3d printing for development hack day in bucharest, session 1
Post on 20-Oct-2014
687 Views
Preview:
DESCRIPTION
TRANSCRIPT
www.econolyst.co.uk Friday 22nd June 2012 - Romania
Dr Phil Reeves - Managing Director, Econolyst Ltd, UK
The 3D for Development Challenge -Bucharest -
Slide 1 of 62
• Personal introduction
• What is 3D Printing & Additive Manufacturing
• What is the current state-of-the-art in 3DP/AM
• What drives companies to use this technology
– Economics, geometries, environment, personalised products, increased functionality, new supply chains
• The growth of low-end / home consumer 3DP
Session 1 – the background (1-hour +)
Slide 2 of 62
About Econolyst
• Econolyst is a UK based consultancy dedicated to the Additive Manufacturing & 3DP sector
• Established 2003
• Built on almost 20-years of AM experience
• Clients in the UK, Western Europe, Scandinavia, Benelux, USA, Israel, India, Middle East & Far East, Africa
Slide 3 of 62
What we do at Econolyst
• Help companies implement 3DP & AM
technology (from design to retail)
• Deliver AM focused training & conferences
• R&D project management & delivery
• AM software development — Establishing supply chain Carbon footprints
— Developing AM part cost and value models
Slide 4 of 62
Things that keep my office busy
• Helping the world largest jet engine maker (GE) use AM
• Helping a global sports brand (Nike) to use AM
• Helping India's largest jewellery retailer (Tanqish) implementing direct metal printing of precious metal into 150 shops
• Advising one of the worlds largest chains of high street chemist (Boots) on how to use 3DP (glasses, hearing aids, drugs)
• Advising VC’s and Private Equity companies on investment in AM
• Advising the UK government on investment strategies to support AM R&D
• Advising the UK Ministry of Defence on AM/3DP capabilities to support security and warfare out to 2030
Slide 5 of 62
So what is 3D Printing & additive manufacturing?
Slide 6 of 62
Agreeing terms – setting the context
Additive Manufacturing is the manufacture of ‘end-use’ component parts using
Additive Layer Manufacturing processes
Slide 7 of 62
What is a 3D printing systems
3DP processes are automated systems that take 2-dimensional layers of computer data
and rebuild them into 3D solid objects
Slide 8 of 62
• AM is also refereed to as: – Generative Manufacturing – Germany
– eManufacturing - Germany
– Constructive Manufacturing - Germany
– Additive Layer Manufacturing (ALM) – Scandinavia & EADS
– Direct Digital Manufacture (DDM) – USA
– Freeform Fabrication (FFF)– USA
– Solid Freeform Fabrication (SFF) – USA
– 3D Printing (3DP)- Global
– Rapid Manufacturing – Global (historic)
Agreeing terms – what’s in a name
Slide 9 of 62
How does the 3D Printing process chain work?
• Start with a 3D geometry • Generate STL file • Orient parts to optimum build
direction • Generate support structures • Slice part & supports
horizontally • Consolidate, deposit or cut out
layer • Index machine down (or up) by
one layer thickness
Link to Video
Slide 10 of 62
There are Four fundamental manufacturing principles:
• Subtractive
– Material is successively removed from a solid block until the desired shape
is reached (2.5M BC – Hominids)
• Fabricative
– Elements or physical material are combined and joined (6,000 BC –
Western Asia)
• Formative
– Mechanical forces and, or heat are applied to material to form it into the
desired shape such as bending, casting and molding (3,000 BC – Egyptians)
• Additive
– Material is manipulated so that successive pieces of it combine to make
the desired object (1984 – Californians)
How does ALM differ from traditional manufacturing
Slide 11 of 62
So what is the current state of the art in 3DP/AM in
2012?
Slide 12 of 62
We have an ever increasing range of technologies
High end
– Stereolithography IPro (3D)
– Selective Laser Sintering (3D & EOS)
– FDM Fortus (Stratasys)
– Connex (Objet)
– Perfactory XE (Envisiontec)
Mid range
– 3D Printing (Voxeljet)
– Stereolithography Viper SLA (3D)
– Polyjet Eden (Objet)
– 3D Projet (3D systems)
– Perfactory (Envisiontec)
Very low end (home users)
– Ultimaker
– Bits-from-Bytes (3D)
– MakerBot
– UP personal printer
– Fab@Home
– PrinterBot
Lower end (desk-top)
– 3D Printing (Z-Corp)
– Ultra Z-Printer (Envisiontec / Z-Corp)
– 24/30 (Objet)
– FDM Dimension (Stratasys)
– UPrint (HP / Stratasys)
– Laminated Objet Manufacture (Mcor)
– V-Flash (3D Systems)
Slide 13 of 62
Today we have a ‘pallet’ of around 200 materials
Waxes
Polyamide (nylon)
Organic
materials
Polymeric
materials
Ceramic
materials
ABS
Filled PA
PEEK
Thermosetting epoxies
Ceramic (nano) loaded epoxies
PMMA
Polycarbonate
Polyphenylsulfone
Tool Steel
Aluminium
Titanium
Inconel
Cobalt Chrome
Copper
Stainless steel
Mullite
Alumina
Zirconia
Gold / platinum
Silicon Carbide
Hastelloy
Aluminium loaded polyamide
Beta-Tri calcium Phosphate
Silica (sand)
Plaster
Graphite
ULTEM
Tissue / cells
Metallic
materials
Slide 14 of 62
So what drives companies to adopt Additive
Manufacturing (or be interested)?
Slide 15 of 62
The core business drivers to AM adoption
1. Economic low volume production
2. Increased geometric freedom
3. Increased part functionality
4. Product personalisation
5. Improvised environmental sustainability
6. New supply chains and retail models
Slide 16 of 62
Lets consider these drivers with some case studies
Slide 17 of 62
1. Enabling low volume production
• Enabled the economic manufacture
of low volume complex geometries
and assemblies
– Reduces the need for tooling (moulds /
cutters)
– Reduced capital investment &
inventory
– Simplifies supply chains & reduced
lead times
Slide 18 of 62
Example – unit volumes of 1
• Bentley is a subsidiary of Volkswagen
• Vehicles from $250K - $1M
• In-house polymeric and metallic AM capacity
Slide 19 of 62
Example – Low volume production
• Problem – customer with limited mobility needed a reversed dashboard
• Production substrate produced by RIM
• Manual modification time consuming
• Solution – Laser Sintered AM part with leathers and veneers veneers
Images courtesy of Bentley
Slide 20 of 62
Example – Low volume production
Images courtesy of Bentley
Slide 21 of 62
2. Maximising design complexity & capability
• AM enables the production of highly
complex geometries with little if no
cost penalty
– Re-entrant features
– Variable wall thicknesses
– Complex honey combs
– Non-linear holes
– Filigree structures
– Organic / genetic structures
Slide 22 of 62
Example – Delphi Diesel Pump
• Conventional product manufactured by
cross drilling an aluminium die casting
• Multiple machining operations
• Multiple post processing ops (chemical
deburring, hole blanking, pressure testing)
• Final product prone to leakage
Slide 23 of 62
With AM - Design the product around the holes
Slide 24 of 62
Example – conceptual Diesel Pump
• Produce the part as one piece using
Selective Laser melting on Aluminium
Slide 25 of 62
3. Increasing part functionality
• AM enabled multiple functionality to
be manufactured using a single
process
– Replacing surface coatings & textures
– Modifying physical behaviour by
designing ‘mechanical properties’
– Embedding secondary materials (optical
/ electrical)
– Grading multiple materials in a single
part
Slide 26 of 62
Example – surface design for bone ingress
Implants (production)
• Accetabular cups
Material: Ti6Al4V
Build time: 16 cups in 18 hours
Images Courtesy of ARCAM – www.arcam.com
Slide 27 of 62
Example – Heat dissipation surfaces
Slide 28 of 62
Example – Energy absorption
Slide 29 of 62
4. Product Personalisation
• Individual consumer centric
products, with customer input
– Medical devices
– Consumer goods
– Cultural & emotional artefacts
– Online design tools
– Co-creation
Slide 30 of 62
Case study - Hearing aids
• Produced using personal data from
each individual patient
– Produced using scan data
– 20 million made every year by 3DP
– Lower cost than traditional
– Every one is different
– Improved fit for the user
– Lots of medical applications using bdy
scan data, CT & MRI data
Slide 31 of 62
The personalisation can be by the consumer
• www.makielab.com
Slide 32 of 62
The Internet lets everyone become designers
This is a bedside light
This is a lemon squeezer
This is a pall point pen
• Some web offering allow us to become the designer in an AM supply chain
– Digital Forming.com
– Jujups.com
– Sculpteo.com
– Landprints.com
Slide 33 of 62
There are lots of new interfaces
Sketch UP
Slide 34 of 62
There are lots of new interfaces
Slide 35 of 62
5. Life cycle sustainability
• Product lifecycle improvements in
economic and environmental
sustainability
– Reduced raw material consumption
– Efficient supply chains
– Optimised product efficiency
– Lighter weights components
– Reduced lifecycle burden
Slide 36 of 62
Case study – aerospace cabin component
Slide 37 of 62
A very different approach to design
Slide 38 of 62
Design optimisation for AM production
Machine from
solid billet
Topologically
optimised
Complex
lattice
Slide 39 of 62
Example – How does the weight compare
Scenario 1 – Machined from solid (0.8Kg)
Scenario 2 – Selective Laser melted lattice (0.31 kg)
Scenario 3 – Selective Laser melted optimised design (0.37 Kg)
Slide 40 of 62
To establish sustainability you have to establish life
cycle boundary conditions
Slide 41 of 62
• Example based on 90M km (Long haul) application
Process Raw
Materials
CO2
Manufacture
CO2
Distribution
CO2
Usage
CO2
Life cycle
Kg CO2
Machining 100Kg 2 Kg 5 Kg 43,779 Kg 43,886
SLM lattice 16 Kg 5 Kg 1 Kg 16,238 Kg 16,260
SLM optimal 18 Kg 7 kg 2 Kg 20,339 Kg 20,366
Environmental benefit over product lifecycle
Slide 42 of 62
So how do our lifecycle CO2 compare
Scenario 1 – Machined from solid (100%)
Scenario 2 – Selective Laser melted lattice
(37%)
Scenario 3 – Selective Laser melted optimised
design (46%)
Slide 43 of 62
Sunday Times 13th Feb 2011
Slide 44 of 62
• 0.49Kg saving per monitor arm
• $1,500 per annum in fuel savings (today's prices)
• $45,000 over 30-year aircraft life
• Product life span 5-7 years (estimate)
• Life-cycle economic saving $6.5K - $9K
• Machined part - $500
• SLM Part - $2,500
• Capital investment repaid in 2-years….
Example – life cycle economic benefits
Slide 45 of 62
This is a step change in design thinking
Slide 46 of 62
6. Supply chain realignment
• New lean yet agile business models
and supply chain
– Distributed manufacture
– Manufacture and the point of
consumption
– Demand pull business models
– Stockless supply chains
– Chainless supply chains (home
manufacture)
Slide 47 of 62
Stockless supply chains – low barriers
$50.00 each
60,000 month
$36M P/A
Slide 48 of 62
Integration with other data sources
$6.2-million (6-machines)
Slide 49 of 62
There are online printing portals to buy & sell
Slide 50 of 62
These portals have volume traffic
$44 average
price of
products
Slide 51 of 62
So what are people designing & sharing
Slide 52 of 62
But what do you do with the data? – Home 3D Printing
Makergear
Start-up Growing Established
Slide 53 of 62
MakerBot – the ‘market leader’
• Less than 3-years old
• Business based on open source
• 6700 machines sold in 2011
• $1,749 per machine
• 20,000 machines this year
Slide 54 of 62
So what are people making
Slide 55 of 62
These machines are based on open-source
Slide 56 of 62
Other supply chain opportunities for all
Slide 57 of 62
Is there a market?
1985 – 2010 = 45,000 machines 2011 = 15,000 machine 2012 = 45,000 machine
2013 = 200,000 machines 2014 = 800,000 machines
2015 = 3.2-million
Moore's law?
Slide 58 of 62
The money will also be in the data & content
Slide 59 of 62
So is AM the new Manufacturing revolution
for the digital age?
Slide 60 of 62
• Of the 200+ products, components, parts & business models we have looked at over the last 7-years, 90% were not immediately suited to AM.
– Piece part economics
– Production throughput
– Mechanical property limitations
– Surface finish
– Part accuracy
– Process variance
– Quality assurance & validation
Not yet - the harsh reality
Next session
www.econolyst.co.uk Friday 22nd June 2012 - Romania
Dr Phil Reeves - Managing Director, Econolyst Ltd, UK
Questions Econolyst Ltd
The Silversmiths
Crown Yard
Wirksworth
Derbyshire, UK
DE4 4ET
+44 (0) 1629 824447
phil.reeves@econolyst.co.uk
top related