disrupting the disruption: how ge additive is pushing the ...leap engine fuel nozzle designed morris...

Disrupt … or be disrupted: Why 3D printing is changing the world of industrial design and manufacturing

GE Additivewww.ge.com/additive

23 April 2019

Additive Manufacturing …

the new revolution

Disruption is here ...

Co

st

of

ma

nu

fac

turi

ng

Degree of complexity

Conventional Manufacturing

Designinnovation

for free

Source:

Design Complexity is free

GE Proprietary Information

Additive Manufacturing

Why use Additive Manufacturing?

Faster product development times

Lighter products

Complexity & sophistication for free

Longer life, more durability

Capital equipment reductions

Better return on investment

5

1. Accelerate design innovationReduce time to market with new-to-the-world parts and

systems

2. Increase product performanceCreate parts and systems that are lighter, stronger and

more efficient

3. Reduce supply chain costNew additive designs reduce the number of total

assembled parts – potentially reducing design, sourcing

and logistic costs

4. Simplify systemsMore robust designs with reduced part counts; reduced

braze/weld/rivet/bolted joints and assemblies

Why invest in additive?

7

Examples and proof points of using additive manufacturing

LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines

PARTS20 1

DURABLEMORE5x

WEIGHT25%

REDUCTION

INVENTORY

95%

REDUCTION

COST EFFICIENCY

30%

IMPROVEMENT

Source: GE Aviation

The LEAP engine fuel nozzle

9

The a-CT7 engine mid frame – an example of additive

7 assemblies to 1

~300 parts to 1

>10 lbm weight reduction~300 1

Mid-Frame Super Structure

}Source: GE Aviation

The GE Catalyst engine

Combustor test

schedule reduced from

12 months to 6 months

PARTS855 12

LOWER20%

FUEL BURN

WEIGHT 5%

REDUCTION

Source: GE Aviation

11

GE9X engine – additive manufactured parts

FUEL NOZZLES

& COMBUSTOR MIXERS

28

PARTICLESEPARATORS

16

STAGE 5 & 6LPT BLADES

228T25 SENSOR

1

HEAT1

EXCHANGER

Source: GE Aviation

GE locomotive heat exchanger

Existing

Rad Cab

Shorten

Rad Cab by ~ 80”

Next gen

Rad Cab

Opens up cost out and new opportunities

SMALLER70%

PARTS2000 1

COOLER

TIER IV EGR

Source: GE Transportation

© General Electric Company – All rights reserved

Reducing satellite antenna components from 100 parts to 1

95%WEIGHT

REDUCTION

11MONTHS LEAD TIME

2

75%REDUCTION

NON RECURRING COSTS

“It’s easy to add features to an existing AM design, easier

to assemble the finished components and, long-term, you

have less testing, maintenance and service when you have

fewer parts.” Rob Smith, COO, Optisys

Stryker medical implants

Courtesy of Stryker Medical

© General Electric Company – All rights reserved

Mass customization for dental

Full production of precious metal dental restorations with a 2-day turnaround

WEIGH

Gold crowns printed on the

Concept Laser Mlab cusing

“…You didn’t restrict us to use

certain materials or exclusively

enforce the use of an OEM’s

powders. It is this flexibility,

coupled with developing our

own parameters, that made

Concept Laser a winner”.

-Paul Cascone, Sr. Vice

President of R&D, Argen

All pictures provided by Argen Corporation, USA

14-unit bridge, printed on

the Concept Laser Mlab

cusing

Single unit crowns and

bridges, printed on the

Concept Laser Mlab cusing

GE Additive

GE’s additive journey … so farT

ech

no

log

yIn

fra

stru

ctu

re

2010 2012 2014 2016

GE Aviation’s

additive team

formed

LEAP engine

fuel nozzle

designed

Morris

Technologies

acquired

1st Heat

exchanger

printedGE90 engine

T25 Sensor

certified

Fuel nozzle

certified

GE Aviation

Additive Technology

Center (ATC) opened

Center for

Additive Technology

Advancement

(CATA) opened

Arcam AB

& Concept Laser

acquired

a-CT7

demo engine

GE Catalyst

engine prelim design

GE Power

F-Class Flex Tip

GE Oil & Gas

Nova LT

Swirler

GE9X LPT Blade

certified

GE Additive

launched

2018

New machine

production

CEC Munich

CEC Pittsburgh

opened

Acquisition

of GeonX

2017

Our ecosystem, built around our customers

• Materials Solutions

• Disruptive Design Solutions

• Industrialization

• Pittsburgh, PA

• Munich Germany

Machines & Services

Materials

Engineering Consultants (AddWorksTM)

Software

Customer Experience Centers

Partner companies

• GE Capital, Financing solutions

• GE Global Research Center

• GE Digital

• GE Inspection Technologies

• Manufacturing Partners

• Concept Laser, Direct Metal Laser Melting

• Arcam EBM, Electron beam melting

• AP&C advanced powders

• Additive powder supplies

• Tested and validated

• GE Digital

• GE Global Research Center

• GeonX

GE … additive by the numbers

EMPLOYEES HIRED

1200LOCATIONS

9

PROJECTS IN PROGRESS

1000+PARTS IN THE FIELD

50K+

MACHINES IN FIELD

1350

OPPORTUNITY BY 2026

$76B$

GE Additive

GE businesses

• Machine types for every application

• Field of application from Rapid Prototyping up to integration in the production environment

• Build space from small (50 x 50 x 70 mm3) to large (800 x 400 x 500 mm3)

• Laser power of 100 watts up to multilaser solutions

• Supreme Quality in Mechanical Engineering

• Innovative Quality Monitoring Systems

• Safety and ease of use as top priority

• Machine design in accordance to ATEX directives

• Spatial separation of process and handling chamber

Direct Metal Laser Melting (DMLM)

M Lab M LINE FACTORY

X LINEM2

High power (3,000 W)

• Allows for high melting capacity

• High productivity

No moving parts in the EB-gun

• Extremely fast and accurate beam control

• Power and focus continuously varied

• Enables EBM MultiBeam™

Vacuum process

• Clean and controlled environment

• Allows processing reactive materials

Hot process (650 °C for titanium)

• No residual stresses

• No heat treatment

• Faster melting

Electron Beam Melting (EBM)

Q10plus Q20plus A2X

22

AP&C offers quality powders designed for the

EBM and DMLM process and will work with the

customer to optimize their powder

specifications for their technology and

application.

AP&C has a validated powder supply chain with

full traceability of every powder batch delivered.

All powders supplied by AP&C are extensively

tested before release to customers,

AddWorks helps your organization successfully

navigate their additive journey.

• Identifies positive use-cases (better performanceand/or cost-reduction)

• Co-designs parts/introduces disruptive design

• Prints prototypes and small-run production

• Begins cultural transformation and training

• Develops adoption roadmap

• Helps to build your business case for transforming operations

AddWorks™

Customer Experience Centers

Machine accessAccess to the latest metal additive machines (Direct Metal Laser

Melting and Electron Beam Melting).

AddWorksCollaborate with our additive experts on product identification, design,

material selection, process optimization and on your own additive

facility plans.

PrototypesBuild prototypes and see your product designs come to life.

Low rate initial productionBuild multiple parts and design your operations process prior

to starting your own full-rate production.

Additive AcademyReceive training from our team of additive experts in all aspects of

additive manufacturing.

Spare parts and powderAccess to our customer support team who can provide machine and

material knowledge, machine spares and operational support to

customers.

PRIMARY AND SECONDARY SCHOOLS

• $2 million for 3D-printing equipment and curriculum

• Focus on STEM/STEAM programs

• Over 400 recipients in 2017

• Approximately 180,000 students impacted worldwide

COLLEGES AND UNIVERSITIES

• $8 million for metal additive manufacturing

equipment

• Focus on additive learning efforts

• Eight recipients in 2017

GE Additive education program

© General Electric Company – All rights reserved

Investing in the future

When we end our day, I may see about

20 designs that were created, but when we start

the next day I see that number increase to about 50.

They are even designing at home.”

Irene Barry-Philord

Eneida M. Hartner Elementary, Miami, Florida, USA

“