Technological Centre for Industrial Design and Manufacturing

PRODINTEC

EUREKA UES

KICK-OFF MEETING

ASTURIAS- NOVEMBER 13RD

PRINCIPADO DE ASTURIAS

International events:

International Descent of the River Sella(Arriondas, August)

Prince of Asturias awards (Oviedo, October)

Population: Asturias: ~ 1.063.000 ; Oviedo: ~ 200.000

A = 10565 Km2

Average temperature: Year= 12 ºC; Jan. =7 ºC; Aug.= 19 ºC

Average precipitation: Year =900 mm

Relative humidity: 88% max.

Madrid

Asturias

~ 500 KmBarcelona

Located in:

Llanes

Somiedo lakes

Beach or mountain?

Caravia

Covadonga lakes

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PRODINTEC’s role:•R&D supplier: projects for industrial companies•Technology consultancy & training•Innovation management

National & international focus•Cutting edge facilities and equipment for testing and prototypes•Interface between Industry and Academia

INTRO

“To boost the competitiveness of companies by applyingtechnological advances to their products and to theirmanufacturing and management processes”.

www.prodintec.com

main goal

AREAS DE ACTIVIDAD

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R&D ManagementIndustrial ProductionIndustrial Design

Product Design

Concept and development of product

Design to rapid manufacturing

3D Modeling for parts and assemblies. CAD-CAE consultancy and training.

3D Scanning

Rapid prototyping and pre-series manufacturing

Polyjet® Objet 3D Print

Silicon Mold. Vacuum injection of silicon or multi-material.

Rapid Manufacturing (EOS M270-DMLS)

High speed Milling (5 exes)

Micromilling (5-exes)

Dimensional Metrology

Mecatronics Department

CEM Laboratory

Maintaining technologies.

Simulation Productive process

Cost reduction

Lean manufacturing

Management project

Innovation agent

Intellectual property rights (IPR)

Technical and economicViability Analysis

R&D at international level

Audit / Benchmarking

Technology consultancy and surveillance

June-2007 7

International activities• Collaborative R+D at a low scale

– : , , BILATERAL

– EU INTERREG• 1 project ESTIIC RFID4SME

• Collaborative R+D at a great scale:– EU Framework Program and Technology Platforms

AREAS OF ACTIVITY

1. Area of Industrial Production

Continuous improvement of efficiency in processes and competitiveness (Costs & Quality). Application of the latest technologies

ServicesRapid manufacturing (EOS M270-DMLS)Polyjet® Object 3D printingZ-Corp Colour printingProcess simulationVacuum casting

IR Thermography5-axis Micromachining5-axis High Speed milling3D Scanning

PRODUCTION METHODOLOGY

Lean Manufacturing

www.prodintec.com

Optimization of organization and

productive process

Plant reengineering

Industry process simulation and

automatization

Specialization Consulting

Search for funding R&D project

Asturias Production System

GAP5S

SMED

TPM

PLANTA VISUAL

6σ

KANBAN

POKA YOKE

EQUILIBRADO DE

LÍNEAS

GEMBA KAIZEN

http://www.manufacturias.com/aps/

Industrial Production

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Calidad

Distribución en planta

Inventario

Control ubicación

Control visual

Rotura stock

Diseño puesto

Flexibilidad

Información

Mantenimiento

Formación y Motivación

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1,0 2,0 3,0 4,0 5,0

Puntuación GAP

Impo

rtan

cia

Strategic Areas for Actions: GAP (Advanced Production Management)

Cuadrante 4Cuadrante 3

Cuadrante 1 Cuadrante 2

Process simulation

Process simulation

RAPID MANUFACTURING

TECHNOLOGIES

Rapid manufacturing (Direct Metal Laser Sintering)

Fundament

Familiy of methods in order to manufacture solid parts by solidifying powder-like materials layer-by-layer by exposing the surface of a powder bed with a laser beam

EOS M270.Materials used: Fe, Ti, Fe-Co alloys

Powder Laser-Sintering Part

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The process: Laser sintering

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RM Objetives• Build REAL parts, real life properties• Reduce “time to market”• Reduce costs for complicated shapes• Bring together different functionalities in one

part• Generate new functionalities• Reduce assembly errors, and hence costs• FREE Design from the restrictions of traditional

manufacturing processes.• Access new market niches• Reduce costs for short series:

– Mass customization, batch of one, custom made…

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2.Prototype gear and production aids1 Gear CoCr: 0,4Kg, 12 h2 Tools: SS 0.09 Kg, 3.5 h

5 Gear +2 Tools: CoCr 2,09 Kg, 47h (9.4 h/e)

8 Gear +2 Tools: CoCr 3,29 Kg, 73h (9.1 h/e)

SS 17-4

CoCr MP1

SS 17-4

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3.Mould, two dies

DM 20, 3.75 Kg, 40 hours

DM20

RAPID PROTOTYPING

TECHNOLOGIES

Fundament

Building of physical model directly from 3D CAD modelUsed techniques LMT: layer-by-layer Manufacturing TechniquesAvailable materials, depending on specific technique: polymers, plastics, wax, metals…

Applications

Communication: between development/design team and with suppliers, clients, managers…

Reduction of ECO (engineering change orders)

Reduction of Time to MarketMasters for silicone moulds, investment castingDirect manufacturing / Rapid manufacturing

Rapid Prototyping

MICROMACHINING

KERN Evo

The Kern Evo is specially designed for applications requiring the following features:

5-axis micromachiningHighest precision on the workpiece (deviation of position ± 0.5 µm) Excellent surface quality Ra < 0.1 µmMilling of critically machinable materials and hardened steelHigh productivity and acceleration ratesAutomatic workpiece loading for batch production

Mechanical micromilling- 5-axis for complex geometries

Drilling of a human hair (30 micras)

Tool Diameter (e.g. R=330 micras)

5-axis mechanical milling Surface finish of up to 100 nanometers

Inspection technologies for the milling process

4. New Group of MECHATRONICS

Creation of added value productsDesign innovationDesign competitivenessElectronics design and implementation

Services

Sensor development and signal conditionIA applied to control system design:

AdaptativeFuzzyNeural

Human interface DevicesPredictive Maintenance Systems

AREAS OF ACTIVITY

Facilities

Half Anechoic Chamber+-4dB NSA5.6X8m inside2x2m cylinder max EUT volume>110dB attenuation 9kHz-18GHzFully automated antenna mast

PRODINTEC ROLE – EUREKA UES

Prodintec will mainly participate in the development of new manufacturing concepts in order to achieve effective costs, fast restructure and high product quality in production chains. The three main pillars of the Prodintec´s contribution are:

A) Implemention of Advanced Management Production methodologies. Specialists from PRODINTEC with broad experience in tools and techniques such as total quality management (TQM), lean production, Six-sigma, total preventive management (TPM), single minute exchange of die (SMED), just-in-time (JIT), human resource management (HRM) etc., will apply a methodology for objectively measuring current productivity, quantifying the possible improvement, proposing solutions and assessing the result after its implantation.

B) Plant reengineering projects. Analysis of production plants in order to solve problems related to work flows, handling, optimisation of space, warehouses, etc.

C) Process simulation services. Analysis of the solvency of a lay-out, the ergonomics of a work station, the flexibility of a work cell, etc. without the need to shut-down the plant, and without making a single move until the best possible option is identified.

Moreover, Prodintec will collaborate in possible dissemination activities derived from the project.

PRODINTEC GOALS– EUREKA UES

Our goals in participating in the project are:

a) to take part in an ambicious research project focused on restructuring modern production from hierarchical into flat, self-organized, efficient, adaptive, production systems.

b) to develop new concepts for adaptive manufacturing that combines the utilization of advanced information and communication technologies (ICT) and lean manufacturing concepts

c) to be a partner of a well-balanced consortium with European members with a wide experience in the advanced manufacturing.

MICROSRUCTURES

The current trend on many fields of science isfocused on miniaturization and automatization ofanalytical systems. This trend has produced thecalled micro-total analysis systems or Lab-on-a-chip.

For any commercial production of micro-structured componentsin high volumes and at low unit costs, a high throughput of thefabrication technology is crucial.These methods should be capable of manufacturing in a widerange of substrate materials such as polymer-based (e.g. poly(-dimethylsiloxane), PDMS; poly(-methyl methacrylate), PMMA;polycarbonate, PC) and silicon-based materials as, for instance,glass substrates.

CNC-Mechanical micromilling for manufacturing micro-structures (30microns)

SYNTEX PROJECT

New and Emerging Science and Technology (NEST)

Project sponsored by the EUROPEAN COMMISSION

OBJECTIVES:

Syntex aims at the development of:• A new measurement method to 'calculate' the degree to which certain feelings oremotionsare associated with a particular texture in an individual subject.• A new investigative method for the modeling of human interpretation of visual andhaptictextures.• A method to synthesize artificial textures specified to evoke certain feelings andemotions.

PARTNERS

NEUROPHYSIOLOGY Functional Magnetic Resonance ImagingMACHINE THAT CAN READ MINDS

For the first time in history, it is becoming possible to readsomeone else´s mind with the power of science rather than humanintuition or superstition.

fMRI shows the flow of blood in the most active parts of the brain,which “light up” in ways characteristics of specific types of mentalactivity

fMRI can even be used to track the social interaction between twopeople by scanning their brains simultaneously.

Courtesy of Frans Cornelissen, Universidad de

Groningen

UNIVERSITY OF AMSTERDAMFacial Emotion Recognition Technology

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Surgical aidsA success case

Complete redesign and manufacturing of a set of instruments for a highly innovative bone surgery

1,9 Kg SS 70 hours unattended

Saw-like geometry : processes 4 and 5

4: milling, difficult.thickness1mm

5: saw-like feature,

Long part

Complex Geometry: Restricted design

Insert capture: processes 4 and 5

Thickness 0.6 mm

complexity: Design limitations

Very long part

4: milling, difficult

Final parts: handle welding and finishing processes 6 and 7

Again Conventional processes

6: Welding both sides

7: Re-milling both sides

Finishing processes

Surgery tools: First design for the customer

PRODINTEC STAFF

Technological Centre for Industrial Design and Manufacturing

PRODINTEC

EDIFICIO CENTROS TECNOLÓGICOSPARQUE CIENTÍFICO Y TECNOLÓGICO

33203 GIJÓN. ASTURIAST +34 984 390 064F +34 984 390 061

www.prodintec.com