how does additive manufacturing complement injection molding? · an injection molding design also...
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How Does Additive Manufacturing Complement Injection Molding?
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
David Tucker – HP Manufacturing System FocusJustin Hopkins – HP Application EngineeringBrian Garvey – Linear AMS
Leading the next industrial revolution
200019001800
Today1784 First mechanical loom
1780s to 1860s 1870s to 1960s 1970s to 2010s 2010s - Future
Industrial revolution Mechanical production.Water and steam power1
Mass production Electric power, labor division and assembly line
2Production automationElectronics and IT3
Digital manufacturing and smart production 3D printing, digitalization and capital efficiency
4
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.2
History is littered wrong predictions, often made by very smart, tech savvy people
3
1889: ‘No one will
ever.’ THOMAS EDISON
1903:
Horace Rackham, bank advisor warning
Henry Ford
1959: ‘World potential for
is 5,000 at most’
IBM CEO to founders of Xerox
1981: ‘
won't replace wire phones:
MARTY COOPER, inventor of
mobile phone
1992:
are a pipe dream’:
ANDY GROVE, former Intel CEO
1995: ‘ will
…catastrophically collapse’
ROBERT METCALF, Founder of 3COM
1966: ‘’
…will flop’
TIME MAGAZINE
Disruptive Technologies are not always obvious
““
1932…not the slightest indication
will ever be obtainable…
- Albert Einstein
Plastics Design based on Decades of Experience
© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.
1872First Injection Molding Machine
1956Reciprocating Screw for Performance Jump
2016HP Jet Fusion 3D 4200 printer
Six levers for disrupting the $12T manufacturing sector
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
$12T
Manufacturing
3D Printing
Manufacturing Sector offers great potential for 3D Printing Six keys to transform the $12T Market
Product capabilities
Material price Material selection
Design for additive
New supply chain
Standards and policy
Accelerate
Unlock
5
Let’s talk process
Over 30 years of
HP Inkjetinnovation…
7 HP Confidential
HP Multi Jet Fusion platform
Basic elements of the process
Fused FusedFused
Fused
Apply energyApply agentsMaterial coating
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Let’s talk science
Material properties defined by:
1) Part density• Layer must fully melt
2) Intermolecular diffusion • Polymer chains must cross
layer boundary and entangle
THEN…
3) Intrinsic polymer properties.• Molecular structure
Accuracy controlled by:
• Resolution of 2D print
• Thermal boundary growth
• Uniformity of crystallization Step and repeat
Intended output
Absorber Ink
Pattern with ink
Fusing lamp
Fuse
“Sintered”plasticSolidify
Layer of pigment
Polymer powder
Build platen
Spread powder
Layer N
Molecular diffusion, reaction and entanglement
Layer N+1
Multi Jet Fusion: “molds” one layer at a time
Area based melting throughput
Energy
Pattern
Heat signature
White powder temperature < melt
Selectivity
The more energy we put into black, the more energy goes into the white.
Materials must melt and consolidate QUICKLY in order to work. • Low melt viscosity• Highly crystalline
However, this comes with a catch…
IR spectrum
Visible spectrum
Differential energy absorbed is achieved by differential IR absorptivity.
Part temperature > melt
200
190
180
170
160
150
140
130
120
1 10
100
˚C
Let’s talk Applications
Manufacturing aids: Jigs, fixtures, and tooling
Spare PartDigital Inventory
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Development Manufacturing Service, MRO, Aftermarket
Pro
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Time along product lifecycle
PrototypingDesign Acceleration
Equipment fixtures and nests
• 2K parts for tooling
• Lead time reduction: 13 weeks to 2 weeks
• 90% cost reduction
• Reduce changeover time
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Insight: Saving in Ongoing Production Cost / Lightweight
95%Cost reduction
90%Weight reduction
Manufacturing technology:
Material:
Weight:
Cost:
MOQ:
TAT:
Manufacturing technology:
Material:
Weight:
Cost:
MOQ:
TAT:
Consolidated from 7 parts to 1
Better performing, Easier-to-build ToolsHP printheads manufacturing line: Drill extraction shoe
Machining
Aluminum
575g
450$
13
3-5 days
HP Multi Jet Fusion
HP 3D HR PA12
52g
18$
1
1-2 days
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Bridge Production
Manufacturing aids: Jigs, fixtures, and tooling
Spare PartDigital Inventory
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Development Manufacturing Service, MRO, Aftermarket
Pro
du
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lum
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Time along product lifecycle
PrototypingDesign Acceleration
Product and Tooling Development
From Prototype into production
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Nu
mb
ero
f p
arts
Early prototypes Final prototypes Ramp production Heavy production
Production
HP Z 3D CameraBrand new market space
Priority on speedand learning
3-in-1 foot
Socket Top
Lower Housing
Upper Housing
Arm Skirt (hidden)Thermal Duct (internal)
Thermal Duct
Intro MJF parts
• Cost avoidance
• Reduce design cycleby 6 weeks
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Addressed Engineering, Manufacturing and Industrial Design issues
Rapid iterations
HP Case Study
>A dozen iterations of design in less than the time to T1 of a molded part
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Full Production
Bridge Production
Manufacturing aids: Jigs, fixtures, and tooling
Spare PartDigital Inventory
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Development Manufacturing Service, MRO, Aftermarket
Pro
du
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nvo
lum
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Time along product lifecycle
PrototypingDesign Acceleration
Why Use Additive Manufacturing for Production
• Balanced capacity
• Flexible manufacturing platform
• Limited fixed cost investment
• Schedule flexibility
• Scalable
• Minimal waste
• Parts delivered ‘just in time’
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
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© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
So we started from scratch – and created a new systemBy ordering in complete sets we were able to
1 Set
Kanban [kahn-bahn] Noun 1. a just-in-time method of inventory control, originally developed in Japanese automobile factories.
Better match supply and demand
Lower our costs
Control inventory
3 Sets
KANBAN BUILDS VS. INJECTION MOLDING
80* parts
*72 unique components
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Accelerated Product Development
Enable New Capabilities
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
2
3
Design For Mass Reduction
1
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© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Optimized Fluid Management SystemsReplacing complex assemblies with a single part provides economic, logistical, and performance improvement
Invented by: Samuel Jeong
>30%total cost reduction
>$190kin capital expense
avoided
Injection Molded VersionMulti Jet Fusion
• No tooling spend or assets to manage • No assembly / testing required • Simplified supply chain and qualification • Time savings for designer
Functionality LossAn Injection Molding Design also would have functionality tradeoffs to get around molding constraints
Blades were too thin for material to be able to flow. Molding would requires much thicker structure, interfering with flow
Side walls would require draft, increasing assembly size, or decreasing flow volume
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
95xMass reduction
93%Mass reduction
Designing to Reduce Mass
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
77%Mass reduction
Plastic 3D MJF PrintingTopological design
23g
Note: this example is from HP Latex Printer
355g
Aluminum machinedTraditional design
80g
Plastic 3D PrintingBlock design
55g
Plastic 3D PrintingLight design
DesignEvolution
No design for plastic tooling 4 - 6 weeks
Internal MJF vs outsourced 1 day vs. 5 day turn for testing
2 - 3 weeks
Avoid tooling and toolingchanges
5 - 7 weeks
Ramp with tested design 0 - 6 weeks
Mfg lead time2 weeks vs 5 weeks
2 - 4 weeks
Total savings 13 – 26 weeks
Accelerated Product Development
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
New subsystems required
Design for functionality inMulti Jet Fusion only
Enables focus on “how it works” not “how to make”
Design for 3D guiding principles
Design strategy
• Commodity and custom parts
• Simple sheet metal
• Minimize custom tool partsfreeze and commit early
• Complexity and design changes in Multi Jet Fusion parts
• Don’t design to be tooled later
• Complexity through integration
• Change in Multi Jet Fusion
Schedule enablers
Results
Enables focus on integration testing
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Accelerated DevelopmentCritical path was no longer defined by tooling
Part Redesign
TestBuildToolFabrication
Tool DesignProcessSimulation
DFMPart Design
TestBuildDFMPart Design
Part Redesign
Innovative Tooling Solutions that Make Better Parts. Faster.
Linear AMS History
➢Linear Mold & Engineering Founded in June 2003
➢Specialized in prototyping of plastic injection molds & low volume production molding
➢Led the industry as an early adopter of DMLM technology
➢Combined DMLM Technology with mold-making capabilities for cycle time improvements
➢Used DMLM technology to print production parts for Oil/Gas & Energy Industries
➢Company Sold to Moog Inc in December 2015 for Metal AM Production Capability
➢Company founder purchased tooling and manufacturing business back from Moog Inc in July 2017
About Linear AMS LLC
Locations:
- 12163 Globe Street Livonia, MI 48150
- 35450 Industrial Road Livonia, MI 48150
Employees: 65
Services:◦ Additive Manufacturing
◦ Metal -DMLS – Powder Laser Bed – EOS M280
◦ Plastic - HP – Multi jet Fusion - 4210
◦ Plastic Injection Molds and Tooling
◦ Conformal Cooling using DMLM technology
◦ Laser Marking
◦ FEA Analysis for injection molds
◦ Injection Mold Part Manufacturing ◦ 9 Presses (110 ton -1650 ton)
◦ Product Design & Engineering
◦ Models & Fixtures
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Development Production Service, MRO, Aftermarket
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Time along product lifecycle
Conformal CoolingInjection Molds
Steel Injection Molds
Aluminum Injection Molds Aluminum Injection Molds
Conformal Cooling
What is Conformal Cooling?
➢ It is the optimization of cooling or heating channels that follow the shape of the molded part surface for productivity and quality improvements
➢ It is a way of reaching area in a mold that have hot or cold spots to help control the part temp. during molding.
How does Conformal Cooling help make a mold more Lean?
➢ Reducing Scrap
➢ Reducing Cycle Time
➢ Increased Capacity
How are Conformal Cooling inserts built?
➢ Simulation
➢ Design and Optimization
➢ Laser Sintering (A.K.A. Additive Manufacturing)
➢ Post Processing
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Development Production Service, MRO, Aftermarket
Pro
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lum
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Time along product lifecycle
Prototype and RampPoduction
Conformal CoolingInjection Molds
Steel Injection Molds
Aluminum Injection Molds Aluminum Injection Molds
Low VolumeProduction
Aftermarket and Service Parts
HP MJF Enables SpeedMJF Version
◦ Delivery Time = 3 Days
Injection Mold Version◦ Delivery Time = 42 Days
1. Reduce Risk of Tool Changes
2. Validates Design During Tool Construction
3. Augments Production Ramp
The Continuing Importance of Process Expertise
Additive manufacturing experts will bridge the gap from design to production
© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.
Identify the build direction
Avoid sudden changes in printed surface area
Think about packing density
Constant wall thickness 2
Think about press size 3
Identify die draw 1
Multi Jet Fusion designIM design
Changing our thinking
Design evolution
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Sample Part from Internal HP analysis
Setting Manufacturing Specifications
© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.
Understanding requirements for functionality and cost will be vital for optimizing performance
Surface Finish
Tolerances Affordability
Ductility
Thresholds
Orientation Options and Tradeoffs
© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.
Optimized for Surface Finish & Strength Optimized for Cost
Accuracy Affordability
Ductility
Surface Finish
Accuracy Affordability
Ductility
Surface Finish
Accuracy Affordability
Ductility
Surface Finish
Optimized for Accuracy
© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.
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3
2
Accommodating Variability to Improve Economics Multi-directional build layouts can
Identify the build direction
Avoid sudden changes in printed surface area
Think about packing density
Constant wall thickness 2
Think about press size 3
Identify die draw 1
Multi Jet Fusion designIM design
Changing our thinking
Design evolution
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
Understanding Thermal and Physical Behaviors on a layer-by-layer basis
Control printedarea, and keeping
it consistent
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Before - Flat
Dome
Corrugation
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Controlling Layer-to-Layer Printed Area
45
Identify the build direction
Avoid sudden changes in printed surface area
Think about packing density
Constant wall thickness 2
Think about press size 3
Identify die draw 1
Multi Jet Fusion designIM design
Changing our thinking
Design evolution
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
SOLVING FOR CAPACITY & EFFICIENCY
A high-value, highly optimized part, was creating supply chain issues
Three per build
Using design collaboration to help alleviate supply chain issues
As originally designedPrinting these three-at-a-time created supplier capacity issues at production volumes
The large number of additional builds also meant there weren’t enough other production parts to fill the unused space, drastically increasing cost per part
A Redesigned version, split into two separate parts, enabled assurance of supply and cost targets, without sacrificing functionality
1
2
As two parts
Eight per Build
A Redesigned version, split into two separate parts, enabled assurance of supply and cost targets, without
sacrificing functionality
SOLVING FOR CAPACITY & EFFICIENCYUsing design collaboration to help alleviate supply chain issues
2
As two parts
The Result was the ability to produce eight assemblies per Build
1
Chosen as the best path forward for its benefit, and low risk-profile
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
QUESTIONS
3D Printinghp.com/go/3Dprint+1 (877) 468-8369David Tucker – [email protected] Hopkins – [email protected]
linearams.com(734) 422-6060Brian Garvey – [email protected]