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