e-Manufacturing applications:

Laser Sintering and Direct Metal Laser Sintering

current status
-AILU
Stuart Jackson
Regional Manager UK & Ireland
EOS 2007 Company Presentation CST Page 2
EOS was founded in 1989 - worldwide market leader
since 2002 for laser-sintering systems
EOS History
Source: EOS
Founding EOS GmbH - Electro Optical Systems
Pilot customer BMW.
Philosophy
1989
2002
Worldwide market leader for laser-sintering systems, the key
technology for e-Manufacturing

.
Application oriented solutions for numerous industries
Technology leader for high-end Rapid Prototyping, Rapid Tooling and
Rapid Manufacturing Systems.
Joint solutions with customers.
2008
71 Mio. Revenue in FY 2007/2008.
EOS 2007 Company Presentation CST Page 3
EOS grows its revenue at + 16 % p. a. since 2000 -
e-Manufacturing major growth driver
EOS Umsatz und # Mitarbeiter [2000 - 2006]
Quelle: EOS
Revenues
[Mio. ]
Employees
21,9
26,4
37,4
38,4
44,4
48,4
2000 2001 2002 2003 2004 2005
107 125 172 140 157 187
+16%
2006
52,3
207
EOS 2007 Company Presentation CST Page 4
EOS is the worldwide market leader, present in all
key regions of the world
Europe
EOSINT installed base of 430
Focus on Germany, France, Italy, and UK
Asia
EOSINT installed base of approx. 100
Thereof approx. 60 in Japan
Growing presence in China, India, and Korea
USA
Approx. 50 powder customers
EOSINT installed base of 40
EOS world-wide 2007
Source: EOS
EOS 2007 Company Presentation CST Page 5
EOS has subsidiaries or distribution partners in all
major markets of the world
Worldwide recognized technology
leader for high-end systems for
e-Manufacturing

Customers in > 30 countries

EOS sales subsidiaries in 5 countries
(UK, France, Italy, USA, India)
Distributors in 10 countries
5 distributors in Asia/Pacific
5 distributors in Europe and ROW
EOS worldwide 2007
Source: EOS
EOS 2007 Company Presentation CST Page 6
Sample EOS customers (incomplete)
Source: EOS
Customers from various industries all over the world
rely on EOS technologies
EOS 2007 Company Presentation CST Page 7
As of EuroMold`06 EOS rejuvenated its plastics
laser-sintering product line
EOS plastics laser-sintering product line
Source: CDR
Pictures not scaled
EOSINT P 730 EOSINT P 390 FORMIGA P 100
EOS 2007 Company Presentation CST Page 8
The EOSINT M 270 for the direct laser-sintering of
metal positions very well in the market
EOSINT M 270
Source: CDR
EOS 2007 Company Presentation CST Page 9
The EOSINT S 750 is used for laser-sintering croning
moulding material
EOSINT S 750
Source: EOS
EOS 2007 Company Presentation CST Page 10
e-Manufacturing: The business case
EOS 2007 Company Presentation CST Page 11
e-Manufacturing means the fast, flexible and cost
efficient production directly from electronic data
Source: EOS
From 3D Data ... ... to laser-sintering ... ... to the final product
e-Manufacturing process
EOS 2007 Company Presentation CST Page 12
With laser-sintering plastic parts can be built in
volumes from one-offs to several hundred thousand
Plastic parts manufactured via DirectPart
Source: EOS, Phonak, Trevisio Tecnologia
Hinged Joints IPCM Fixtures
Sunglasses
Hearing Aid Shells
EOS 2007 Company Presentation CST Page 13
Plastic parts can also be generated with tools built on
EOSINT M
DirectTool

Injection moulding tools

Injection moulding tool inserts
Blow moulding etc.
Plastic parts manufactured via DirectTool
Source: EOS, Arberg, Kashiyama Kanagata, Transcat
Mobile phone tooling Above: Twin colour key ring
Below: Fan wheel
EOS 2007 Company Presentation CST Page 14
With laser-sintering metal parts can be built in
volumes from one-offs to several hundred thousand
Metal parts manufactured via DirectPart
Source: EOS, Sirona
Chess set Dental Crowns (left: veneered) MotorSport parts
EOS 2007 Company Presentation CST Page 15
Metal parts can also be casted with patterns built
on EOSINT P
DirectPattern

Lost patterns for plaster casting

Lost patterns for investment casting
Metal Parts via DirectPattern
Source: EOS, Poggipolini
Gearbox Housing
(DirectPattern)
EOS 2007 Company Presentation CST Page 16
Metal parts can also be cast with moulds and cores
built on EOSINT S
DirectCast

sand moulds and cores

for metal castings
Engine blocks
Pumps
Hydraulic devices
Housings
Special castings
Metal parts via DirectCast
Source: EOS, ACTech
EOS 2007 Company Presentation CST Page 17
This way e-Manufacturing offers solutions meeting
current market trends
Solutions to market trends with e-Manufacturing
Source: EOS
Solutions
Rapid Product
Development
Freedom of design
Flexible manufacturing
New business models
Market trends
Mass Customization
One-off production
Shortening life-cycles
Cost pressure in development
and manufacturing
Customer proximity
e-Manufacturing

EOS 2007 Company Presentation CST Page 18

Sample applications
EOS 2007 Company Presentation CST Page 19
With laser-sintering complexity is not a cost driver
anymore - profitable business models possible
Any shape (I)
Source: Freedom of Creation, EOS
Laser-sintered handbag by Freedom
of Creation
Content
Freedom of design
Integration of functions
Minimal limitations of manufacturing
Think the impossible. You can get it.
Means
Make Mass Customization real
Add complexity
Result
Market success in low volume niche markets
Convincingly attractive product selling @ 400
project partner:
EOS 2007 Company Presentation CST Page 20
Arts and fashion industry are potential markets for
laser-sintering
Any shape (II)
Source: Connet, Ron Arad, EOS
Content
Art is not subject to manufacturing
limitations
Means
Industrial manufacturing of art
Complexity without extra costs
Result
Artists can embrace industrial
manufacturing
Artists and designer can make
visionary ideas reality
Bonsai as silver cast via DirectPattern, Ron Arad Rings and
Paeloith watch made by laser-sintering via DirectPart
EOS 2007 Company Presentation CST Page 21
EOS customers create convincingly attractive
products winning market success and awards
Any shape (III)
Source: Freedom of creation, EOS
Future Factories light + Freedom of
creation 1597: Winner of the interior
innovation award, Kln, 2006
Content
Art is not subject to manufacturing
limitations
Means
Industrial manufacturing of art
Complexity without extra costs
Result
32 cm diameter Scon with 16 cm
in height
Convincingly attractive product
selling @ 600
project partner:
EOS 2007 Company Presentation CST Page 22
Laser-sintering stems from product development -
value add for speeding up design process
Content
Prototypes
Means
Communication model for customers and
employees
Result
Reduction of development costs
Minimize development risk
Speed up design process
Anytime: Product development
Source: EOS, Shonan
Laser-sintered car dashboard module 1:2
(4 pieces)
project partner:
EOS 2007 Company Presentation CST Page 23
The future of laser-sintering is series manufacturing
- value add not only to small series
Content
Customized products
Series manufacturing (down to one-offs)
Increase number of varieties offered
Means
Reducing economies-of-scale dependency
Minimize risks by eliminating tooling
Integrate customer into product development
Result
Serve low volume niche markets
Increase customers willingness to pay
Customization (e. g. for regions)
Create convincingly attractive products
Anytime: Series manufacturing
Source: Hettich, EOS
Hettich washing rotor with inner
structures, manufactured with
laser-sintering (24 berth)
EOS 2007 Company Presentation CST Page 24
With conventional tools the product caused
significant costs in finishing
Conventional tooling manufacturing:
Variety of tools needed
32 different parts to be manufactured and assembled
Intensive post processing (chamfering)
Problems:
Burrs at berths and stainless-steel tubes
Intensive finishing required
Therefore product very cost intensive
Costs
Tools mean extensive investments
Dependency on economies of scale is significant
Assembling is cost intensive
Product prior to using laser-sintering
Source: Hettich, EOS
Hettich washing rotor with
inner structures,
manufactured with
conventional tooling (12
berth)
EOS 2007 Company Presentation CST Page 25
Laser-sintering has no fixed costs - elimination of
costs in tooling
Cost comparison laser-sintering vs. tool based manufacturing
Source: EOS
Costs Costs Costs Costs
n nn n
Laser-sintering
costs
Tool based
manufacturing
costs
No risk Still profitable N NN N
EOS 2007 Company Presentation CST Page 26
If functions are integrated with laser-sintering, the
gap widens in favor of laser-sintering
Cost comparison laser-sintering vs. tool based manufacturing
Source: EOS
Increased tooling
complexity required
to make up for the
integration of
functions.
Costs Costs Costs Costs
n nn n
EOS 2007 Company Presentation CST Page 27
Customized hearing aid shells are an ideal laser-
sintering application
Content
Customized (one-off) hearing aid shells
Large volume of one-offs
Means
Flexibility of laser-sintering to create individual
parts
Fast, industrial manufacturing
Result
Customer satisfaction
New market opportunities
Anytime: Series manufacturing - Medical (I)
Source: Phonak, EOS
Hearing aid shells
manufactured by laser-
sintering
project partner:
EOS 2007 Company Presentation CST Page 28
A continuous data flow from CAD to the finished
product is the key driver for e-Manufacturing
Anytime: Series manufacturing - Medical (II)
Source: Phonak, EOS
From wax imprint ... ... to the finished
product
... to CAD
manipulation ...
... to laser-
sintering ...
EOS 2007 Company Presentation CST Page 29
Laser-sintering implants is beneficial to patients and
reduces health care costs
Content
Patient specific implants and
prosthesis also bespoke tooling
Means
Exact fit to the patients anatomy
Mechanical follow up processes
(e. g. coating)
Result
Reduce time spent in hospital
Minimize follow-up problems
Reduce health care costs
Improve quality of life for patients
Anytime: Series manufacturing - Medical (III)
Source: EOS, Stryker
Top: Knee implant laser-
sintered on EOSINT M
Right: Dental crowns (left:
coated, right: laser-sintered
on EOSINT M
EOS 2007 Company Presentation CST Page 30
In aerospace laser-sintering can add value where
complexity and individuality coincide
Content
Design and manufacture complex geometries
Meet individual customer needs
Fit special purpose equipment
Means
Flexibility of laser-sintering to create individual
parts
Fast, industrial manufacturing
Result
Improve aircraft reliability
Boost customer satisfaction
Target new markets
Anytime: Series manufacturing - Aerospace
Source: EOS
Complex part for the aerospace industry
EOS 2007 Company Presentation CST Page 31
Jaguar uses EOSINT P Laser-Sintering technology
for manufacturing production aids
Requirement:
Cost-effective manufacturing of
production aids for the assembly of a
window opener mechanism
Solution:
Laser-sintering on EOSINT P
Result:
3 000 production aids are produced via
Laser-Sintering at Jaguar
Savings of cost and time during the
assembly process
Anywhere: Window opener
mechanism
Production aid for the assembly of window opener
mechanism. Produced on EOSINT P in PA material
(nylon).
Source: JAGUAR CARS, EOS
project partner:
EOS 2007 Company Presentation CST Page 32
Jaguar expects Laser-sintering as key for the next
generation of volume production technologies
Part used for positioning of the window opener mechanism during the assembly
process
At Jaguar XK Coup and XK Convertible assembly lines
Whereabouts of the production aid during the entire assembly process on the car
Replacement of production of injection moulding tools
Cost savings
No limitation in design
Elimination of tooling- and warehousing-costs
EOSINT as key for the next generation of volume production technologies
Details and in general
Source: JAGUAR CARS, EOS
EOS 2007 Company Presentation CST Page 33
e-Manufacturing @ EOS
EOS 2007 Company Presentation CST Page 34
Reducing
time to market
approx. 2 600 parts p. a.
Minimizing logistics
IPCM-Fixture:
Integrated functions of
high volume part
Speeding up Innovation
Tests/Mock-ups
M 270 handle: Living
design-driven manufacturing
Offering
customized products
Manufacturing
spare parts on demand
98 99 00 01 02 03 04 05 06 94 95 96 97
EOS itself is an e-Manufacturing company - 2 600
parts per year manufactured by laser-sintering
Laser-Sintering @ EOS
Source: TOM, AZ
rapid prototyping
e-Manufacturing
07
EOS 2007 Company Presentation CST Page 35
Requirement:
small series production of functional
parts in design quality
Solution:
e-Manufacturing with EOSINT
EOSINT M for small parts
Alumide

for large parts

Result:
high functionality
economical production
cost-efficient production with high
flexibility
Convincingly attractive product to
EOS and customers
e-Manufacturing @ EOSINT M 270
EOSINT M 270:
process chamber
door handle
made using
laser-sintered
parts
Source: EOS
EOS manufactures the EOSINT M 270 door handle
with laser-sintering
EOS 2007 Company Presentation CST Page 36
Door handle:
3-piece handle frame in Alumide

Button and locking device in

EOS StainlessSteel 17-4
Pin with internal features in DirectMetal 20
Alumide

parts:
built on EOSINT P 380
build time for 20 sets approx. 52 hours
Autofinish and varnishing
DMLS parts:
built on EOSINT M 270
post processed
EOSINT M 270 Door Handle - Details
Source: EOS
The handle consists of 3 Alumide parts that are
combined with DMLS parts
Small series production
of the Alumide parts in
EOSINT P 380
EOS 2007 Company Presentation CST Page 37
Source: EOS
Working principle EOSINT M 270 handle (I)
EOS 2007 Company Presentation CST Page 38
Source: EOS
Working principle EOSINT M 270 handle (II)
EOS 2007 Company Presentation CST Page 39
EOS GmbH
Electro Optical Systems
Robert-Stirling-Ring 1
D - 82152 Krailling
Germany
EOS

, EOSINT

, DMLS

, DirectPart

, DirectTool

, DirectPattern

, DirectCast

and Alumide

are registered trademarks of EOS.

Tel:
Fax:
eMail:
web:
+49 89 893 36 -0
+49 89 893 36 -285
info@eos.info
www.eos.info
Source: EOS
EOS 2007 Company Presentation CST Page 40
www.eos.info