construction process during laser sintering is the preparation and control of CAD data. Orientation and positioning is handled by rapid prototyping software such as Magics RP. The component data required for the construction process is transformed into layer data either by means of EOS RP tools or by means of the BuildProcessor available for Magics.

Procedure for data preparation

Procedure for data preparation 1

Procedure for data preparation 2

Procedure for data preparation 3

Procedure for data preparation 4

Procedure for data preparation 5

Rapid Prototyping with Additive Manufacturing Solutions by EOS

Additive manufacturing is ideally suited for Rapid Prototyping.

Thanks to the highest possible degree of design freedom, even complex shapes such as bionic structures can be manufactured. It is possible to manufacture physical presentation and functional prototypes quickly and cost-efficiently without the need for manual processing – directly using three-dimensional CAD construction data. This makes the entire product development process considerably faster.

Flexible construction and material variants

EOS systems build up prototypes as well as end products layer-by-layer. Different metal and plastic powder materials are available. Products made of different materials belonging to one material family (metal or plastic) can be processed on one machine. This is especially interesting for prototype manufacturing.

Companies in many sectors of industry are now making successful use of laser sintering processes in their development and manufacturing processes.

Tool Repair with Additive Manufacturing by EOS

EOS Additive Manufacturing can also be used to repair damaged tool inserts, saving manufacturers time and money.

The repair of damaged tool components is an application area in which innovative Additive Manufacturing technology from EOS can really demonstrate its strengths. Instead of having to dispose of a worn-out tool and replacing it with a new one, the damaged areas can be repaired quickly using laser sintering. This enables manufacturers to benefit from a longer operating life, also reducing operating costs.

Repair instead of replacement

Here is an example to show what can be achieved: Ecoparts AG in Rüti, Switzerland uses DMLS technology from EOS to provide services to customers from a wide variety of industrial areas. These include rapid manufacturing, rapid tooling and solution engineering for injection moulding.

One of the solutions on offer is the repair of partly defective tool inserts. Ecoparts first produces a new reference surface through grinding and sharpening. The EOSINT M 270 laser sintering system is then used to build up the missing structures layer-by-layer on the prepared pre-form using the CAD construction data. This means that users do not need to rebuild the components from scratch. This saves them time and money.

Tool Repair with Additive Manufacturing by EOS

Tool insert before repair (Source: Ecoparts)

Tool Repair with Additive Manufacturing by EOS

Tool insert after repair (Source: Ecoparts)

Optimizing Die-Casting Operations with DMLS by EOS

EOS Additive Manufacturing can integrate tempering channels in a tool directly and in near-contour conditions, thereby optimising heat diffusion. This facilitates higher productivity and part quality in die-cast serial production.

Optimizing die casting operations with DMLS by EOS 

Tool insert for die casting (Source: LBC)

 

One of the major challenges in die-casting is the defined cooling of the tools used during serial production. This is where conventional tool production processes reach their limits: Tempering channels can only be drilled in straight lines. This means that critical hotspots can often not be reached with coolants and thus cannot be relieved. As a consequence, the tool can become misshapen and its service life will be reduced. In addition the partly deficient heat dissipation is responsible for long cooling times for the manufactured products.

Innovative Additive Manufacturing from EOS on the basis of DMLS (Direct Metal Laser Sintering) is the answer: This makes it possible to integrate optimized tempering channels in the tool directly and under near-contour conditions during production. This means that heat can be dissipated much after and more evenly, while hotspots can be cooled on a targeted basis. Manufacturers benefit from numerous advantages: the tool retains its shape better and lasts longer. In addition, the plastic product quality and dimensional accuracy of the manufactured parts is enhanced, and drastically reducing cycle times.

Laser sintering technology irons out weaknesses

One example illustrates the huge potential of DMLS for die-cast serial production. The LBC laser processing center in Kornwestheim uses modern laser technology to offer its customers new solutions. LBC focuses on the area of mould making, in other words the manufacturing and final processing of moulds. The company either adapts parts to the process line or adjusts the whole process line to the customer's processes. Thanks to the regular exchange of ideas with universities, research institutions and laser manufacturers, the laser process center is able to operate at the highest level using the latest technology.

LBC managed to design and manufacture a tool insert with significantly optimized tempering performance for a die-cast application. LBC constructed the insert from EOS MaragingSteel MS1 using the DMLS technique on an EOSINT M 270 laser sintering machine. During manufacturing, near contour tempering channels were integrated in the tool at defined points, significantly improving cooling performance. This enabled the manufacturer to reduce the cycle time by 20 %.

Optimizing Injection Moulding Operations with DMLS by EOS

EOS Additive Manufacturing allows direct integration of conformal cooling channels in moulds and mould inserts. Optimized heat dissipation enables shorter cycle times and increased productivity and plastic product quality in injection moulding operations.

Optimizing injection moulding operations with DMLS by EOS 

Tool insert for injection moulding made from MaragingSteel MS1 (Source: LBC)

 

In injection moulding, the cooling time of a finished product can constitute up to 70 per cent of the cycle time in series production. One reason: in conventional mould making, temperature control or cooling channels can only be drilled in a straight line. Critical hotspots often remain out of the coolant’s reach – and therefore cannot be mitigated.

Using Direct Metal Laser Sintering (DMLS) by EOS however makes it possible to integrate optimized, conformal cooling channels into the mould during the production process. This ensures faster and more even heat dissipation. It reduces thermal stress in the mould and prolongs service life. The plastic product quality and dimensional accuracy of the parts is also increased as well as reducing warpage. In addition, this also allows for a drastic reduction of cycle times.

Here are some illustrative examples:
  • LBC focuses on mould making using innovative laser technology, and adapts parts or the entire process chain to the customer’s operations. Using DMLS, the company was able to optimize the thermal performance of a mould insert. This reduced cycle time by 55 per cent from 90 to 40 sec., corresponding to a productivity increase of 125 per cent per annum. The 3,250 Euro investment was recouped within two months, and the company was able to save almost 20,000 euro per annum.
  • In another application, LBC was able to reduce cycle time by two-thirds, using a DMLS-manufactured core to ensure effective cooling of critical hotspots.
  • Es-Tec increased the mould productivity of a blow die with a build time of 50 hours by 20 per cent.
  • SIG Blowtech was able to lower cycle times from 15 to 9 sec. For a 4-bottle blow die with DMLS-manufactured inserts, the company now has achieved a 75 per cent increase in productivity.

 

Industrial 3D printing for Tooling - Function Integration, Faster Amortisation

Additive manufacturing from EOS increase both the productivity of the tools and the product quality.

Industrial 3D printing for Tooling faster amortisation 

Break even analysis for costs in injection moulding illustrates economic benefits of DMLS in comparison to conventional manufacturing (Source: EOS)

 

In many industries, the production of specialist tools us one of the most expensive aspects of the production processes. It is generally expensive, time consuming and very technically demanding to use conventional processes. EOS has the solution: Based on Additive Manufacturing, EOS enables single parts or individualized serial products to be manufactured quickly, cost-effectively and flexibly – even in small batch sizes.

Even highly complex forms and designs with integrated cooling or tempering channels are not a problem for Additive Manufacturing. Conventional production processes reach the limit of their capabilities here: They restrict design and construction freedom because, for example, the only solution for cooling is often simply to drill the required channels. Also, as a tool becomes more complex, so the costs associated with it rise enormously.

The design benefits of Additive Manufacturing from EOS increase both the productivity of the tools and the plastic product quality. Scrap rate and cost per part decline. In addition, manufacturers profit from cycle time reduction and longer service life for tools. They can also bring their products to market more quickly: For example, Innomia managed to reduce the time-to-market from 18 to 13 days in comparison with conventional tool manufacture as part of a tool optimisation project by using Additive Manufacturing.

Benefits of additive manufacturing for Tooling
  • Maximum freedom of design
  • Design-driven manufacturing
  • Highly productive tools, faster amortisation
  • Flexible manufacturing processes, for example the choice between hybrid construction/non-hybrid construction
  • Function integration
  • Reduction in wage costs thanks to standalone processes

EOS also helps businesses to achieve their sustainability targets: overall, Additive Manufacturing enables more efficient, faster production with less scrap. This reduces CO2 emissions.

Partner Case Study

 

FADO, established in 1984, is a tooling and injection moulding company based in Bydgoszcz, Poland. FADO is one of EOS official service providers for DMLS (direct metal laser sintering). The EOS Additive Manufacturing technology enables FADO the manufacturing of inserts equipped with conformal cooling channels, which can reduce cycle time by 30% on average, as well as improve the overall quality of injected parts.

Toolless Production of Medical Devices with Industrial 3D Printing

The EOS Additive Manufacturing process allows for fast, flexible, and cost-effective production of individual or small customized lots of medical devices and instruments.

Toolless production of medical devices with industrial 3D printing

Toolless production of medical devices with industrial 3D printing

Automatic cell washing system for serological testing produced with EOS Additive Manufacturing (AM) technology (Source: Hettich).

 

Many medical devices and laboratory equipment components are complex, high-quality niche products manufactured in small series. Conventional production often requires expensive tools whose costs will have to factor into the price of these products. Additive Manufacturing, on the other hand, requires no tools and therefore enables cost-effective production of components in smaller series up to a batch size of one.

Medical technology companies have recognized this outstanding business potential and are now firm proponents of the additive layering process. An example is Andreas Hettich GmbH, a centrifuge manufacturer, where the process is used for product development and production. In this way, the company has managed not only to increase the value of its products but also to lower production costs.

The typical production volume of the company's centrifuges amounts to between 10 and 1,000 units per year. Hettich has invented and patented a new type of centrifuge which enables the sedimentation and separation of blood components in one device. The ROTOMAT consists of a drum motor with six containers and drip trays. The containers have a complex geometry and are subject to high rotational speeds with acceleration forces
up to 1,200 g.

Manufacturing the container components using conventional methods required complex tools and time-consuming assembly procedures. After a comprehensive technical evaluation, this specialist manufacturer decided to change its method for producing centrifuge housings: they are now made using the EOS Additive Manufacturing process.

Economical production

While the cost of producing the modified component is slightly higher, Hettich saves the costs for an entire set of tools. Reduced assembly and logistics costs provide further savings. In addition, the production technology is available "on demand". If required, this enables further design modifications or product variants to be implemented quickly and at minimal cost. For example, different versions can be manufactured for different blood bags.

Function integration

Hettich was also able to improve product functionality. The now toolless production of the containers and the ability to integrate functions enabled the company to achieve a higher product value – while at the same time reducing production costs.

EOS systems are able to manufacture medical devices. However, EOS cannot offer any guarantee that these devices meet all requirements.

Additive Manufacturing Solutions for Orthopedic Applications

Industrial 3D printing by EOS delivers tailor-made, flexible solutions for orthopedics applications, with quick and cost-effective production of high-quality patient-specific implants and disposable surgical instruments.

Additive manufacturing solutions for orthopedic applications 

Acetabular cup with lattice structures for improved osseointegration produced with EOS Additive Manufacturing technology. (Source: Autodesk Within Medical)

Additive manufacturing solutions for orthopedic applications

Spinal implant encouraging bone fusion produced with EOS Additive Manufacturing technology. (Source: Autodesk Within Medical)

Additive manufacturing solutions for orthopedic applications

Bone rasp demonstrating feature replication on a complex surface produced with EOS Additive Manufacturing technology. (Source: Within)

Additive manufacturing solutions for orthopedic applications

Stereotactic STarFix Medical fixture with two targets produced with EOS Additive Manufacturing technology. (Source: FHC, Inc.)

 

Orthopedics companies have increasingly come to rely on EOS Additive Manufacturing (AM) solutions to produce implants and disposable surgical instruments. This solves present-day challenges: even though no human body is exactly like another, implants must fit perfectly and be quickly tolerated by the body so they can bring about a long-term improvement in the patient's quality of life. Standard products are inadequate here. Instead, products must be tailor-fitted to the patient, with an added need for fast availability at a reasonable price.

Compared to conventional implant production methods, EOS AM offers multiple benefits. Based on 3D CAD data for example, patient-specific parts can be generated without using tools, using high-quality, medically compatible materials. Lattice structures can help to accelerate post-operative healing significantly. In addition, a definable degree of surface roughness helps bones and implants fuse better. Improved implant fit also makes the surgeon's job easier. EOS AM ensures that production costs remain economically viable, even for highly individualized products. Implant manufacturers are able to optimize 3D CAD data-based models quickly and benefit from maximum flexibility. The use of AM optimizes patient treatment, shortens hospital stays and minimizes unpleasant side effects.

For complicated operations, surgeons are increasingly using patient-specific disposable surgical instruments. These enable more precise implant positioning, increasing the success rate of operations for patients, surgeons and hospitals. Additive Manufacturing methods can also be used to produce such individualized instruments. The surgeon receives a high-quality, precise product that fulfils the stringent requirements for medical applications. Compared to non-disposable instruments, hospitals save sterilisation and storage costs and benefit from increased productivity. EOS systems are able to manufacture medical devices. However, EOS cannot offer any guarantee that these devices meet all requirements.

Additive Manufacturing for the Dental Industry

Fully integrated dental solutions from EOS permit the manufacture of final dental products and a process with high reproducibility and constantly high quality.

It doesn't matter whether you are producing crowns and bridges or removable partial dentures, with EOS Additive Manufacturing solutions you always get exceptional value for money. Laboratories and manufacturing services providers can thus work much more efficiently.

Additive manufacturing for the dental industry 

Sample Application from the Dental Industry on a EOS M 100 Building Platform

Additive manufacturing for the dental industry

Additive Manufacturing: The laser fuses the metal powder layer by layer with 200 W and a temperature of 1400°C

Additive manufacturing for the dental industry

Polished dental bridge made from EOS CobaltChrome SP2

Additive manufacturing for the dental industry

Dental prostheses (steps in production from left to right: with support structures,surface ready for veneer, after ceramic veneer) on a dental model and removable partial denture (right)

Additive manufacturing for the dental industry

Productive: A building platform can be charged with up to 450 units

Additive manufacturing for the dental industry

Design variety thanks to digital production: Complete jaw model in form of a solid piece to check for occlusions, saw-cut model with pinholes, model with removable stumps (left to right)

Additive manufacturing for the dental industry 7

Stages of production for an additive manufactured removable partial denture: Dental prosthesis directly after manufacturing, with support structures removed and surface polished, after completion (left to right)

Additive manufacturing for the dental industry

Removable partial denture with support structures made from EOS CobaltChrome RPD

Additive manufacturing for the dental industry

Dental model made from PA 2105 in the form of a solid complete jaw model to check for occlusions

 

The successful realisations of reproducible industrial quality standards at great value for money are the result of EOS`s integrated quality management system, which ensures the quality of EOS products, processes and service.

  • Fully certified processes and products e.g. EOS Cobalt Chrome SP2, certified as a class II medical material for dental applications (Directive 93/42/EEC)
  • EOS Research and Development Center: Development and manufacture of materials and processes for applications in dentistry (ISO 13485: 2003)
  • Advice and support during the validation process (EOS service products)

EOS systems are able to manufacture medical devices. However, EOS cannot offer any guarantee that these devices meet all requirements.

Additive manufacturing (AM) for dental prostheses & models

Additive manufacturing is a 3D printing process that builds up parts layer by layer and differs greatly from conventional manufacturing techniques. It uses 3D data on the oral situation of the patient as a basis; this is generated using intraoral scanners or by impression or model scans. The data set is processed directly with no loss of accuracy, such as is experienced with conventional impression methods, to produce the dental prosthesis or model and then 'sliced' into layers. The EOS system, which contains a bed of metal or plastic powder, generates the desired geometry layer-by-layer. A focused laser beam then fuses the powder material on the basis of the digital data provided. Once one layer has been completed, the powder bed is lowered by a few hundredths of a millimetre and the process begins again. The final product is characterized by a consistently high quality. It meets the needs of precision and aesthetics and satisfies budgetary/financial requirements.

Open process

The EOS process chain offers great flexibility since it has open system interfaces. The users can select the module of their choice and exchange data with this. The EOS systems work with STL data (STL = Surface Tessellation Language, a standard file format for 3D data) so that the dental technician can use a wide variety of computer-assisted design programs (e.g. from 3Shape, Dental Wings, Exocad etc.). Thanks to the independent system structure, the digital CAD/CAM process in design and data processing can be adapted to the economic, indication-specific and dental technology requirements of practices or laboratories so as to achieve and optimum production process.

Crowns & bridges

Additive Manufacturing has been available to produce crowns and bridges since 2005. With over 60 installed systems worldwide, it is the most widespread solution on the market. Around 6.8 million units are currently being produced with these machines every year. Proof enough that the hardware and process have established themselves in dental technology. The CE-certified material EOS CobaltChrome SP2 (CE 0537) and the EOSINT M 270 system are used for the digital production of crowns and bridges. Both elements of the process chain come from EOS and satisfy the high quality standards for medical products. The finished products comply with the relevant standards EN 1641 as well as EN ISO 22674.

Fast and economical production of top-quality dental prostheses

The EOS systems work very accurately and can produce around 450 units at low cost within 24 hours. The digitally produced dental prosthesis is of a constantly high quality. Following the construction process, the dental prosthesis only has to be separated from the platform and finished. The composite strength of the ceramic veneer is outstanding compared to other manufacturing techniques. Hardly any personnel are needed to operate the EOS system. This means that two production cycles can be run per day depending on the daily number of units and capacity utilisation and up to 80,000 units can be produced each year. People are only needed to set up and unload the system. The Additive Manufacturing of dental prostheses is an industrial production process and, thanks to the high productivity of the system, the production costs fall whilst the quality of the final products remains consistently high.

Removable partial dentures

Compared to conventional production methods the digital production method saves a lot of time: the design for the removable partial denture is ready in around 15 minutes with only a few mouse clicks. Thanks to the flexibility of design of Additive Mnuafcturing, the modeling software is not restricted by the manufacturing technique. High strength, rigid and at the same time filigree geometries can be produced and casting errors can be ruled out.

Precise and at the same time economical technology

The EOS system works very very accurately and therefore makes laboratory work easier. The removable partial denture that is produced is of a consistently high quality. But the method is at the same time economical too, around 48 units can be produced within 24 hours.

Certified process chain with a specially developed material

Removable partial dentures are made with the EOSINT M 270, which is already established on the market. The fine powder particles of the material produce a finegrain structure compared to that of the casting and the material characteristics are matched to the application. The removable partial dentures produced with the aid of computers have a higher strength than a conventional model cast and the risk of a clamp breakage is lower. The high level of detail supports the reproduction of pitted structures. Both the material and system come from EOS and satisfy the high quality standards that apply for medical products. The end products comply with the relevant standards EN 1641 as well as EN ISO 22674.

Additive Manufacturing for Medical Devices

EOS' industrial 3D printing technology allows to produce specialized surgical instruments and medical devices quickly and cost-effectively

Additive manufacturing for Medical Devices 1

Pleasant breathability: the perforations in this ankle/foot orthosis with a ring closure system cover virtually the entire surface, preventing excessive sweating. (source: plus medica OT)

Additive manufacturing for Medical Devices 2

The titanium implant has a large number of cavities. These weight-reducing recesses in otherwise solid parts can only be achieved through Additive Manufacturing (courtesy of EOS GmbH).

Additive manufacturing for Medical Devices 3

Thin cross-sections of alloy powder are sequentially melted by a laser driven by this geometry, automatically building complete 3D restorations with structural fixtures not yet snapped off (Source: EOS GmbH).

Additive manufacturing for Medical Devices 4

Improved performance at an identical price: the patient-specific implant benefits from a higher precision fit and a price that is in line with the market (Courtesy EOS GmbH).

 

Every person is unique. Therefore, optimal patient care in dentistry, orthopedics and implantology requires medical products that provide a perfect fit. There is a high demand for one-off components and components produced in small production runs whose materials and manufacturing standards have to fulfil extremely stringent quality requirements. This also applies to specialized surgical instruments and medical devices. In addition, these products must be made available quickly and cost-effectively.

Additive Manufacturing is meeting these exact requirements – while paving the way for improved, patient-specific medical care. Additive Manufacturing enables producers to come up with faster, more flexible and more cost-effective development and production methods. Unlike conventional manufacturing methods, EOS Additive Manufacturing allows maximum design flexibility, enabling the implementation of innovative functions. Thus, test series, prototypes, patient-specific one-off parts and small production runs can be manufactured at a profit. To give an example, several hundred individual dental crowns can be produced in a single operation.

EOS provides far more than the necessary materials and systems for Additive Manufacturing: comprehensive market knowledge and a precise understanding of specific development processes in the field of medical technology enable EOS to collaborate closely with a strong network of partners. From Rapid Prototyping to series production – EOS provides comprehensive and competent advice and continuous support to customers during the entire development and production process.

EOS systems are able to manufacture medical devices. However, EOS cannot offer any guarantee that these devices meet all requirements.

Customer Statement: 3DLMS

 

Marco Ravanello, General Manager at 3DLMS talks about the usage of industrial 3D printing, addressed markets and the benefits of working with EOS.

EOS Additive Manufacturing for the Sport Industry

Sporting success through additive manufacturing: EOS Additive Manufacturing allows product innovations to be implemented in the sport industry, thus offering athletes high-performance sports equipment.

Sporting performance not only depends on athletes’ mental and physical constitution. Equipment is a decisive factor in many disciplines too. High-tech materials and specialized equipment tailor-made to athletes’ requirements lead to success.

To remain competitive, the development departments of the sports equipment industry deviate from series products. They come closer to their objective of optimizing the system "athlete and equipment" with new ideas for product improvements.

These ideas are turned into product innovations through the use of production technologies such as additive manufacturing. This results in the production of robust lightweight versions of complex sports equipment, for example, which would not be able to be produced using conventional production technology.

For athletes, this mainly means one thing: a competitive lead in the fight for medals and podium places.

Additive Manufacturing Kappius rear hub 1a

Kappius rear hub with oversized design (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 1b

Inner pawl ring manufactured from an extremely durable “tool steel” using direct metal laser sintering (DMLS™). (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 1c

Toothed drive ring manufactured from “tool steel” using direct metal laser sintering (DMLS™). (Courtesy: Kappius Components & Ben Delaney/BikeRadar)

Additive Manufacturing Kappius rear hub 2a

The 3D CAD model is used to guide the sintering operation in an EOSINT M 270 System (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2b

The screenshot from the system’s PSW software illustrates how parts are laid out on the build platform to maximize the manufacturing run (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2c

A 200-watt laser melts the powdered maraging steel (bottom left and middle), joining one layer to the next (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2d

A 200-watt laser melts the powdered maraging steel (bottom left and middle), joining one layer to the next (Courtesy: Harbec).

Additive Manufacturing Kappius rear hub 2e

The finished components are covered in excess steel powder which is then removed using compressed air and recycled before final machining and heat-treating steps are performed. (Courtesy: Harbec).

Additive Manufacturing for the Production of Footwear

EOS Additive Manufacturing provides footwear designers with unlimited freedom of design. It is suitable for rapid prototyping as well as allowing product variants to be manufactured cost- efficiently in serial production using high-quality materials.

Kerrie Luft created innovative shapes for the upper of the shoe and the heel by rapid manufacturing titanium

Rendered heel images using 3D Software, made from titanium (Design and source: Kerrie Luft)

 

Additive Manufacturing (AM) and shoes? British footwear designer Kerrie Luft has demonstrated that this unusual combination is in fact highly effective. She uses the innovative EOS AM technology, utilising it in a conceptual way. Her latest collection "Nouveau" features elements of art nouveau. Inspired by nature, the designer created innovative shapes for the upper of the shoe and the heel by rapid manufacturing titanium, applying the complex geometry of the shoe heels to the actual product.

Kerrie Luft says she loves the design process and its application - translating the original concept to an entirely unique and special collection:
"Additive Manufacturing from EOS gives me the freedom to do just this!"

The filigree structure of the heels requires a high-strength material, and Kerrie Luft selected titanium. The unusual shoes of her MA collection caused a sensation and were showcased at the Mall Galleries in London.

Additive manufacturing for the production of footwear

Laser-sintered soles, made from flexible polymer (Design and source: Ross Barber)

 

Ross Barber is another designer who combines innovative technology with the traditional craft of the shoemaker. Ross first came across tool-less laser sintering while taking a BA in Industrial Design. He then decided to use it to implement his shoe concept for an MA assignment. The latter consists of eight pairs of men's shoes that symbolize a spreading virus attack: it starts on the sole of the first pair and gradually spreads through to the shaft of the last pair.

One great advantage for designers like Ross Barber is the unlimited freedom of design offered by laser sintering. Complex geometries can be applied swiftly. Since the production technique is flexible and does not require tools, variants of an original design are simple to create too, so Ross Barber was able to apply the iteration stages of his series with minimal effort.

Jewellery & Watches - EOS Additive Manufacturing Gives Jewellery and Watch Designers Maximum Freedom in Creation

It enables individual specimens and customized serial products to be manufactured cost-efficiently.

Design Icon

Design „Icon“: Lionel T. Dean, Future Factories; Material: 18-carat yellow gold (Source: CPM)

cufflinks on building platform immediately after manufacturing

Design: Digital Forming; Material: 18 ct yellow gold; cufflinks on building platform immediately after manufacturing; (Source CPM)

post processed and polished cufflinks

Design: Digital Forming; Material: 18 ct yellow gold; post-processed and polished cufflinks; (Source: CPM)

 

EOS has optimized its Additive Manufacturing with gold in collaboration with Cookson Precious Metals (CPM). Cookson is a leading European provider of precious metal products, supplying alloys, wire, sheet, tubing, coin blanks and casting grain in gold, silver, platinum and palladium. The company is also a major precious metals refiner with London Bullion Market Association "Good Delivery" status.

Drawing on the digital data of CAD models, the EOS Direct Metal Laser Sintering system (DMLS) builds up the part layer by layer - without this process being visible in the finished product. The appearance created is entirely pure - indistinguishable from traditional goldsmith work. Unlike the latter however, Additive Manufacturing provides the option of reducing the quantity of material required. Thanks to the defined cavities, pieces can be produced more easily, economically and cost-efficiently.

Designers benefit from having complete freedom since Additive Manufacturing removes all shaping constraints. Even complex structures such as one-off interlocked or interwoven pieces can be produced in high-end quality. DLMS does not require tools, so it can be put to economical use both in manufacturing single items and for customized serial production.

Producing an item which has been designed using a CAD program is remarkably simple. DMLS draws on the digital data and a user-friendly software prepares the production process. This means that designers do not have to become technology experts to be able to benefit from the innovative advantages of Additive Manufacturing.

Lifestyle Products - Turn any Conceivable Shape into a Real Product with Additive Manufacturing

EOS Additive Manufacturing opens up a whole new universe of production possibilities for designers and design engineers.

Additive Manufacturing is not subject to design restrictions and breaks down the boundaries imposed by conventional manufacturing methods. The latter tend to be geared towards high quantities: design changes cannot be implemented at short notice and individualized serial production involves considerable effort. This puts pressure on companies in areas such as jewellery and watches, footwear and web applications: they struggle with increasing raw material prices, rising demand for individualized products and a need for more flexible and decentralized serial production.

Additive Manufacturing provides new solutions to meet these very challenges. It opens up a whole new universe of possibilities for designers and design engineers. Users can turn virtually any conceivable shape into a real product - economically, flexibly, quickly and involving minimum use of material. By means of Additive Manufacturing, objects are built up layer by layer in a single process. Material is applied selectively as required, enabling products to be manufactured which are both stable and very light.

Additive Manufacturing is based on an entirely digital process, ensuring consistent high quality, optimum scalability and short lead times. Production is economical from a batch size of one. Some lifestyle companies have already set up special departments in which product designers systematically sound out the possibilities of the new technology. They use Additive Manufacturing to produce furnishing items such as lamps and chairs as well as fashion articles such as jewellery, handbags and glasses featuring unusual shapes and structures. In view of the benefits it offers, EOS Additive Manufacturing will become established on an equal footing with conventional production techniques in the years to come. This will lead to novel applications in the future: products such as footwear and watches will be configured online and then printed out in the store, for example.

Customer Statement: Hettich

 

Dieter Sorg, Head of CAM at Hettich talks about the use of additive manufactruing technology by EOS at Hettich, the benefits of the collaboration with EOS and the challenges that implementing the technology brings with.

Other Industrial Applications Manufactured Additively with EOS

EOS Additive Manufacturing is suitable for a great many industrial applications. It is also a fast, flexible, and cost effective solution for the production of complex parts.

The innovative Additive Manufacturing (AM) technology offered by EOS also finds application for industrial heat exchangers. Often, these must supply and draw off thermal energy as efficiently as possible in confined spaces. In addition, some applications require that the heat exchanger geometry is adapted to the part that must be cooled – a complex step that conventional production methods can realize only with difficulty. This imposes limitations on designers who must develop end products as a compromise between an optimized layout and its technical feasibility.

EOS AM technology, on the other hand, provides maximum freedom of design, and so opens up new paths for the geometrical layout of heat exchangers. For instance, turbulators can be integrated in fluid channels. Turbulators deliberately generate turbulence in the flow for optimized heat transfer. The technology used in the laser sintering systems can therefore build up highly compact and highly efficient designs that can also be adapted to the installation environment. This Additive Manufacturing (AM) method does not need any tools, so single, individual items can be produced requiring almost no additional costs.

Complex Components for Special Machinery Manufactured Additively with EOS

EOS Additive Manufacturing enables machine building companies to produce high-quality metal and plastic parts cost efficiently – even down to a batch size of just one.

Frame System for EOS Formiga P 100 1Frame System for EOS Formiga P 100 2

Frame System for EOS Formiga P 100 (Source: EOS)

Mirror Deflection Unit for EOS Formiga P 100Laser Adjustment Unit for EOS Formiga P 100

Mirror Deflection Unit and Laser Adjustment Unit for EOS Formiga P 100 (Source: EOS)

Powder Dispenser Unit for EOS Formiga P 110 2Powder Dispenser Unit for EOS Formiga P 110 1

Powder Dispenser Unit for EOS Formiga P 110 (Source: EOS)

 

Laser sintering systems from EOS are unique in enabling components to be produced cost efficiently in small volumes down to a batch size of just one. This is a huge advantage in mechanical engineering in particular: here there is an increasing demand for customer-specific components and individual part manufacturing. The components in question are mainly plastic or metal. The production of these components in small batches is a complex matter that is rarely profitable. For example, injection moulding tools are usually required for the production of plastic components. These are expensive and generally have an impact on delivery dates.

The Additive Manufacturing process from EOS is based on metal and plastic laser sintering and offers numerous advantages to machine building companies: It means that they can produce complex components almost overnight by making direct use of the CAD construction data. It is also possible to make changes at short notice without requiring tools.

EOS technology offers users maximum freedom when constructing components. The layered structure makes it possible to apply material in a targeted way and therefore to produce very light and yet rigid components. These can even incorporate functions like hinges, air ducts or fluid lines.

EOS has developed an extensive portfolio of high-performance materials designed to meet the various demands of its customers. It is also possible to produce spare parts with almost no lead time. These are also available without any time constraints.

Handling and Robotics with Innovative Additive Manufacturing Technology from EOS

Automated handling devices and robotic systems often form the heart of industrial production. The gripper systems used must always be designed specifically for the product to be transported.

The greater the variance of the products, the greater the need to adjust the gripper systems accordingly. In addition, the productivity of a production machine is often directly proportionate to the acceleration capability of the gripper systems. Lightweight grabbers thus play a central role in handling and robotic system applications.

The innovative Additive Manufacturing (AM) technology from EOS offers ground-breaking benefits in relation to the design and manufacture of gripper systems: The targeted use of materials means that even complex structures can be produced as stable lightweight components. The reduced moving masses have a positive direct effect on the achievable acceleration and therefore on the productivity of the machine. AM makes it possible to adjust the design of gripper systems very quickly if the product to be transported changes.

One of the particular strengths of laser sintering technology from EOS is the fact that functions can be integrated directly in components. Hinges, gripper mechanisms, air channels, mounts for sensors and other functions can be incorporated in the components during production. This makes it possible to dispense with additional assembly steps for many individual components, further increasing cost efficiency.