TechCenter Additive Manufacturing: Unlocking New Opportunities for Industry

Mr Stapelmann, 3D printing has been a topic in the domestic context for several years now. However, you refer to the process as “Additive Manufacturing.” Isn’t that essentially the same thing?

Andreas Stapelmann: Fundamentally, there is no difference. That said, the term “3D printing” has certainly been in use for longer, whereas “Additive Manufacturing” is a more recent term that more comprehensively describes the underlying process. It therefore makes sense to distinguish between the two. In the past, 3D printing was largely limited to the production of conventionally designed components. In other words, it was used to produce tangible models that could be quickly held and inspected – the so-called “rapid prototyping.”

Andreas Stapelmann has been with thyssenkrupp since 1999, initially in the automotive sector and today as Head of the TechCenter Additive Manufacturing.

In additive manufacturing, we focus on developing and producing components that really work. Which would sometimes be impossible to produce using conventional means. With the help of additive manufacturing, we are able to realize completely new geometries and production methods. In short: for us, additive manufacturing encompasses the holistic development of industrial components in metal and plastic - from the idea to product and process development.

But isn't the technical side comparable? What distinguishes 3D printers for private users from your industrial printers in Mülheim?

Andreas Stapelmann: Well, first of all, we can use our printers to produce components that can be used industrially. This is because printed metal components in particular, which are equivalent to their conventionally manufactured counterparts, cannot be produced with such printers. And we have the option of using various materials approved by industrial customers. So we can print both - prototypical illustrative objects as well as functional components. Components that can carry loads, for example, because our team has proven their suitability through appropriate simulations.

In addition, 3D printers for private users have a lower reproducible quality in terms of geometric accuracy and surface quality. This severely limits their industrial usability. With our industrial printers, we can deliver precisely this accuracy, robustness and quality. Another point is, of course, cost-effectiveness: our printers take less time, their installation space is much larger. And they work extremely efficiently. All of this is crucial for the sale of our products in the end.

In traditional production, milling, punching, bending and more is done - you print. What is the advantage of additive manufacturing processes?

Andreas Stapelmann: This becomes particularly clear when you look at the entire process of creating a product. Additive manufacturing gives companies the freedom to completely rethink production. They can develop components more efficiently, flexibly and cost-effectively and give them new functions for new requirements. This ranges from more compact designs and angled channel geometries to the smallest functional structures. Such things are either not possible at all or only possible with extreme effort using conventional means. Additive manufacturing can also avoid downtimes, minimize production times and be used to produce specially tailored tools. In addition, spare parts can be manufactured to individual requirements that would otherwise be difficult to obtain or have long delivery times. And finally, it enables the cost-effective production of individual parts and small quantities, which has always been a huge challenge in the past.

Are there business areas that particularly benefit from these advantages?

Andreas Stapelmann: It's not really a question of industry. Additive manufacturing offers practically every form of industrial application the opportunity to work more economically and to implement special components and applications in process engineering. But if you want to hear examples: In chemical process engineering in particular, it is important to optimally mix or separate liquids or gases in a confined installation space under high temperatures. This usually requires geometric shapes that are much easier to implement additively or can only be implemented in this way. Other fields include aviation and shipping, where small quantities and lightweight construction play a decisive role. The automotive industry also benefits from this potential - not only in terms of faster development processes, but also in series production.

How can we basically imagine the printing process, i.e. from the first customer meeting to the finished printed product?

Andreas Stapelmann: Interested customers can send us their technical requirements and design data quickly and easily via our website . This can be a simple idea, but also the desire to explore the potential of additive manufacturing for your own company. To do this, we either design the actual 3D model for the application. Or we take up the customer's idea and work with them to develop proposals for implementation and quality assurance. This also includes training concepts with which the customer can train their employees in the correct use of the technology. Sometimes, however, customers simply want us to implement their print job. This is usually followed by finishing or post-treatment of the printed raw parts so that the component can also be assembled. Of course, we are just as well positioned for these tasks.

A look into the future of industrial production: the Mülheim printers for metal and plastic products process powdered base materials using the selective laser melting or sintering process, building up components layer by layer. Only a CAD file is required as a construction plan. The conventional process step of tool or mold making is no longer necessary.

Despite this, the competition never sleeps. Why should customers come to you in Mülheim in particular?

Andreas Stapelmann: Our customers keep telling us: "We really appreciate the fact that your proposed solutions are process- and material-neutral." And that is precisely our strength: while other providers often use individual "use cases" as an introduction to additive manufacturing, we at thyssenkrupp offer a wide range of experience in all relevant industries. And thanks to our material and service expertise, we have direct access to many potential customers - large corporations as well as SMEs and smaller companies for whom it is not worthwhile to have their own printer or who still have reservations about getting into additive manufacturing. Customers who trust us as an experienced industrial group. The key here is to complement our strengths as an industrial group, our engineering expertise and our customer base with start-up virtues such as speed.

Can you already tell us something about current orders?

Andreas Stapelmann: Since the opening of our TechCenter in September 2017, we have gained a lot of experience in over 300 projects in a wide variety of application areas - and applied this in practice, especially at industry level.

The year is almost over and New Year's resolutions are just around the corner. What will change at the Mülheim site in 2019?

Andreas Stapelmann: Developments in additive manufacturing are rapid and fast-moving - new processes are constantly coming onto the market. That's why we need to further deepen our own technological expertise in both product implementation and process know-how. This will enable us to further expand and intensify the quality of our range of services in the form of consulting, development and 3D printing. To this end, we will also continue to develop our IT tools step by step in order to identify new areas of application, further improve our processes and ultimately be able to implement them faster and in a more qualified manner. In this context, we are also constantly reviewing the extent to which we can expand our location and our capacities.

You worked in the automotive sector for a long time. What led you to seek out the new challenge in Mülheim?

Andreas Stapelmann: Until 2017, I was exclusively responsible for the research and development of drive components for many years and previously worked as a project manager for chassis components. I describe myself as a generalist and was able to take on management tasks early on as a development engineer. What has always driven me forward in my career is my curiosity and enthusiasm for new things. I like to say that staying young at heart helps even at an advanced age.

I like to think broadly, always take a holistic view of processes and enjoy working with people who are characterized by their diversity. This is more demanding in terms of leadership, but the results are simply better. I have noticed that if you stay true to this attitude, you will always discover new opportunities to expand your expertise and your network. In my opinion, all of this is not only worth a lot in the automotive sector or in additive manufacturing, but everywhere. And in the end, this thinking also led me to Mülheim.

Were there any particular printing inquiries that have stuck in your mind in particular?

Andreas Stapelmann: Immediately after opening, we had a rather unusual inquiry from the steel sector - asking whether we could also print slabs. We first had to do a bit of educational work to explain what additive manufacturing can and cannot do. I also remember our first metal print, which we took out of the printer to present to the Management Board. A lot of sweat went into achieving this goal, not just from me, but especially from our materials expert Corinna Bischof - this really great experience and the very positive feedback was fantastic.

And you printed your own Christmas presents this year, didn't you?

Andreas Stapelmann: (laughs) I'm at the TechCenter too long for that during the rest of the year. Christmas is Christmas, and this time belongs to my family. We had a wonderful holiday season - with very traditional gifts. So I prefer to share my passion for additive manufacturing with my colleagues, although my professional passion is of course also reflected in my private life. But that's also a good thing, because you're the same person in both worlds.

Would you like to find out more about the thyssenkrupp TechCenter Additive Manufacturing? You can find all information on services, materials & processes, references and contact options here.