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3D printing is revolutionizing every industry around the world.

We speak to the CEOs, vice presidents and decision makers at businesses

that are at the cutting edge of the cutting edge.

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

Courtesy of Invent Medical

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This revolution isn’t restricted to one or two

markets. Any industry that relies on manufacturing

can benefit from change, whether that’s through

efficiencies or a new, disruptive way of thinking.

To demonstrate the views from the boardroom,

we’ve spoken to chief executive officers, chief

operating officers, vice presidents — and many

of the people “on the ground” who are putting

the theory into daily practice.

Some of the stories you will hear come from industry

leaders. Take BMW, which has just produced its one

millionth part using HP Multi Jet Fusion 3D printing.

Or Volkswagen, which is integrating HP Metal Jet into

its design and production roadmap.

We also speak to the world’s third largest

contract manufacturer, Jabil — one of the world’s

most technically advanced manufacturing solutions

providers, whose products you will almost certainly

have in your home. They are using HP’s 3D printers

to nimbly respond to demand, producing large

volumes of products that will also satisfy their

demanding clients’ needs for quality.

Other companies are taking a disruptive approach.

We speak to startups who are embracing

the personalized nature of 3D printing to create

unique, one-off products to satisfy a user demand.

That varies from LookReal, manufacturers

of customized dolls that have the same facial

features as the children who they’re made for,

to an Australian orthotics company that creates

parts perfectly tailored to the patient.

One thing links all these companies, they’re

thinking big. We constantly hear the words

“scalable” and “global” when talking to these

high-level executives.

3D printing is disruptive, it drives differentiation,

and can release incredible new opportunities.

For now, we will sum up with these words from

Magi Gallindo, Technical and Scientific Director

of IAM 3D Hub, an organization formed as part

of a collaboration between several industry

players (including HP), with the idea that they

would support clients in many different industries

to take advantage of 3D printing. “Our advice to

other companies in the manufacturing industry is

to start using it now and begin taking advantage

of the opportunities that 3D printing provides.”

Introduction

3D printing is already big business. All around the world, manufacturing companies are using it to give them a competitive advantage: fast turnaround times, low costs, opportunities to create totally new business models.

LEAN MANUFACTURING: VIEW FROM THE BOARDROOMintroduction

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3D printing for consumer goods

Forget prototyping: a number of forward-thinking manufacturers are using 3D printing

to produce final parts taking advantage of HP’s Multi Jet Fusion technology to create

personalized products that give them a distinct selling point over rivals.

“HP’s 3D printing technology is one of the few

in the world that has the ability to produce

parts at speeds — and at levels of quality that

make it competitive with traditional manufacturing

processes,” says John Dulchinos, Jabil’s Vice

President of Digital Manufacturing. “That’s

a game changer for Jabil and for manufacturing.”

And Jabil makes for a fascinating example. While you

may not be familiar with the company’s name, it’s

highly likely you will own a product that includes a

Jabil component. That’s because Jabil is the world’s

third largest contract manufacturer, working with

most major consumer brands in over 100 facilities

in 26 different countries.

“Product companies are all trying to get to market

faster,” says Mr. Dulchinos. “And they’re all trying

to do it at a lower cost point and higher level of

quality.” After 30 years of relatively unchanged

manufacturing technologies, Jabil is now using 3D

printing in a way that many analysts forecast is

the beginning of the fourth industrial revolution.

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“In terms of speed, cost, and

large-volume manufacturing, the HP

3D printing technology possesses

a truly unique advantage.”

- John Buffington, Lead

Manufacturing Engineer at Jabil

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

Jabil’s lead manufacturing engineer,

John Buffington, is working at the

sharp end of this revolution. “Cost

is the number one concern of our

customers, followed by quality and

then repeatability — that is, how can

we deliver in volume?” After bringing

his first two HP Jet Fusion 3D Printers

online for Jabil, he’s convinced that he’s

seen the future. “In terms of speed, cost,

and large-volume manufacturing, the

HP 3D printing technology possesses a

truly unique advantage. It’s really new

and it’s very strategic, and we see it

having a significant impact.”

“How do we take 3D printing — and

really, the broader category of additive

manufacturing — and disrupt the

traditional manufacturing industry?”

Mr. Dulchinos asks, immediately

answering: “By being able to

make products at a higher level

of customization, with more

complex geometries, at a cost

that’s competitive with traditional

manufacturing processes.”

As further proof, you only need look at

Spanish startup LookReal, which creates

one-of-a-kind personalized dolls. It’s

an idea enabled by new technology:

previously, dolls have either been hand-

made or mass manufactured using

injection molding. Each mold typically

costs thousands of dollars and the

parts often take two months or more to

make. To be made affordably, the doll

manufacturer must commit to buying

thousands of each part.

“The goal for LookReal was to create

one doll for each kid with the highest

possible resemblance,” says LookReal’s

CEO, Philippe Joubert. “To do that,

we had to go beyond painting and

decoration. People have different facial

features and we wanted to capture

them in real life. We needed a way

to produce each face independently.

“We analyzed other 3D printing

technologies,” he says. “It would take

us eight hours to produce one doll head.

There was no way we could scale at

that pace. We needed to be much more

productive, and we needed a solution

that would allow us to meet our

targeted sell price of $99 (USD).”

And that’s why the company chose

HP Multi Jet Fusion.

Image courtesy of LookReal

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But it’s not just about price and customization:

the other key advantage companies see by

partnering with HP is speed.

That’s crucial for Shapeways because its whole

business model is about enabling designers to

not only print but sell their 3D printed products.

“We live in an e-commerce society,” says Debbie

Claxton, a senior 3D printing engineer at the company.

“People have an expectation that if they place

an order for something online, they are going

to get it the next day. In 3D printing that has

not been realistic until recently.”

This level of excitement is shared in boardrooms

around the world. “In many ways 3D printing

reminds me of the Internet in 1995,” says

LookReal’s Joubert. “The future is brilliant.

Opportunities abound. HP makes me feel safe

in my investment and I highly recommend their

3D printing technology to others.”

We will leave the final word to Jabil VP Mr. Dulchinos.

“We think that HP Multi Jet Fusion technology

is really one of the first technologies that can

move 3D printing from a prototyping tool

to a production tool,” he says. “That’s a huge

leap forward.”

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

3 opportunities for Consumer Goods

Revolutionary Levels of Personalization

Fast Fulfilment

Optimize Costs, Maximize Profit

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3D printing for automotive

While a fully 3D printed car has yet to become a reality, it’s close(1). The automotive

industry has been quick to see the competitive advantage that 3D printing can give,

beyond conventional manufacturing. Take the BMW Group, which is using the

HP Jet Fusion 3D 4200 Printing Solution as part of its process.

“Using our automotive standards and HP’s Multi Jet

Fusion technology, our manufacturing team is able

to produce durable, reliable final parts such as the

window guide rail for our BMW i8 Roadster,” says

Dr. Dominik Rietzel, head of non-metal Additive

Manufacturing at the BMW Group.

“In the past decade, we are proud to have

produced more than one million 3D printed parts,

and it’s fitting that one of these window guide rails

was identified as the one-millionth part printed.”

He adds: “Complex parts that require reliable

functionality and a small footprint are a perfect

example of the power of additive manufacturing

and together with partners such as HP we are

excited about the possibilities ahead.”

And BMW isn’t the only industry pioneer to

take advantage of HP’s 3D printing technology.

Volkswagen plans to produce every single tool

used to manufacture its new T-Cross SUV using

HP Multi Jet Fusion technology.

1 https://www.autocar.co.uk/car-news/motor-shows-beijing-motor-show/

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LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

“We could design parts with

much less complexity, in some

cases reducing the number of

components by 80%.”

- Magi Galindo, Technical and

Scientific Director at IAM 3D Hub

The company is also integrating HP Metal

Jet into its long-term design and production

roadmap, starting with the manufacturing

of metal parts parts such as individualized

key rings and exterior-mounted name plates.

It should be no surprise that the automotive

industry, one of the first to embrace robots

in its manufacturing lines, is also at the

cutting edge of the 3D printing revolution.

Until now, robots have concentrated on

the chassis with the final finishing and

assembly operations mostly performed

manually by human operators.

To take just one aspect of this, consider

Continental Automotive. It has two factories

in Spain: one focuses on manufacturing

and assembling instrument panels, the

other is devoted to injection molding. In

particular, making plastic parts that are

used in the construction and assembly of

dashboards, center consoles, and other

interior automotive components.

The company is under constant pressure to

reduce costs and operate more efficiently.

Robots already play a big part in its

processes, with robotic arms and grippers

used to grab, position and transport

the various parts that make up a final

component. However, given their complex

nature, final finishing and assembly is

normally left to humans.

Continental recently began studying

how these tasks could be automated by

combining new types of jigs and fixtures

with robots using specialized grippers.

Specifically, the newly designed grippers

would be used to greatly reduce the

amount of time required to carry out

the assembly, coupling, calibration and

maintenance of the tooling.

“With HP’s Jet Fusion 3D Printing Solution

we had the ability to simplify both the

operation of the grippers and the tooling

required for final assembly,” says Magi

Galindo, Technical and Scientific Director

of IAM 3D Hub, which counts Continental

Automotive Spain as one of its clients.

“We could design parts with much less

complexity, in some cases reducing the

number of components by 80%. Further,

we could create less expensive parts that

were more robust and reliable, in addition

to being easier to connect and control.”

Courtesy of BMW Group

Courtesy of Volkswagen

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As IAM 3D Hub studied the problem, it became

evident that simpler solutions were required to

solve the complex challenges associated with final

assembly. “The grippers and tooling designed by

IAM 3D Hub will help Continental Spain continue to

automate its workflow, solving one of the biggest

challenges in the construction of automotive

interior components,” says Mr. Galindo.

“With this breakthrough at their factories in Spain,

Continental now has a best practice they can

apply at other locations in their manufacturing

network. Further, it validates the adoption,

integration and implementation of additive

manufacturing for production tooling across the

automotive industry.”

The new design strategies employed by IAM 3D

Hub helped decrease the amount of time it took

to create the new grippers by 30%. HP’s Multi Jet

Fusion technology also played an important role,

helping replace the complex and intricate design

of previous grippers with newer organic structures

that reduced their weight by more than 85%.

In total, the new design reduces the process and

installation time by 40%.

“HP’s Multi Jet Fusion technology allows

organizations to completely rethink their

approach to complex workflows,” says Mr.

Galindo. “Our advice to other companies in the

manufacturing industry is to start using it now and

begin taking advantage of the opportunities that

3D printing provides.”

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

3 opportunities for Automotive

Add value: Performance & Customization

Accelerate Time to Market

Optimize Costs

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3D printing for healthcare

In Healthcare, customization is a must. 3D printing helps every supplier in the industry

deliver customized services and products quickly and cost-effectively.

Johnson & Johnson has already used 3D printers

to make a prototype of a medical device used for

spinal surgeries, and sees opportunities in being

able to quickly print custom medical devices

for individual patients, based on their bodies.

And it’s not alone. Phoenix Children’s Hospital

is also inspired by the HP Jet Fusion 500/300

Series’ ability to print in full color enabling doctors

to create full-color anatomical models of hearts,

for example. “From visually-appealing casts and

corrective devices, to custom surgical guides,

to interactive and personalized anatomical

models, we see tremendous value in the design

possibilities and highly-accurate and durable

parts from HP’s new 3D printers,” says Justin

Ryan, 3D Print Lab, Phoenix Children’s Hospital.

Innovative hospitals from all around the country

are investing in on-site 3D printing facilities

so they can print on demand. This leads to an

improved patient experience – a 3D model will

always beat an x-ray when explaining a complex

procedure – and also helps when training

physicians. Plus, hospitals can print their own

prosthetics, create prototypes and use 3D models

to help plan for surgeries.

Outside of hospitals, forward-thinking medical

Data courtesy of Phoenix Children’s Hospital; Heart of Jemma

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LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

“Our digital workflow requires far

fewer steps... We routinely go from

scan to shipment in three to five days.”

- Jiri Rosicky, CEO at

Invent Medical

suppliers are using 3D printing to

revolutionize the production process.

Take iOrthotics, an Australian

manufacturer that develops custom-

made orthotic devices for podiatrists.

“As a rapidly growing business, we

needed to innovate our manufacturing

process to keep up with demand,” says

iOrthotics Founder and General Manager,

Dean Hartley.

“It was impractical to continue utilizing

subtractive milling, which could produce

just 30 plastic devices per day,” he

explains. “With 3D scanning and

printing we saw an opportunity to

improve the quality of orthotic devices,

while also scaling up our production

and reducing the waste involved with

traditional methods.”

iOrthotics invested in an HP Jet Fusion

3D 4200 Printing Solution in late

2017, and the technology has created

a “paradigm shift”. “[It] makes mass

customization possible, says Mr. Hartley.

“All industries will go through change

in the Fourth Industrial Revolution, but

perhaps none as dramatically as the

manufacturing sector. iOrthotics has

transformed itself to take advantage of

this technological shift.”

3D printing can also ignite new business

ideas. “Our whole business model is

based on 3D printing,” says Invent

Medical’s Vice President of Business

Development Jan Rosicky. “In 2015, we

were just days away from buying a large

SLS machine. Then we heard about HP’s

plans to disrupt the 3D printing industry.

We decided to cancel our order and

postpone our launch until we could

learn more.”

In Invent Medical’s case, this was a

potentially existential decision. The

company, based in the Czech Republic,

was founded with the intent to use

digital technologies such as

3D scanning, computational modelling

and 3D printing to reinvent how custom

orthotics and prosthetics are made.

Choosing the wrong technology

would have a significant negative

impact on production times, cost

and customization.

“We approached HP with our concept

and had an early opportunity to see

their technology in action,” says CEO Jiri

Rosicky. “They were focused on taking 3D

printing beyond rapid prototyping and into

manufacturing of real-world products.

That was exactly what we needed.”

Courtesy of Invent Medical

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Fast forward to now and the theory has turned

into thriving practice. “Our digital workflow

requires far fewer steps,” says iOrthotics

Technical Development Manager, Thomas Leahy.

“We receive a scan from a podiatrist, load it into

our custom software, 3D print it, clean it off,

glue on a top cover, and we’re done. Traditional

manufacturing of orthotics would often take up

to two weeks from start to finish. We routinely go

from scan to shipment in three to five days.”

Invent Medical’s investment in HP Jet Fusion

3D Printing is also enabling it to scale its model

worldwide. “We believe that with our unique

software and technology from HP 3D Printing

we can completely transform the industry,”

says Jan Rosicky. “We can provide patients all

around the globe with advanced, new products,

helping improve their lives. Further, we create a

sustainable business model for the healthcare

providers who support them.”

As Invent Medical executes its strategy, HP Jet

Fusion 3D Printing Solutions will continue to play

a central role. And as HP 3D Printing continues to

innovate with HP Multi Jet Fusion, Invent Medical

will further fulfill its mission of developing and

delivering the world’s most advanced 3D-printed

orthotic and prosthetic products.

iOrthotics also has global expansion on its mind,

with a remarkably similar take on the scalability

of HP’s 3D printing technology. “iOrthotics

produces custom foot orthotics for podiatrists in

Australia and around the world,” says Mr. Hartley.

“Our business model is based on innovation.

We’re leading the way in materials, software,

hardware, and design processes — with the goal

of creating a better, more scalable solution for

our growing list of clients.”

“Until recently, our biggest limitation was

manufacturing,” echoes Jan Rosicky.

“We needed a strong partner with technology

we could rely on to deliver.

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

3 opportunities for Healthcare

Enhanced Quality and Customization

Scale your Business

Accelerate Production Times

LEAN MANUFACTURING: VIEW FROM THE BOARDROOMpart i

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3D printing for industrial use

Creating products for industrial use brings unique challenges: get something wrong

and you could hold up a production line for hours, days, even weeks. That’s why the

companies we speak to in this final section have a very different experience to the

others. Their whole business model is built round reliability and trust.

“Gimatic is a global leader in automation and gripping

solutions,” says the company’s COO, Guerino Rosso.

“We have over 30 years’ experience developing

components for robotic gripping.” But the company

faced a challenge. With a growing product line,

and demands for customization from its global

customers, it was finding the development process

both expensive and time-consuming.

In mid-2017, it began exploring how 3D printing could

help them improve their product development. They

started with early stage prototyping, working with a

service bureau that utilized SLS-based machines.

“While it was a great way to familiarize ourselves

with 3D printing, especially with design for additive

manufacturing, it didn’t 100% fit our needs,” says

Gimatic’s Quality Manager, Pietro Belleri. “We started

looking for a different technology to have in-house.

At the end of 2017 we bought an HP Multi Jet

Fusion 4200.”

The more Gimatic learned about 3D printing, the

more they could imagine the use cases extending

beyond early stage prototypes. “With Multi Jet

Fusion we can now provide our customers with a

complete solution that includes grippers, fingers,

and 3D-printed parts,” says Mr. Rosso.

Courtesy of Gimatic

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LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

“With Multi Jet Fusion we can

now provide our customers with

a complete solution that includes

grippers, fingers, and

3D-printed parts.”

- Guerino Rosso, COO at Gimatic

“For our customers, the big benefit is

having a single supplier.”

“As we continue to deepen our knowledge

of design for additive manufacturing, I

trust that we will continually improve the

number of products that are 3D printed,”

adds Mr. Belleri. “From a quality perspective,

that’s very exciting.”

It’s a similar story for FICEP Steel Surface

Systems (S3), a high-tech engineering and

R&D company that is part-owned by FICEP

S.p.A — a company that manufactures

machines and develops production

management software for structural

steel fabricators.

The idea behind FICEP S3 is to be flexible

and innovative in its approach, enabling

rapid prototyping and a faster response

to variable market demands. One such

demand came from the daVINCI Automatic

Paint Line, which primes and paints

structural steel.

“We spent a lot of time trying to figure

out how to make some of the parts,”

says FICEP S3 CEO, Nuno Neves. “It was

extremely complicated to machine some

of them due to limitations with current

machining technology. It just wouldn’t

work. Around that time I was invited to

see HP’s 3D printing technology and I

immediately wondered if it could help

solve our problems.”

In some cases, the parts used in the

Automatic Paint Line were too complex

for machining. In others the weight of

producing them in metal put too much

stress on the rest of the system. “There

was a cumulative effect,” says Mr. Neves.

“To make the line operate as efficiently

as possible, we needed to create several

parts that together were of lighter weight,

permitting faster movements and more

precise control.” The parts also needed to

be strong and resistant to chemicals and

fluctuations in temperature.

Once they received their HP Jet Fusion

3D printer, the team at FICEP S3 spent

approximately three months testing

materials and output. They subjected parts

to extreme heat and cold repeatedly.

They also confirmed that the resolution

and surface finish would meet their needs.

“With HP’s Multi Jet Fusion technology we

can produce parts quickly enough to keep

up with demand,” says Mr. Neves. “Other

technologies would take 12 hours to

produce one part, now we can produce 100

parts in that time.”

FICEP S3 is currently developing a new

version of the Automatic Paint Line. With

HP’s Jet Fusion 3D printing technology,

they aim to replace as much as 40% of the

machine’s traditionally manufactured parts.

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“While we’ll continue to support our company’s

current needs, FICEP S3 has a real opportunity with

3D printing,” says Mr. Neves. “I believe that within

three years, outside work for new clients could

account for 90% of our business.”

Then there’s the small matter of supporting existing

customers. Here, HP is applying 3D printing across

other divisions within it’s own company by using

Multi Jet Fusion technology to keep HP’s legacy

large-format 2D printers running. “We have several

thousand parts that are very low volume,” said Luis

Fernandez, HP 3D Customer Assurance Expert,

“and manufacturing them is always a problem.”

The answer? Print spare parts on demand, enabling

HP to keep customers happy and extend the life of

its 2D printers in a sustainable and cost-effective way.

HP is even using 3D printing when developing

its own products. Previously, it would always use

injection molding and machining when designing

and manufacturing large-format printers, right

down to the smallest parts. But that was costly

and took time.

“With 3D printing we were able to optimize a design

that required less material, lowering our design

and production costs,” says Isabel Sanz, HP 3D

Applications Engineer. “HP’s Multi Jet Fusion allowed

us to create functional parts faster. Once the new

design was approved, we went immediately into

production, using the same file, the same equipment

and the same material as we used in prototyping.”

In this case, HP saw savings of 73% - $5.89 per

part to the $22 of CNC machining - while reducing

its weight from 355 grams to 44 grams, and its

carbon footprint by 95%.* So it brings logistical and

sustainability benefits too.

The innovations don’t end there. HP’s designers

saw an opportunity to replace a drill extraction

shoe, a vital component in HP printheads. The

existing part was composed of seven sub-parts,

all CNC-machined, but it has now been replaced by

a single part created by a Jet Fusion printer. This

time the cost savings were a drastic 95% - from

$450 to $18 - while reducing the weight from 575

grams to 52 grams.

LEAN MANUFACTURING: VIEW FROM THE BOARDROOM

3 opportunities for Industrial Use

Maximize Machinery Performance

Produce Parts Fast

Customize Parts for Specific Needs

*Aluminium machined part carbon footprint: 19.7 kg CO2 eq. MJF part carbon footprint: 0.97 kg CO2 eq.

© Copyright January 2019 HP Development Company, L.P. The information contained herein is provided for information purposes only. The only terms and conditions governing the sale of HP 3D printer solutionsare those set forth in a written sales agreement. Theonly warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty or additional binding terms and conditions. HPshall not be liable for technical or editorial errors or omissions contained herein and the information herein is subject to change without notice.

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