Simulation Software

This informative feature was contributed by CENOS, a simulation software developer. Read on to learn about how 3D printing is revolutionizing the heat treat world, particularly in the production of copper coils.

3D printing, also known as “additive manufacturing,” is a hot topic now as it broadens possibilities for on-demand and customized products, even with complex geometries. It eliminates the need for welding, soldering, bending, and similar steps in coil design as 3D printers build the object in one piece and in the exact shape as drawn in CAD.

“3D printing unleashes design opportunities for induction coils, while 3D simulation software allows validating design performance. . . . We believe that 3D printing of copper will grow even more in significance for coil production, and possibly even become a part of the conventional manufacturing process,” said Max Wissing, Development Engineer at PROTIQ.

Currently additive manufacturing is widely used for steel parts, and for a long time printing machines were not able to print pure copper items. But now the technology has developed, and since the second half of 2019, it’s possible to print on demand 100% pure copper coils. Some companies with notable success offering this innovation are PROTIQ and GH Induction.

Main Benefits Simulations Enable Together with 3D Printing:

• freedom of design
• optimized geometry
• more homogeneous heating
• lower lead time
• less material waste
• cost reduction

3D Printed Copper Comparison:

RS-cooper	Pure copper
Electrical conductivity: 50 MS/m	Electrical conductivity 58 MS/m
Elongation at break: 25%	100% IACS
Improved strength for high loads	Elongation at break: 50%
Tensile strength: 230 Mpa	Tensile strength: 220 Mpa
Yield strength: 180 Mpa	Yield strength: 125 Mpa
Density: 98%	Density: 99.8%

Fewer Man-Hours, Faster Processes

Coils are a critical part of induction heat treatments as they must be replaced from time to time due to deterioration. This interrupts production and requires several man-hours for recalibration. In comparison to conventional manufacturing, 3D printing induction coils offer great benefits.

First, additive manufacturing provides better reproducibility and higher accuracy compared to the manual bending, which reduces necessary recalibration times. Second, it allows lower cost and faster production of inductors. Finally, using numerical simulation methods, the coil’s heat pattern is precisely predicted and visualized, helping optimize inductor geometry. This allows for creating a perfect coil with the first prototype.

Simulation and 3D Printing Process Illustration:

Simulations as the Enabling Factor for Coil Durability

Simulations allow full freedom of design and point out places for improvement in producing a more efficient coil production process. 3D printers build objects layer upon layer, allowing them to make even complex geometries in one piece without soldering. Simulation of the design process allows predicting coil heating, which altogether results in a longer coil lifetime. Because there is no need to bend or join parts together with heat treatment, this also allows for eliminating some intermediate steps of the supply chain. Another notable benefit is that the lifetime of 3D printed coils can exceed conventionally manufactured copper coils up to two times, as reported by PROTIQ’s automotive industry clients.

Currently there are only a few copper coil printing companies because the material is not easily processed in additive manufacturing.

Comparison of maximum copper coil dimension as a single piece:

PROTIQ	GH Induction
Length: 250mm	Length: 200mm
Width: 250mm	Width: 200mm
Height: 300mm	Height: 100mm

The possible size of the printed coils varies between really small ones, measuring only a few millimeters, and bigger shapes that are used in the automobile industry. Coils that exceed the maximum printable dimensions can be joined together afterward via welding or brazing without problems.

Regarding the time, copper coils can be printed within a few days. Compared to the conventional way, which takes up to several weeks, this method enables fast-paced product tests and generates flexibility for the customer due to shorter delivery times.

3D Printing Future Forecast

GlobeNewswire market research shows that the global 3D printing metals market is estimated at USD $774 million in 2019 and is projected to reach USD $3,159 million in revenue by 2024. This suggests we will see even more and bigger 3D printed metal parts.

In a greater perspective, Boeing is demonstrating an impressive point that additive manufacturing currently has no limits. Boeing’s GE9X engines are now fully 3D printed, combining more than 300 engine parts into just seven 3D printed components.

Taking into consideration all of the benefits listed above, one has to wonder whether additive manufacturing will become the norm in the coming decades in many of the traditional manufacturing processes.