Meet our new PhD student Jeroen Knippenberg at AMSYSTEMS Center. During his mechanical engineering bachelor and master studies at the TU/e, he developed a passion for the engineering of high tech materials in challenging environments. This passion has enabled him to work for example on lightweight carbon fiber composite structures in racing cars and from 1 July 2017 in the challenging field of industrial additive manufacturing. Within this field Jeroen sees an opportunity to enhance his skills as an engineer and researcher while contributing to the advancement of the industrial applicability of additive manufacturing.
For the upcoming 4 years Jeroen will be focusing his fundamental research, which is part of the European Hyb-Man project, on hybrid 3D manufacturing methods for multi-material products with integrated electronic components. The goal of the methods is to enable flexible first time right production of smart systems for lighting and automotive products. “Currently the combination of multiple materials and multiple functionalities into a single AM product significantly increases the complexity of the production process,” Jeroen explains. “To be able to manufacture such products first-time-right,” Jeroen continues, “a thorough understanding of the relation between process parameters on one hand and intrinsic material properties and functionalities on the other hand is required.” For example it is important to understand the relation between sintering temperature of a conductive track and the corresponding electrical resistance. The possible track sintering temperature can be limited because of the use of other materials less resistant to temperature in the hybrid product, while the track resistance specification still has to be met. The research of Jeroen is to get this understanding by providing design rules for the hybrid 3D manufacturing process, based on the obtained insight in the process.
“The goal of the methods is to enable flexible first time right production of smart systems”
Approach and challenges His research starts with identifying individual input-output relations between process parameters and material properties. Then the relations will be studied by various numerical models and experimental material characterization. These models, each representing a small part of the production process, will be combined in a design structure matrix (DSM) and system optimization techniques will be used to identify the opportunities and constraints in the hybrid manufacturing process. Jeroen foresees a challenge in creating suitable numerical models for the additive manufacturing process, as the models are generally new for this industry. Another challenge is the effort of creating an overview in the large parameter space with these different relations. Two challenges that Jeroen is eager to take up.
Cost effectiveness and meeting rapid changing requirement Jeroen hopes successfully to develop a 3D hybrid manufacturing process that allows local production of highly personalized electronic products without the need for product specific tooling and large stock of parts or products. “Advantages of such process is the cost effectiveness of the production of the small series and rapid changing in requirements from the market can be accounted,” Jeroen says.
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After a successful kick-off meeting in April 2017 the Hyb-Man project has started, with the goal to develop hybrid 3D manufacturing methods to enable flexible first time right production of smart systems for lighting and automotive products.
Together with 11 partners from Germany and the Netherlands we will develop and integrate technologies for additive manufacturing, 3D electrical structures, 3D assembly and interconnect. First time right production will be achieved by creating design rules based on understanding of product-process relationships and by developing in-line testing and quality monitoring as integral part of the complete production chain. In parallel we will develop two innovative product cases covering different applications and sectors (LED luminaires, automotive adaptive sensors) to demonstrate the hybrid 3D manufacturing approach.
Highly flexible The resulting manufacturing process is highly flexible through the removal of product specific tooling, no large stock of parts or products, local production and form freedom in production. This results in substantial business benefits, such as: faster response to changes in the market, cost effective manufacturing of small series and customer centric solutions, and new product designs offering improved functionality and new form factors.
The project duration is 3 years, with a total effort of 56 person years from 11 partners: Philips Lighting, TNO, Bosch, Fraunhofer IFAM, Reden, VSL, Henkel, Technolution, Neotech, Xenon and Eindhoven University of Technology.
Thomas Hafkamp is one of the first doctoral students who has begun at the AMSYSTEMS Center. Following his TU/e Master at the department of Mechanical Engineering (specializing in Control Systems Technology, graduating in the design principles group), he began his PhD research for the AMSYSTEMS Center on 1 March 2016.
“AM equipment has to be scaled up to larger product formats and higher product quality if the needs of high-tech industry are to be met. To be able to achieve this we have to investigate modeling, measurement and control in industrial AM processes,” Thomas explains. “The AMSYSTEMS Center has defined two PhD assignments for the additive production of high-grade ceramic products, each concentrated on one of these three aspects,” Thomas continues. The third assignment is focused on fluid dynamics.
Tackle challenges “My research is geared to the control side of the print process and the aim of my research is to develop new equipment concepts and integrated control architectures.” The challenge faced by Thomas in his research is the simultaneous scaling up of the three characteristics of AM equipment: from its current small format to industrial scale, to boost the product quality and reproducibility, and to increase production speed. “To further develop AM technology new concepts need to be generated on the basis of a holistic, systematic approach that is able to tackle these challenges (scalability, quality, productivity) at one and the same time,” Thomas clarifies.
Cross-fertilization The collaboration between TNO and TU/e HTSC is already very noticeable and will become ever more evident. “Given the powerful multidisciplinary nature of additive manufacturing, there is plenty of potential for cross-fertilization between and perhaps even within the two organizations. It’s something I already see happening during the regular meetings of the AMSYSTEMS Center.”
The AMSYSTEMS Center had its exhibition debut at the IDTechEX, which took place on 10th and 11th May in Berlin, Germany. The booth presentation was a co-creation with BigRep, who exhibited its One printer, which continuously printed a sizeable part during the 2-days exhibition.
The 3D printed demonstrators attracted good interest from the visitors, showcasing the combination of 3D printing stereolithography (SLA) and selective laser sintering (SLS), the pick & place of electronic components and the direct write of conductive silver tracks. Program manager Wijnand Germs was one of the speakers at IDTechEX. Around 150 participants attended his presentation on the AMSYSTEMS Center program on 3D printed structural electronics.
AMSYSTEMS Center is currently bringing companies from different parts of the value chain together to accelerate the innovations in the field of industrial additive manufacturing of electronic devices with new functionalities, improved product performance, lower cost and risk in low-series manufacturing.
Have you missed us in Berlin? Please contact the AMSYSTEMS Center or come to IDTECHEX in St. Clara, USA on 15th and 16th November this fall.
Riley recently joined AMSYSTEMS Center in March and is focusing on 3D printing in medical and pharma. After seeing AMS’ automated manufacturing platform, PrintValley, he was convinced this was the vehicle for mass customization of end-use parts. Motivated to further develop this technology and explore immediate applications, Riley joined the AMSYSTEMS Center team as a program manager.
Prior to AMSYSTEMS Center, Riley cofounded a company, Arevo, which develops 3D printed composites. Located in Silicon Valley, Arevo introduced advanced materials, intelligent software, and deposition technology to print end-use production parts. Riley also worked at Stryker as an advanced senior quality engineer integrating surgeon feedback into device design prior to launch. Riley first discovered 3D printing during his master’s research on electrospun heart tissue scaffolds. He studied at UC Berkeley, where he received a B.S. in Bio-engineering and Materials Science and Engineering and an M.S. in Materials Science and Engineering.