Electron Beam Melting is a cost-efficient and proven additive manufacturing solution that has developed rapidly over the last years as a result of dedicated system development. Significant improvements have been made concerning system productivity, system reliability and part quality of built parts, turning EBM into a mature production technology. Today, EBM is an integral part of several production chains in various applications.

EBM is used for production of CE-certified and FDA-cleared orthopedic implants. EBM is also used for production of aero engine components by several OEMs and Tier 1 suppliers in the aerospace industry, with the common goal to use the EBM technology for series production of commercial aero engine components.

Recent innovations in beam control have led to a revolutionary new melting strategy using point exposures instead of traditional hatched line melt. With Point Melt, a new journey begins in what can be achieved with EBM concerning building without any supports; surface finish and microstructural control.

Join this webinar as GE Additive’s Mattias Fager describes how Point Melt was developed and explores the many benefits that result from this innovation.

Speaker

Mattias Fager

Senior Staff Engineer, Materials Science and Engineering, GE Additive

With a background in solid state physics, Mattias Fager joined the metal additive industry in its genesis in 2001. Mattias has experience in research and development as well as sales and application development, as both as manager and tech lead. He has been an integral part in both introducing AM to the medical industry as well as guiding the GE9X LPT EBM production through the engine test programs. Mattias is one of the true process architects behind the success of EBM.

Successfully deploying metal additive binder jetting technology cannot be accomplished by simply buying and installing a machine. It requires a complete, configurable ecosystem of production hardware and software that addresses critical business objectives:  safety, quality, cost, and scale.

In order to achieve those goals, GE Additive’s Binder Jet hardware and processes were designed and tested for scaled throughput and high uptime.  The closed-loop, inert material handling system was developed with high EHS standards and minimal powder interaction. And the patented GE binding agent allows printing, depowering and sintering large complex parts with superior green strength, which promotes production automation processes.

Appropriate geometric tolerancing and dimensional control is achieved by the use of GE Additive’s Amp™ software, a single data flow from design to accurate final parts. The software characterizes the sintering process, simulates the expected deformation, and compensates the geometry to yield near-net-shape parts.

Join this session to learn more about how the GE Additive Binder Jet Line is helping customers establish full-scale production.

Speaker:

Sammie Rowe

System Validation Engineer
GE Additive

Sammie Rowe is an accomplished chemical engineer with a passion for additive manufacturing and the potential of disruptive technologies that will revolutionize the industry. She has been working at GE Additive for the past four years, where she has played a critical role in the R+D, and subsequent technology maturation of GE’s Binder Jet products.

During her time at GE Additive, Sammie has been involved in early parameter and binder development, as well as system validation. For the past three years, she has been focused on testing and validating the Series 3 Binder Jet product. Her work has helped to optimize the product performance and ensure its quality.

Sammie is particularly excited about Binder Jet’s ability to produce complex parts more quickly and at a lower cost than many other manufacturing methods. This has significant implications for a range of industries, from aerospace and automotive to healthcare and consumer products. Sammie is passionate about Binder Jet technology and looks forward to sharing how GE Additive has created a quality, production-ready machine.

During her time at GE, Sammie has received one patent and filed four others related to Binder Jet.

Prior to joining GE Additive, Sammie spent three years at GE Renewable Energy. While there, she completed the Edison Engineering Development Program and moved on to lead the testing and validation of the pitch-bearing system for onshore wind turbines.

Sammie graduated summa cum laude from the University of Kentucky with a bachelor’s in chemical engineering. She furthered her education by completing a master’s in mechanical engineering from the Georgia Institute of Technology.

Inspired by magnetic levitation technology that is being employed to propel high-speed trains, MagLev Aero is applying this next-level technology to the concept of electrical vertical takeoff and landing (eVTOL) aircraft. The company's breakthrough MagLev HyperDrive™ platform will enable a new generation of eVTOL designs that are dramatically more quiet, efficient, safe, sustainable, and emotionally appealing to the mass market.  

To achieve their goals, MagLev has enlisted GE Additive’s AddWorks™ consultancy team, recognized for extensive additive industry experience, to help take advantage of metal AM for optimal weight, performance, and repeatability in their design.
 
Join this webinar to hear from MagLev's co-founder and chairman of the board, Roderick Randall, and GE Additive’s AddWorks team leader, Dave Chapin, as they explore this exciting new opportunity in air travel and how additive manufacturing will play an important role in enabling magnetic levitation propulsion to advance urban air mobility.
 

Speakers:

Roderick Randall
Co-Founder and Chairman of the Board
MagLev Aero

Roderick Randall is a highly accomplished tech entrepreneur, senior executive and venture capitalist with more than 25 years of experience in the wireless, telecommunications, computer-networking and electric vehicle industries. He is the co-founder and chairman of the board of MagLev Aero Inc., a pioneering electric aerospace technology company headquartered in Boston that is poised to revolutionize the industry – as well as a member of The Board of Trustees at Vaughn College of Aeronautics and Technology.

Mr. Randall is an executive partner at Siris Capital Group, LLC (since 2010), and had 10 years of experience as general partner at two venture capital firms. His venture investments and PE board positions have included Tekelec (sold to Oracle), TNS (sold to Koch Borthers), Stratus Technologies (sold to SGH), YMAX (magicJackVocaltec NASDAQ: CALL), Dynamicsoft (sold to Cisco Systems), Bitfone (sold to Hewlett-Packard Company), Snowshore (sold to Brooktrout/Cantata), FusionOne (sold to Synchronoss), ProQuent Systems (sold to Bytemobile), Bytemobile (sold to Citrix) and Visage Mobile.

Mr. Randall started his career at AT&T Bell Laboratories as a member of technical staff/supervisor and holds several US patents. He currently also serves on the boards of Fisker Inc. (NYSE: FSR) and Mavenir Systems Inc. He holds a Bachelor of Electrical Engineering with Highest Honors from Georgia Institute of Technology, and a Master of Sciences in Electrical Engineering and Computer Science from the University of California, Berkeley.
 

Dave Chapin
AddWorks Application Consulting Engineering Team Leader
GE Additive

Dave Chapin has the privilege to lead GE Additive’s AddWorks Application Consulting Engineering Team. His team works daily to drive the additive epiphany with customers.Over the last 20 years, Dave has focused on bringing new technology and innovation to commercial products at GE’s Global Research, Power, Aviation and Additive divisions.

Prior to joining GE Additive, Dave most recently spent five years developing production additive aerospace parts for GE Aviation. Dave’s global consulting team brings its additive hardware design, materials, and process expertise along with GE’s deep technology expertise to partner with clients and accelerate their additive journey.

Dave graduated from Union College with his BSME and from Georgia Tech with his MSME. He resides in Cincinnati, OH with his family.

Join Kelly Brown and Nick Buhr to delve deeper into a recent collaboration between GE Aviation and GE Additive that converted four conventionally cast parts to additive and sliced up to 35 percent of their cost in the process. This game changing initiative, that took only 10 months from identifying target parts to 3D printing final prototypes, shows that metal additive can go toe-to-toe with conventional castings on price.

独Premium AEROTEC社がGEアディティブとともに、GEアディティブの金属3DプリンターM2を活用し航空用チタン部品のプロセス認証を取得した過程を紹介するウェビナー。 
特に注目すべきはM2の特徴であるデュアルレーザーによる生産性の高い造形プロセスの認証を達成している点です。 
Premium AEROTEC社でアディティブ製造部門を率いるビーレフェルト博士に話を伺います。 
*Presented in English with Japaneses subtitles.

講演者

Dr. Thomas Bielefeld

アディティブ・マニュファクチャリング統括責任者
Premium AEROTEC
1993年にライプニッツ材料工学研究所（the LEIBNIZ Institute for Material-Oriented Technologies (IWT)）にてリサーチエンジニアとして勤務。国内および国際的な研究プロジェクトを担当し、プロセスイノベーションやイノベーションの工程削減に焦点を当てたエンジニアリングチームの指揮を執る。冶金工程の短縮化に関する博士号を取得した後、彼は2000年に国際的なCIRPテイラーメダルを授与された。

1999年以来、彼はさまざまな業界で重要なポジションを務めた。ASTRIUM Spaceでは、タンク、バルブ、スラスター、チューブ、断熱材などの衛星推進装置を担当するタンク&コンポーネント生産センターの責任者を務めた。2006年にはAIRBUSに入社し、生産システムのコンピタンスセンターを担当。同センターは、カーボンファイバー積層装置と航空機組立てライン用の革新的な治具と工具の開発と製造を担当する年間6,500万ユーロ規模の拠点である。2009年のPremium AEROTEC の設立により、取締役として複数の改善プロジェクトを率いる。微細部品の供給管理およびエアロストラクチャー部門の責任者として、新規受注からサプライチェーンまでを管理するプロセスを導入した。2015年、PAGは航空宇宙産業向け生産のためにアディティブ・マニュファクチャリングの採用を決定し、彼はその責任者として技術開発、プロセスの成熟度と再現性、認証取得および連続生産に関するビジネスを率いている。

彼の科学的および技術的な知見は主に以下の通り。材料除去加工および熱処理における冶金工程の短縮化、電子ビームによるチタン合金の溶接および熱処理、レーザーによるアルミニウム合金の溶接および熱処理、チタン/アルミニウムのPBF-LBM方式。

ドイツ北部在住、既婚、5人の子供あり。

Udo Burggraf
シニアグローバル＆キーアカウントディレクター
GEアディティブ
バーググラフは1991年にシュトゥットガルト大学で航空宇宙工学の修士号を取得。ドイツ航空宇宙研究センターで国内および国際的なプロジェクト管理に８年間従事したのち、Engineering and Design AG でエンジニアリングサービスに8年間在籍し、同グループのエグゼクティブバイスプレジデントおよび理事を務めた。現在、GE Additiveのシニアグローバル&キーアカウント・エアロスペースディレクター。

Achieving AS9100/ISO 9001 certification is a crucial key for companies wishing to open the door to doing business with major aerospace manufacturers and suppliers. AS9100 creates a global standard for manufacturing compliance in the industry, so the certification process can be both rigorous and time consuming.

GE Additive Cincinnati recently achieved AS9100/ISO 9001. Quality Manager Maria King spearheaded the company’s certification efforts, and this webinar will share her learnings as she went through the process.

Topics that will be covered in this session include:

• What is AS9100? 
• What is the difference between AS9100 and ISO 9001?
• Why get AS9100 and what are the benefits?
• How long does certification take?
• Steps involved to get there
• Setting milestones and overcoming obstacles
• Next steps – other certifications

Speakers

Maria King
Quality Manager
GE Additive, Cincinnati

Maria King has 20 years of experience with GE and has held diverse roles in Supply Chain & Engineering, including EHS leader for GE Power. From there, she moved into Aviation in various roles such as Quality, Six Sigma Black Belt, Sourcing and Compliance Leader. While in Sourcing, Maria was appointed small business liaison officer and supplier diversity leader, managing the supplier strategy on $1B military subcontract spend.  She also was engineering operations leader in CMCs, supporting the NPI programs to support hardware delivery and engine certification and improved process for IP generation.

For the last five years, Maria has worked for GE Additive as quality manager. She built teams and led two sites through AS9100 certification and has unique experience in developing processes for a supply chain site that prints parts and designs/develops additive machines.  

Maria holds a bachelor’s degree in Environmental Engineering from the University of New Mexico and a master's degree in Chemical Engineering from the University of Cincinnati.

Kevin Grider
Senior Production Quality Manager
GE Additive, Cincinnati

Kevin Grider has more than 30 years of experience with GE Aviation with more than 15 year quality experience with a focus on Quality Systems (QS) and Nonconformance (NC) management. Currently, he works as the QS leader for the GE Additive Cincinnati site. Previously, he was in a global QS and NC management role. In this role, Kevin provided leadership and consultancy to all GE Aviation sites and many suppliers on FEE/ Quality System requirements while managing the Aviation NC process for over 150,000 records and performing multiple headquarter audits each year. 

In the first webinar of this two-part series, we introduced the new 3D printed heat exchanger for GE Aviation’s GE9X jet engine. This new design has a completely different profile - one that includes optimized channels and complex internal geometries that take full advantage of AM’s design freedoms. We also discussed the large opportunity for growth of applications like this in the aerospace market segment. Click on the link above to watch Part 1. 

At the conclusion of the webinar, we asked for feedback from attendees on topics they would like to hear about in more detail. We will use “Part 2” to address several of those topics.

Join James Bonar, GE Additive’s AddWorks leader focused on new product integration and technology maturation programs; Mark Fuller, senior designer with more than a decade of AM experience; and Curt Hogan, additive technologies design engineer, as they discuss:

• Management of complex CAD geometries
• Details on the development process of an AM heat exchanger
• Characterization of additive critical engine parts
• Certification and qualification of thermal management devices for aerospace

Speakers

James Bonar
AddWorks people leader focused on new product integration and technology maturation programs
GE Additive

James Bonar has 10 years of aviation experience at GE. He has executed both new-product integration and technology maturation programs. James worked on some of the earliest trade studies at GE in both military and commercial programs to understand additive thermal technologies and the potential to reduce part counts, increase performance, reduce cost, and change the traditional supply chain. The furthest maturity of these efforts resulted from his leading the additive heat exchanger team through GE9x certification for production. James is a GE Additive AddWorks people leader and has a Bachelor and Master’s of Mechanical Engineering degrees from the University of Cincinnati.

Mark Fuller
Senior Designer
GE Additive

Mark Fuller is a senior designer with 11 years of experience in additive manufacturing. He started with GE Additive in 2017 and before that Gulfstream Aerospace. He is extremely passionate about additive manufacturing and pushes the limits of the technology daily. Mark enjoys helping customers on their metal additive journey. He has designed a wide variety of DMLM parts for military heat exchangers as well as larger 250lb rocket parts. Back in March of 2020 his simple plastic 3D-printed face mask was certified and approved for use by the Navy and National Institute of Health. To date, over 200,000 units have been produced to help with the fight against Covid-19.

Curt Hogan
Advanced Lead Engineer
GE Additive

Curt Hogan is a mechanical engineer who enjoys the details of data. A University of Cincinnati graduate with Bachelor and Master’s degrees in Mechanical Engineering, Curt has nine years of experience with GE, including five years designing additively manufactured aviation components. He is a former hardware owner of several new product introductions for GE Aviation, including the first aluminum additive heat exchanger certified by the FAA for use on the GE9X engine. Curt is currently an advanced lead engineer within GE Additive’s AddWorks team, continuing to progress the thermal technologies of additive for both commercial and military applications.

Volunteer Aerospace is an advanced manufacturing company that was founded in 2016 to promote additive manufacturing and offer customers solutions that were not available in the marketplace. The leadership team at Volunteer has a combined 32 years in additive manufacturing and offers advanced manufacturing solutions to meet any project needs.

Join GE Additive’s webinar to hear Volunteer Aerospace co-founder Jonaaron Jones explain how their acquisition of a Concept Laser X Line 2000R expands the company’s additive capabilities and enables them to drive true customer outcomes and reduce costs for single, large parts all the way to serial production. Rene du Cauze de Nazelle, Senior Product Manager as GE Additive,  will also walk you through the latest upgrades of the X Line 2000R that offers the unique ability to print otherwise impossible parts safely, efficiently, and consistently. With a generous build volume of 400 x 800 x 500 mm, the X Line 2000R offers reliable, consistent performance with one of the largest build volumes available today. The X Line 2000R was designed specifically for the production of large, quality parts, which makes it ideal for a variety of industries, including space, aviation, and automotive.

 
Speakers

Jonaaron Jones
Vice President of Manufacturing
Volunteer Aerospace

Jonaaron Jones serves as Vice President of Manufacturing at Volunteer Aerospace. He founded Volunteer Aerospace along with Devon Burkle and Rachel Jones in 2016 to advance additive manufacturing and offer customers solutions that were not available in the marketplace. He manages all aerospace and defense systems projects and production in addition to leading research and development efforts. Jonaaron has an extensive background in metal joining technologies including welding and various metal additive manufacturing processes.

René du Cauze de Nazelle
Senior Product Manager
GE Additive

With more than three years of experience in several engineering roles in additive manufacturing, René du Cauze de Nazelle is currently the Senior Product Manager for GE Additive’s X Line direct metal laser melting (DMLM) machine. Before working in additive manufacturing, René worked in a variety of engineering roles at GE’s Global Research Center in Munich, supporting various industries, including oil & gas and aviation. René holds a master’s degree in Space & Aeronautical Engineering from Imperial College London.

The M2 Series 5 provides an increased level of productivity and faster builds that help drive lower cost for your business. Finer feature resolution, improved part quality and consistency enables you to unlock new revenue opportunities with new and innovative designs and builds.

The powerful dual laser system provides up to 100% coverage per laser and 2x faster build speeds. Due to the small spot size of 70-500 microns, multiple exposure strategies within a single part are possible. The M2 Series 5 offers full control of the process critical variables. The flow-optimized build chamber provides a constant gas flow due to volume flow monitoring. In addition, multiple internal sensors ensure a more controlled build environment, resulting in significantly better part quality and consistency which are critical for safety relevant industries like aerospace and medical.

With the new all 2 x 1,000W laser option, the M2 Series 5 now offers even more productivity, safety and ease of use for the customer that further helps to reduce time and costs and increase profitability.

Speakers

Jon Ortner
Senior Product Manager
GE Additive

Jon Ortner is the Senior Product Manager for the GE Additive Concept Laser M2 machine. He started at GE Aviation as a mechanical engineer in 2007 & while there he worked as an additive manufacturing engineer & developed manufacturing processes & machine technology for Aviation part production. After the acquisition of Concept Laser, he relocated to Germany to develop machines to meet the demanding needs of GE Additive customers using additive manufacturing at scale.

Premium AEROTEC and GE Additive have been partnering on the serial production of titanium parts for the aerospace industry for over five years now. Until recently, only parts that were built with a single laser per part on GE Additive's Concept Laser M2 were able to be qualified for aerospace. This limitation affected the productivity of the machines and technology. The stitching zones of the different lasers were the critical piece in the qualification. Together, we reached a major milestone with the validation of a part that was produced in line with the process qualification requirements with two corresponding lasers. Overcoming this challenge will allow a major productivity increase.

Join this webinar to learn from Dr. Bielefeld, Head of Additive Manufacturing at Premium AEROTEC, and Udo Burggraf, Senior Global and Key Account Director Aerospace at GE Additive, about the process to get to this validation and get a look into the future collaboration of the two companies.
 

Speakers

Dr. Thomas Bielefeld
Head of Additive Manufacturing
Premium AEROTEC

In 1993 he started his professional career as research engineer at the LEIBNIZ Institute for Material-Oriented Technologies (IWT). He managed national and international research projects and headed an engineering team focussed on process innovation and process chain reductions. After an outstanding PhD on short-time metallurgical effects in metals Thomas was awarded the international CIRP Taylor Medal in 2000.

Since 1999 he took leading positions in different industries. For ASTRIUM Space he served as Head of Production Center Tanks & Components with responsibility for satellite propulsion equipments like tanks, valves, thrusters, tubings and insulation. Joining AIRBUS in 2006 he get in charge of the competence center for production systems, an annual 65 M€ business on developing and producing advanced jigs & tools for carbon fiber placement and aircraft assembly lines. With foundation of Premium AEROTEC 2009 Thomas served the Board of Management on several improvement projects. As Head of Supply Management Detail Parts and Aerostructures he implemented new order and operational supplier management processes. 2015 PAG decided to industrialize Additive Manufacturing for aerospace serial production and Thomas as Head of AM leads the activities on technology development, process maturity and reproducibility, qualification and serial production.

His scientific and technological background is mainly in the field of short-time metallurgical effects in material removal and thermal processes, electron-beam welding and heat treatment of titanium alloys, laser welding and heat treatment of aluminium alloys and PBF-LBM of titanium/aluminium.

He lives in North Germany, is married and has 5 children.

Udo Burggraf
Senior Global and Key Account Director
GE Additive

Udo Burggraf has a master degree in aerospace engineering from the University of Stuttgart from 1991. He spent his entire professional career in the aerospace industry incl. eight years in national and international project management at the German Aerospace Research Center, followed by eight years in engineering services at Engineering and Design AG most recently as EVP and member of the group’s executive board. Today he is acting as Senior Global & Key Accounts Director Aerospace for GE Additive.