Mann Engineering has the capability to offer design, product development and prototyping services to its customers. And in conjunction with our partners in SEAM (South East Applied Materials Research Centre) in the Waterford Institute of Technology, our Engineering Department can help with the design and development of products using 3D metal printing techniques.
As a company that is looking to the future, we are now at an advanced stage of planning to enter the Aerospace supply chain. This includes garnering both AS9100 and SC21 accreditation over the next few months. The global Aerospace market is expected to be worth $5.70 Trillion over the next twenty years. Notwithstanding, it is imperative that we as a company are aware of technological advancements, that could affect the precision engineering industry in years to come.
We have already seen the initial impact of 3D Printing in the aerospace industry so we find it prudent to partner with SEAM as they are the leaders in researching 3D Direct Laser Metal Sintering (DLMS) in Ireland
We can also carry out analysis of where potential stresses or faults may lay in a specific design using Finite Element Analysis (FEA). FEA software is capable of modelling complex components and systems such as thermal analysis and coupled-physics capabilities involving acoustic, piezoelectric, thermal-structural and thermoelectric analysis, producing stress and strain visualisations to aid in the minimisation of components weight and cost and the refinement and optimization of designs prior to manufacture
With regards to reverse engineering, we can measure existing parts using X-ray Micro tomography (XMT), develop CAD drawings and produce samples using our extensive CNC processes and/or using 3D printing giving customers the opportunity to potentially produce component that are lighter, stronger and ultimately more reliable.
X-ray Micro computed tomography (XMT)
Problems addressed: Defect analysis. Nominal comparison to CAD. Wall thickness analysis. CMM type measurements. Analysis of unusual features. Powder analysis.
Advantages: Significantly faster than micro-sectioning. Non-destructive.
3D Direct Laser Metal Sintering (DLMS)
DLMS produces components by means of Additive Manufacturing – fully automatically, without tools and based directly on three-dimensional CAD design data. For this purpose it is equipped with a 200 W fibre laser which melts fine metal powder and builds up the product layer by layer. This method allows you to create products with extremely complex geometries including elements such as free-form surfaces, deep slots and coolant ducts.
What is Additive Manufacturing and how is it revolutionising traditional manufacturing processes?
Additive Manufacturing (AM), more commonly known as 3D Printing, is a manufacturing process that transforms a 3D model into a physical object by joining together successive layers of the same material. This contrasts with more traditional manufacturing techniques, such as machining, which are subtractive, and involve removing material to create a final piece.
Advantages of AM (Additive Manufacturing)
- Design complex components without adding cost
- Surpass limitations of conventional technologies
- Change designs without hassle
- Skip investment in manufacturing tools
- Shorten time to market
- Without disrupting supply chain
Finite Element Analysis (FEA)
Capabilities: Computational technique for design optimisation and a powerful tool for understanding failure mechanisms.
Advantages: Finite Element Analysis (FEA) is a powerful, computer-based modelling tool, applicable to a wide range of industrial sectors for the design and development of products. SEAM possesses FEA software capable of modelling complex components and systems such as thermal analysis and coupled-physics capabilities involving acoustic, piezoelectric, thermal-structural and thermoelectric analysis. This enables;
- Stress and strain visualisations to aid in the minimisation of components weight and cost
- Refinement and optimization of designs prior to manufacture
Other services available:
• White light Interferometry
• SEM with EDX
• Differential Scanning Calorimetry (DSC)
• Dynamic Mechanical Analyser (DMA)
• Mechanical Testing (Destructive testing of materials)
• Smartscope CNC System
• Optical & Digital Microscopy
• Spray Drying
• Microwave Processing
Hardness Testing: A technique for small-scale hardness testing of composite structures, as well as ceramic, metallic and polymeric materials. (Vickers, Rockwell and Shore A&D Hardness).
Furnace: Equipment for production of materials, replication of thermal cycling and thermal analysis of materials to 1400°C.
Micro-sectioning: The key pieces of kit in the micro-sectioning process, namely the encapsulating materials, grinding wheel, cutting equipment and automated polishing system, are all available at SEAM. Chemical etching of metallic samples can also be undertaken to investigate the micro-structure of metal components and welds.