IGA TECHNOLOGIES IS BUILDING THE MECHANICAL ENGINEERING OF THE FUTURE

Our team, lead by Alexey Siversky, head of digital twins, accumulated competencies and an integrated approach are the main advantages of working with IGA Technologies. And, of course, the Dassault Systèmes software products are some of the best on the market. These solutions for process control in industrial production are used by such giants as Airbus, Boeing, BMW, Tesla, et

Our customers come from industries such as the automotive, aerospace, industrial equipment and transportation systems. The main customers of IGA Technologies in the framework of additive manufacturing are the developers of SLS printers, the largest Russian aluminum company Russian

Aluminum (UC RUSAL), Novolipetsk Metallurgical Plant NLMK, St. Petersburg Marine Technical University. Our major clients also include the Gorskor- corporation “Rosatom”, VNIIA (NL Dukhov All-Russian Research Institute of Automation) and many others.

Additive technologies are widely used in mechanical engineering, the aerospace sector, where there is a high demand for products of complex geometry. What digital solutions does IGA Technologies has to offer for this sector?

In the production of parts using the method of additive technologies, the entire process of creating a part from powder to workpiece can be divided into several stages: design and topological optimization of the part, planning the printing process, virtual testing and reverse shape compensation. Traditionally, each of these steps is performed in separate software and has its own model for work. Data is transferred from engineer to engineer using the universal STEP and STL file formats, but in the process, some of the data is lost and version control becomes difficult.

In turn, Dassault Systèmes offers the PRINT TO PERFORM solution, which is a set of integrated applications for the full cycle of digital additive manufacturing on the 3DEXPERIENCE platform. The solution includes tools for both design and mathematical calculations, and production planning.

The key advantage of the 3DEXPERIENCE platform is that it has one data model for all domains. This greatly simplifies the organization of teamwork on a project. When promoting a product through all stages of the life cycle from department to department, the model remains unchanged, all work takes place within a single digital space. Thus, time is saved for organizing work on the project and transferring, as well as converting data. In addition, Dassault Systèmes digital products are among the best for engineering calculations. And this allows us to reduce the number of full-scale cultivation due to preliminary numerical calculations. And, of course, CATIA tools allow us to compensate for the geometry of the part, if necessary, so that it falls within predefined tolerances.

Advantages of the 3DEXPERIENCE platform when using additive technologies

A single collaborative environment for all participants in the product development process

Integration of design, production and simulation

Working with one model throughout the entire product creation process – without conversions and file sharing

Recreate rules to improve efficiency

Reduce the number of field grows with a powerful built-in virtual test module

What are the economic benefits of implementing additive technologies?

All customers want to experience the economic benefits of implementing a digital twin of their additive manufacturing. With a fully digital approach to the additive grow preparation process, we can significantly reduce the number of field grows.

The realities of additive manufacturing are such that in order to perfect the process, manufacturers are forced to make prototypes – physical prototypes of the product, which, given the high cost of the powder and the duration of printing, becomes economically unprofitable.

After the prototype is printed and analyzed, changes are made to the geometry of the product, the position of the product on the 3D printing platform, configuration of support structures, printer settings, etc. This process can be repeated many times until the desired result is obtained. In such conditions, the design and manufacture of a product takes months, rarely weeks. As a result, manufacturers are constantly looking for ways to shorten production cycle times.

I would like to note that our software products help to simulate the technological process on a virtual machine before the start of real printing. Significantly, virtual printing allows you to identify potential sources of problems – stress cracking, part deformation, part collision with the hard recoater blade – and make the necessary corrections.

An example of a successful experience of introducing additive technologies

As a first example, I will cite the R&D center IlMiT of RUSAL. Here you can see a detail of the wing mechanization created in their production and pre-designed, topologically optimized and prepared for growing using Dassault Systèmes solutions. (Note: Topological optimization is a computer-aided design method that allows you to select the filling of the design space with material, taking into account the specified target indicators, for example, stiffness, mass, stress, natural frequencies). The main requirements that the customer made for this part are durability, long service life.

The second customer that I would single out is the St. Petersburg Marine Technical University. Its specialists are engaged in the production of their own DMD-printers, and the parts grown on these printers are often very voluminous and thin-walled. When faced with the problem of buckling during

3D printing, our product did an excellent job of simulating the growth of thin-walled shells. That, ultimately, made the printing process easier and faster.

Additive technologies always come to the rescue when businesses need efficiency, flexibility and competitiveness. How does IGA Technologies see the future of additive technologies?

Additive manufacturing brings many benefits to the businesses that integrate it. Its principles are laid down in the roadmap for the development of large high-tech enterprises, including those that are part of the Roskomos Group of Companies. Russian industry is an ideal platform for the effective implementation of additive technologies, it is based on high-class specialists, and we, in turn, are ready to help them organize joint work on projects as conveniently as possible, and use additive manufacturing in the market as efficiently and successfully as possible.

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