Additive Manufacturing Design for Wärtsilä Wärtsilä was willing to redesign their valve springs press tools by having a lighter structure made by additive manufacturing. The initial “standard design” was machined and welded, but there were fears that it would not withstand the spring forces of over 30 kN generated during use. Wärtsilä involved Etteplan to co-design and rethink the manually operated pressing tool for mounting cylinder head valves. Case Wärtsilä Expertise Engineering Four potential metals were considered for the final additive manufactured component, and design objectives included restrictions on manufacturing cost and material usage. The customer also wanted to understand how quickly this type of engineering and design task could be completed. Image: Original welded pressing tool design Simulation-driven design approach To tackle this project, Etteplan assembled a team that included experts in AM production, AM design, topology optimization and print process simulation. The design workflow started with definition of available design space, boundary conditions and maximum potential loads that the tool would be exposed to during operation. Altair OptiStruct and SolidThinking Inspire software were used to run topology optimization and FEM analyses for design concept generation. Inspire PolyNURBS were used to generate smooth CAD surfaces over the topology optimized results while allowing the organic features of the design to be maintained. OptiStruct was then used for performance evaluation of the final component design, and Additive Works Amphyon software, part of the Altair Partner Alliance (APA), was utilized to simulate the print process to ensure that the component was printable and that maximum distortion levels were within reason. Image: Etteplan’s simulation driven AM design workflow for the Wärtsilä tooling case Benefits Etteplan was able to create a pressing tool design that was ready to be printed within one week from when the project starting data was frozen. The topology optimized design met both the cost and material usage targets. Additionally, care was taken so that the design was self-supporting, which further reduces manufacturing costs by eliminating material waste and minimizing post-processing costs. Keys to success Etteplan’s final design of the pressing tool for mounting cylinder head valves met and exceeded all of Wärtsilä’s initial AM design objectives. The fast turnaround in this project was made possible by assembling a team of experts who used topology optimization to eliminate excess material usage in a self-supporting design and print process simulation to guarantee that it could be successfully manufactured. Image: Additive manufactured pressing tool designed by Etteplan’s AMO team for Wärtsilä
Photonic Integration Conference 2021 Tegema Etteplan exhibits at the Photonic Integration Conference hybrid event Read more about Photonic Integration Conference 2021
Productization of Kemira’s KemConnect™ wastewater treatment solutions Kemira is a global leader in sustainable chemical solutions for water intensive industries. They provide best suited products and expertise to improve their customers’ product quality, process and resource efficiency. Kemira’s focus is on pulp & paper, water treatment and oil & gas.
Creating a digital era dental robot Rayo 3DToothfill aims to improve the lives of billions of people with affordable, high-quality dental health. Their solution provides the best results with comparable costs for the dentist and for the patients. To ensure their solution is usable in different surroundings, it is simple and easy-to use.
Beyerholm & Moe International speeds up their development process Beyerholm & Moe International are among the world leaders in the development of control units for precision milling and engraving machines. The company has a development department in Denmark, production in the United Kingdom and dealers all over the world.
EOT 2021 (Electronics of Tomorrow) TekPartner exhibits at EOT 2021 and becomes officially Etteplan from September 1st, 2021 Read more about EOT 2021 (Electronics of Tomorrow)
Etteplan helps to design and produce the battery-charging device for Oticon Medical Oticon Medical offers bone anchored hearing systems and cochlear implant solutions to address the needs of different patient groups, especially those who face the hardest hearing challenges. With its origins in Oticon, and as a member of the William Demant Group, they are international market leader in hearing healthcare.
