Additive World MasterclassSophie Jones
5th March 2015
Session 1: Understanding AMWhat is Additive Manufacturing?
What is the difference between each process?
What are the business drivers for AM?
What are the barriers?
Session 2: Building a Business CaseThe business case process
Case Studies
What future developments can we expect?
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About Us
• Newly-founded Stratasys Strategic Consulting Division
• Part of Stratasys Services Group
• Formed from the acquisition of Econolyst – a specialist
consultancy with 12 years’ of experience helping companies
understand additive manufacturing and 3D Printing technology
We provide independent, expert consulting to help global brands
understand additive manufacturing and 3D Printing technology,
identify opportunities to use the technology and develop adoption
strategies.
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Some of our projects
• Helping Philips understand & modelling the current and future economics of using Additive Manufacturing to support volume production (2014)
• Helping FedEx understand the impact of Additive Manufacturing and 3D printing on their long term revenue steam as a global logistics business (2014)
• Helping BMW understand the capabilities and limitations of low cost consumer 3D Printers used within the professional design environment (2013)
• Helping the Intellectual property office understand the legal implication of online STL file sharing website and online product design services (2014)
WHAT IS
3D PRINTING?ARE ALL TECHNOLOGIES
THE SAME?
No Consumer 3D Printing is typically associated with people printing at home or in the community
Industrial 3D Printing is typically associated with production technologies & supply chains
BUT they both produce parts by the addition of layers
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AM/3DP Processes
3D Printing / AM processes are
automated systems that take
2-dimensional layers of computer data
and rebuild them as 3D solid objects
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Not all machines are the same
$200$35,000
$1,400,000
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This is not a new concept
• 1902 - Peacock patent for laminated horse shoes
• 1952 - Kojima demonstrated layer manufacturing benefits
• 1967 - Swainson files US patent for dual light-source resin system
• 1981 - Kodama publishes 3 solid holography methods
• 1982 - Chuck Hull experiments with SLA
• 1984 – 3D Systems files US patent 4,575,330
• 1987 - Rapid Prototyping became a commercial reality
• 1990 - Layer manufactured parts used as casting patterns
• 1995 - Layer manufactured parts used as tools
• 2000 - Layer manufactured parts used as production parts
• 2011 – 45,000 ALM machines globally (in total since 1984)
• 2012 – 45,000 new machines sold in 1-year
• 2013 – 100,000 consumer & pro machines estimated
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7 Types of AM Technology
Additive Manufacturing
Binder Jetting
Vat Photo-polymerisation
Material Extrusion
Powder Bed Fusion
Sheet Lamination
Material Jetting
Directed Energy
Deposition
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Powder Bed Fusion
AKA. Selective Laser Sintering (SLS), Selective Laser Melting (SLM),
Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM)
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Vat Photopolymerisation
AKA. Stereolithography (SLA), Digital Light Processing (DLP)
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Directed Energy Deposition
AKA. Laser Cladding, Blown Powder, Wire Feed, Powder Feed, Hybrid
Manufacturing
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Sheet Lamination
AKA. Laminated Object Manufacture (LOM), Ultrasonic Consolidation
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Binder Jetting
AKA. 3D Printing, Sand Printing
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Material Jetting
AKA. Polyjet, Multimaterial Printing
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Material Extrusion
AKA. Fused Deposition Modelling
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What can we 3D print after 30 years?
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
Multimaterial – multifunctional systems
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And what are we making?
Rapid Prototyping – models for assessment
Rapid Casting – patterns
Rapid Tooling – cavities and moulds
Additive Manufacturing – end use parts
Why is AM becoming so important to manufacturers?
1. Low Volume Production
2. Design Complexity
3. Personalized Products
4. Part Functionality
5. Life Cycle Sustainability
6. Supply Chain Realignment
6 fundamental drivers
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1. Enabling Low Volume Production
Enables 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
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2. Maximise Design Complexity
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
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Flow optimisation
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Flow optimisation
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Internal flow
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Flow optimisation
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3. Product Personalisation
Individual consumer centric
products, with customer
input (low volume & complex
geometry)
• Medical devices
• Consumer goods
• Cultural & emotional artefacts
• Online design tools
• Co-creation
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40,000 orthopaedic implants 12,000,000 hearing aid shells
17,500,000 dental aligners
Product Personalization
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4. Increasing Part Functionality
AM enables 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
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5. Lifecycle 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
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1kg weight saving = $3,000 fuel saving
annually**EADS quoted by The Telegraph
5. Lifecycle Sustainability
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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)
Lots of drivers, but there are still some big barriers…
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Barriers
• Part acceptance
─Mechanical property limitations
─Surface finish
─Part accuracy
─Process variance & quality assurance
─www.Epic3DPrintingFail.tumblr.com
• Product liability
• Limited materials available
• Data protection, IP control
THE MYTH“Manufacturers will make products using AM, and consumers will repair products using AM”
THE REALITY
I can only replace 17% (€44) of the BOM by value with AM Parts
83% of parts cannot be functionally replicated
Those 17% of parts would cost €9,524 to make using current AM processes
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Conclusions
• Additive Manufacturing offers great benefits,
especially for small, high-value, complex
parts
• The benefits have to be considered against
the economics
• You need to look at all the ways in which AM
can add value to a product
Next up…Building a Business Case With AM
There is no one-size-fits-all approach to deciding if AM is suitable for you
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Our Methodology
• What considerations are
important when you’re
building a business case?
• How do you select the
most appropriate process?
• How do you estimate cost
to print?
www.wi l l i t3dpr in t .com i
Let’s look at some case studies…
Acetabula JointsOrthopedic Implants for hips and knees
Average implant costs around $6,000
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Why Use AM?
Personalized Products
Increased Functionality
Implants require a special
surface to allow bone to
fuse. This is expensive and
surrounded by IP.
Implants can either be
patient-specific or made to
stock
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Alternatives to manufacture
- CNC Machining, followed by a
plasma coating process
- Manufacturing costs for a
traditional implant are $1,716
- The cost is driven by the
high cost of the coating
process
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Implants
Titanium
50 50 50
10
?
?
?
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Implants
Could be made nestable
In body – biocompatible,
Constant- and shock-loading
$1,716?
?
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Implant Considerations
SLM EBM MBJ FEED
Process needs to support titanium * * * * * - * *
Process needs to support overhanging structures * * * * * * * * * *
Process needs to be scalable to production volumes * * * * * * *
Parts need to be biocompatible * * * * * * *
Component needs excellent mechanical properties * * * * * * * *
Cost needs to be comparable or lower than $1,716 * * * * * * *
108 cups = 95 hours
7,470 per annum per machine
$150 - $200 per stock cup
In-ear Hearing AidsPersonalized products
Commercialized by Siemens
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Why Use 3DP?
Supply Chain Realignment
Personalized Products
Part Functionality
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Alternatives to manufacture
- Originally made manually
- Wax impression taken
- Copy milled into moulds
- Resin cast into moulds
- Very expensive and skilled
process
- The industry faced a severe
labour shortage
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Hearing aids today
- 80% of the world’s hearing aid shells are manufactured
using Envisiontec
- Approximately 10million shells per year
- Shell costs less than $5
- Dedicated resins and machines now service market
- Optimized design featuring air vents
How will AM technology develop?
5 – 10 years outTechnology convergence & Consolidation of the Ecosystem
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Machine prices are tumbling…
SLA Viper Si2 - $250K
Formlabs Form 1 - $3.2K
Fortus MC400 - $106K
Makerbot - $6.5K
EnvisionTec
perfactory - $79K
B9 Creator - $3.5K
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…or capabilities are improving
1995
EOS M250
2015
EOS M400
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Technology Convergence
CAPABILITY
LowHigh
COST
Low
High
Not
good e
nough
Too expensive
Barriers to
technology
adoption
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Will manufacturing be disrupted?
Additive Manufacturing
Binder Jetting
Vat Photo-polymerisation
Material Extrusion
Powder Bed Fusion
Sheet Lamination
Material Jetting
Directed Energy
Deposition
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Will manufacturing be disrupted?
Additive Manufacturing
Binder Jetting
Vat Photo-polymerisation
Material Extrusion
Powder Bed Fusion
Sheet Lamination
Material Jetting
Directed Energy
Deposition
Thank [email protected]