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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

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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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“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.”

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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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“Our digital workflow requires far fewer steps... We routinely go from

scan to shipment in three to five days.” - Thomas Leahy, Technical

Development Manager at iOrthotics

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.

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3 opportunities for Healthcare

Enhanced Quality and Customization

Scale your Business

Accelerate Production Times

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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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“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.

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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 2019 - 2020 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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