Industrialization of additive manufacturing enables mass production of customized helmets

Bicycle helmets made to measure and in an affordable framework for everyone - what was unthinkable a few years ago is now becoming reality thanks to digitalization and additive manufacturing.

The head is simply scanned with a smartphone app and the process for the custom-made helmet is initiated. Siemens, together with EOS, has supported this vision of the bicycle helmet manufacturer Hexr. Siemens' Digital Enterprise portfolio consists of software and automation solutions that optimize process steps along the entire value chain of additive manufacturing.

This holistic approach is unique in the field of the industrialization of additive manufacturing. With the help of end-to-end solutions, Siemens has created the digital twin of an industrialized additive manufacturing factory, helping to optimize the design and streamline the production processes for customized bicycle helmets even before production begins. By combining simulation, design optimization and a high degree of automation in production, the costs per part could be predicted and significantly reduced, allowing Hexr to scale the scan-to-print application to mass production.

End-to-end solutions with the Digital Enterprise portfolio
Whether Powder Bed Fusion, Directed Energy Deposition, Material Extrusion or Jetting all processes have in common that workpieces are built up layer by layer based on digital 3D design data. This makes it possible to produce highly complex structures that can be both light and stable at the same time and can also be economically manufactured individually in batch size 1. Progressive digitalization offers the possibility of optimizing additive manufacturing processes. With its Digital Enterprise portfolio, Siemens offers integrated solutions for additive manufacturing. The holistic approach, which covers the entire value chain, leads to sustainable competitiveness. More than 60 OEMs worldwide are already industrializing with automation from Siemens. Siemens itself today operates more than 200 industrial AM machines at over 45 locations and thus also occupies a leading position as a producer. An expert pool for AM design through to factory planning offers customers value-add services.

End-to-end workflow
With NX software, a leading integrated solution for computer-aided design, manufacturing and engineering (CAD/CAM/CAE), Siemens offers functions specifically for additive manufacturing. In an integrated workflow, NX covers the entire process from development and design, through preparation of the construction job, to generation of the machine code for the 3D printing system. The entire digital process chain is represented in a single, integrated, associative software environment and can be operated via a uniform user interface. This eliminates error-prone data conversion with possible loss of information content. This increases process reliability and efficiency and enables users to mass-produce high-quality products even with complex printing processes.

PLC and CNC automation solutions for production
Intelligent automation of production systems plays a decisive role in the industrialization of additive manufacturing. Totally Integrated Automation (TIA), the industrial automation from Siemens, stands for the efficient interaction of all automation components. With Simatic, the core element of TIA, users rely on a maximum of consistency. The basic automation with Simatic, the Sinamics drive system and the Simotics motors for moving the mechanical units of the machine for Powder Bed Fusion and Jetting brings benefits to users. Thanks to their scalability, these solutions can be adapted to actual requirements in an extremely flexible and economical manner. Integrated engineering and efficient programming in the TIA Portal reduce the time-to-market and diagnostic functions are projected instead of complex programming. Sinumerik's multi-axis technology opens up a high degree of freedom for Material Extrusion or Directed Energy Deposition. In conjunction with Sinamics S120 and Simotics motors, the CNC allows precise and dynamic multi-axis motion control.

Siemens Advanta with planning services for the digital AM factory
Siemens Advanta, the IoT integration branch of Siemens, supports the industrialization of AM technology with a modular approach - starting with strategy development, optimization of product design, design of the manufacturing process, piloting and profitability analysis, through to the planning and realization of a turnkey AM factory. Based on the digital twin, a flexible and scalable manufacturing concept will be developed and validated, which will already meet the requirements of a classical serial production with regards to productivity and costs before the start of production and will allow an early certification

The Additive Manufacturing Network - a digital platform for the AM ecosystem
The Additive Manufacturing Network from Siemens creates an online platform based on partnership, offering on-demand design, engineering know-how and production capacities for industrial 3D printing worldwide. The network immediately connects qualified members with each other to foster collaboration and process orchestration between engineers, procurement and suppliers of 3D printed parts. Parts buyers and manufacturing service providers benefit from the network because it gives them the opportunity to collaborate, bid, purchase and track orders. As a result, it simplifies the development of innovative additive manufacturing products and physical inventory can be replaced by digital inventory. The network also contributes to the Siemens vision of reducing the risks that can arise when entering additive manufacturing.

Additive Manufacturing Experience Center (AMEC)
Siemens has an interactive Additive Manufacturing Experience Center (AMEC) in Erlangen, Germany, where the integrated, seamless additive manufacturing process chain and AM-related products from Siemens are demonstrated. The AMEC provides an overview and insight into the various industrial AM technologies as well as information on the demanding industrial requirements for AM design, simulation and production. So far, 4,500 visitors have taken part in interactive workshops at the AMEC. Since the opening of the digital AMEC in mid-May, over 1,500 interested people have already visited the AMEC virtually. The AMEC demonstrates Siemens' experience as a producer and solution provider.

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