ThinKing May - Intelligent development and manufacturing with help from the cutting edge manufacturing technology



With Digital Twin by FEINGUSS BLANK, it is now possible to simulate production steps and identify areas of weakness before the actual production begins. Additive manufacturing offers the possibility of simulating each manufacturing step before taking the much more cost intensive steps of ordering tools and producing prototypes. These two procedures allow the actual component, as well as its production capability and cost structure, to be optimized and improved before the actual production begins.

The Developement Agency for Lightweighting Baden-Württemberg is presenting this innovation as its ThinKing for May 2017. Leichtbau BW gives this label each month to promote innovative products or services from the lightweighting sector in the federal state of Baden-Württemberg in the southwest of Germany. Is the geometry of the cast part right for the job? Is the material the optimal choice? Can material be saved? How can parts be manufactured at the lowest cost? How can the value for customers be improved? The FEINGUSS BLANK team works to provide answers to all of these questions early in the development phase of a product. Digital Twin by FEINGUSS BLANK is the key to achieving long-term customer value.

Fully digital development chain

Different simulations are possible as part of the Digital Twin process. These include material simulation, FEM calculation, solidification simulation and topology optimization. From data provided by the customer, the development chain then proceeds as a digitized simulation. The simulation results for the different design and prototype phases allows the serial production in the manufacturing phase to be tailored to provide optimal value for the customer.

After the optimization of the parts and the production process, additive manufacturing allows for a quicker time to market for innovative product solutions. The Company FEINGUSS BLANK has several processing strategies for the rapid production of affordable prototypes. Additive manufactured wax components for casting allow for the initial simulation of prototypes. The package also includes milled parts made of metal or wax for the initial attempts at production and implementation. Last but not least, the Riedlingen based company also produces additive manufactured prototypes made of metal using SLS (selective laser sintering) and other production methods.

Reduced processing effort through intelligent lightweighting

The Digital Twins simulation process offers the potential for weight optimization and reduced material and processing costs in cast component production. It also allows for the production of complex geometries, and materials can be implemented that are otherwise difficult to process. Primarily however, it is the ability to recognize and exploit the potential for savings that makes the process more economical and attractive. Other advantages include the reduction of processing effort through intelligent lightweighting, the minimization of development time and the reduction of serial production set-up costs.

The advantages of Digital Twins are clear: simulation allows for different versions of a product to be tested before the best version is selected. In addition to cost savings, the customer can also rely on secure planning and a competent and dependable development partner.