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Mapping the Market for 3D Printing Materials

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  • 1. Enabling Materials for 3D PrintingEnabling Materials for 3D Printing Mapping the Market for 3D Printing MaterialsMapping the Market for 3D Printing Materials Aarthi Janakiraman, Senior Industry Analyst © 2014 Frost & Sullivan. All rights reserved. This document contains highly confidential information and is the sole property of Frost & Sullivan. No part of it may be circulated, quoted, copied or otherwise reproduced without the written approval of Frost & Sullivan. Aarthi Janakiraman, Senior Industry Analyst Chemicals and Materials, Technical Insights July 15, 2014
  • 2. Today’s Presenter Functional Expertise Expertise covering broad range of sectors including: • Materials & Coatings • Polymers and Biomaterials • Food & Beverages • Health and Nutritional Supplements • Dietetics and Healthcare Industry Expertise Experience base covering broad range of sectors, leveraging long-standing working Aarthi Janakiraman 2 Experience base covering broad range of sectors, leveraging long-standing working relationships with leading industry participants’ Senior Executives in • Chemicals and Materials • Coatings • Food and Beverages • Healthcare and Wellness Education Post Graduate Program in Business Administration from Indo-German Training Centre, awarded by German Commerce of Industry & Trade, Germany Master of Philosophy from Avinashilingam Institute of Higher Education for Women, Coimbatore, India. Senior Industry Analyst Technical Insights – Chemicals, Materials and Foods Frost & Sullivan Global Chennai, India
  • 3. Agenda Today’s presentation will cover: A Brief Snapshot of 3D Printing Materials Technology Trends Factors Influencing Material Selection 3 3D Printing Materials- Process and Application Mapping 3D Printing Materials- Patent Mapping Recent Developments Drivers & Challenges and their Impact What Next???
  • 4. 3D Printing Transforming Conventional Manufacturing Practices Smaller batches of production with high levels of customization Lower throughput compared to traditional manufacturing. But faster time to market Demand happens parallel to production Demand Supersedes production Eliminates the need to store finished products based on forecasted demand; Mass Production to MassMass Production to MassMass Production to MassMass Production to Mass CustomizationCustomizationCustomizationCustomization Supply Chain Focus: from “PUSH” to “PULL”Supply Chain Focus: from “PUSH” to “PULL”Supply Chain Focus: from “PUSH” to “PULL”Supply Chain Focus: from “PUSH” to “PULL” Forecasted Demand to RealForecasted Demand to RealForecasted Demand to RealForecasted Demand to Real----time Demandtime Demandtime Demandtime Demand ConventionalConventionalConventionalConventional ManufacturingManufacturingManufacturingManufacturing to 3D Printingto 3D Printingto 3D Printingto 3D Printing---- 4 To document, relay and realize demand in real-time Eliminates the need to store finished products based on forecasted demand; lesser storage space required Manufacturers will store only the raw materials to meet on-Demand production requirements Low-storage space requirements as raw materials occupy lesser volume than finished products Raw materials for 3D printers manufactured or procured and provided by 3D Printer manufacturers Wide choice of feed materials for a broad range of commercial and industrial applications. Inventory: Finished Products to Raw MaterialsInventory: Finished Products to Raw MaterialsInventory: Finished Products to Raw MaterialsInventory: Finished Products to Raw Materials Raw materials: Customized to Wide Choice AvailabilityRaw materials: Customized to Wide Choice AvailabilityRaw materials: Customized to Wide Choice AvailabilityRaw materials: Customized to Wide Choice Availability ConventionalConventionalConventionalConventional ManufacturingManufacturingManufacturingManufacturing to 3D Printingto 3D Printingto 3D Printingto 3D Printing---- Paradigm ShiftParadigm ShiftParadigm ShiftParadigm Shift Increasingroleofraw materialsuppliers
  • 5. Technology Trends Early Current Future Materials Metallic powders and Alloys Functional Fillers Polymeric Gels Hydrophobic materials Smart Polymers Reinforcements Copolymers Customized and Bio Inks Biomimetics Advances in nanotechnology and functional chemistry Innovations in Chemical formulations Advances in Multimaterial technologies and synthetic biology 5 Early Current Future Manufacturing Processes Rapid Prototyping EBM, LOM, FDM Selective Laser Sintering (SLS) Peel off process Advances in Precision manufacturing Advances in surface engineering and Multimaterial joining Advances in self assembly and integration of different techniques
  • 6. Commonly Used 3D Printing Materials ABS, PE, PET, PP, PA PLA Polycarbonate Polyamide (Nylon) PMMA Steel and St. Steel Titanium Nickel Aluminum Palladium Gold Zirconia Alumina Graphite Mullite Silicone Carbide Silica (sand) Waxes Tissues Paper Bio inks: Stem Cells & Tissues Bone Material: Beta-Tri calcium Phosphate Nanomaterials Fibers : Carbon fiber, Glass Fiber Composites Resins: Furan, Melamine, Phenolic Wood Pulp Aerogels Methacrylic Photopolymers Polyolefin Polyvinyl Acetate Polyvinyl Chloride Polyvinylidene 3D Printing Materials Ceramics Metals and Alloys Polymers Organic materials Others 6 PEEK Epoxy Polyphenylsulfone Gold Platinum Copper Silica (sand) Plaster Clay calcium Phosphate Aerogels Graphene Polyvinylidene Chloride Elastomers HDPE Key Applications
  • 7. Factors Influencing Material Selection End – Product Features Parameters Dimensions •Size •Volume, and Material Selection Processes Used End Product Features Availability and Compatibility of Materials Ceramics Metals and Stereolithography (SLA) Selective Laser Melting (SLM) 7 •Volume, and • Surface Area Mechanical Loading •Structural •Cyclic Surrounding Environmental Conditions •Thermal Loading •Thermal Cycling •Moisture level •Chemical Level Functionality •Aesthetic •Water Proof •Shock Proof Metals and Alloys Polymers Organic materials Others Fused Deposition Modelling (FDM) Selective Laser Sintering (SLS) Laminated Object Manufacturing (LOM) Electron Beam Melting (EBM)
  • 8. 3D Printing Materials –Comparative Analysis Materials Advantages Limitations Plastics • Design flexibility • Biodegradable in case of bioplastics • Durable • Availability of colors • Limited weathering resistance • Flammable with high smoke generation • Possibility of warping Metals • Strong • Malleable and Ductile • High Weathering Resistance • Low design flexibility • Costly 8 • Corrosion Resistance Ceramics • Strong but Flexible • Availability of colors • Low detail • Rigid compared to other materials Precious Metals • Strong but Flexible • High detail • Can be plated • Costly Composites • High Mechanical Strength • Can be used for intricate design • Good Feature Resolution • Good Surface Finish • Difficult to work with due to complicated interlocking assemblies and joints
  • 9. 3D Printing Materials – Process and Application Mapping Direct Metal Laser Sintering (DMLS) StainlessStainless Steel Steel Nickel Electron Beam Melting (EBM) Titanium Fused Deposition Modelling (FDM) Thermoplas tics Eutectic Selective Heat Sintering (SHS) Selective laser sintering (SLS) Selective laser melting (SLM) Laminated Object Manufacturing (LOM) Thermoplas Metal Alloy Thermoplasti cs Steel Stainless Paper Metal foils MaterialsProcesses 9 Alloys Nickel Titanium and Aluminum Alloys Aerospace Dental Medical Implants Medical Devices Tooling Titanium Alloys Medical Implants Aerospace Eutectic Metals Food ingredients Aerospace Tissue Engineering Commercial Products Food Industry Thermoplas tics cs Ceramics Composites Carbon fibers Stainless Steel Metal Alloys Metal foils Plastic films Tooling Industry Consumer Products Building and Construction Aerospace and Defense Automotive Manufacturing Building and Construction Aerospace and Defense Tooling Gas Turbines Consumer Goods Sporting Goods MaterialsApplications
  • 10. Key Materials Used by Application Segments- Patent Mapping Materials Type TissueEngineering Clothing Tooling Automobiles PrintedCircuit Board Mechanical Medical Phones Aircraft FoodIndustry Aerospace Prosthesis Robotics Defence Toys Scaffolding Jewellery Furniture Shoes Televisions Watches Construction Non-Metal Ceramic Polymer Plastic Metals Aluminium Polymer Polyethylene Terephthalate Paper 10 Paper Polymer Polycarbonate Rubber Metals Titanium Resins Epoxy Wax Metals Nickel Polymer Polyamide Polymer Polyethylene Polymer ABS Plastic Polymer Thermoplastic Polymer Polypropylene Number of Patents 91 to 100 51 to 60 41 to 50 31 to 40 21 to 30 11 to 20 1 to 10
  • 11. Recent Developments Titanium Powders Bio functionalized materials Metalysis, UK has developed a low cost and environmental-friendly manufacturing technology for production of metals, rear earth metals and alloys. Arevo labs customizes CFRP that is obtained from Solvay Polymers customizing to eanable 3D printing for high performance applications. Organovo bioprints structural and functional human tissue models for therapeutic and research application; aiming to bring accuracy closer to the native human tissue. Recent CFRP 11 Wood Filaments The second generation ABS material is specifically designed for Stratasys’ PolyJet 3D Printers and can enable users to produce thin-walled models (thinner than 1.2 mm /.047 in.) with high dimensional stability, improving form fit and assembly for prototyping or production applications. Recent Developments Digital ABS2 3NTR, Italy has developed 3mm polyamide 6 filament, which is is made up of 99.9% PA6 Polymer and doesn’t contain any plasticizers, fiberglass, and has 0.1% soap to ease processing. PA nylon filaments Helian Polymers company, The Netherlands has developed woodfill/ wood filaments, PLA / PHA filaments and co polyester filaments that can be used for consumer goods sector.
  • 12. Factors Influencing Material Adoption in Key Applications Development of new and unconventional materials Manufacturing & tooling Automotive Aerospace & defense Healthcare Commercial Short term Long term Manufacturing & tooling DRIVERS 12 Flexibility in using Multi materials Automotive Aerospace & defense Healthcare Commercial Customization of Material Properties Manufacturing & tooling Automotive Aerospace & defense Healthcare Commercial Scale 1 2 3 4 5Note: Short Term – 1 to 3 years Long Term - 6 to 9 years DRIVERS
  • 13. Factors Influencing Material Adoption in Key Applications Quality, Durability and Reliability Short term Long term CHALLENGES Manufacturing & tooling Automotive Aerospace & defense Healthcare Commercial Manufacturing & tooling Automotive 13 Consistency in Mass customization Cost of Raw materials Scale 1 2 3 4 5Note: Short Term – 1 to 3 years Long Term - 6 to 9 years CHALLENGES Automotive Aerospace & defense Healthcare Commercial Manufacturing & tooling Automotive Aerospace & defense Healthcare Commercial
  • 14. 3D Printing Industry Expectations to Raw Material Suppliers •Scalability tests to find the suitability of the materials for large scale adoption across various sectors, esp. in case of electronics and healthcare. •Collaborative research focusing on bridging the industry needs with academic capabilities. •Establishing knowledge transfer networks Establish USP for application sector Alignment of Design Academia to Industry Scalability for large scale adoption 14 •Pre- market harmonization •Regulations to govern the use of 3D Printing materials. • Framing industry standards •Understand interactions between materials and processes. •Data on long term durability, safety and reliability of materials esp. for healthcare. Alignment of Manufacturing and Testing processes Standardization of materials and methods Raw materials matching to Industry needs Quantitative data on Characteristics, Safety and Reliability Regulations and Standards
  • 15. What Next for 3D Printing Materials Early AdoptersEarly AdoptersEarly AdoptersEarly Adopters Late AdoptersLate AdoptersLate AdoptersLate Adopters Energy Defense Automotive** Aerospace Automotive* Healthcare PenetrationLevelPenetrationLevelPenetrationLevelPenetrationLevel PenetrationPenetrationPenetrationPenetration ClassificationClassificationClassificationClassification High Levels 15 Consumer goods Defense PPE Jewelry Healthcare Consumer goods (Novelty Products) Sporting Goods Textiles PenetrationLevelPenetrationLevelPenetrationLevelPenetrationLevel Raw material ReadinessRaw material ReadinessRaw material ReadinessRaw material Readiness Medium Levels Low levels * Specialty vehicles and parts **Mass vehicles and parts
  • 16. Next Steps Develop Your Visionary and Innovative Skills Growth Partnership Service Share your growth thought leadership and ideas or join our GIL Global Community 16 Join our GIL Community Newsletter Keep abreast of innovative growth opportunities
  • 17. Your Feedback is Important to Us Growth Forecasts? Competitive Structure? What would you like to see from Frost & Sullivan? 17 Emerging Trends? Strategic Recommendations? Other? Please inform us by “Rating” this presentation.
  • 18. Follow Frost & Sullivan on Facebook, LinkedIn, SlideShare, and Twitter http://www.facebook.com/FrostandSullivan http://www.linkedin.com/companies/4506 18 http://twitter.com/frost_sullivan http://www.linkedin.com/companies/4506 http://www.slideshare.net/FrostandSullivan
  • 19. For Additional Information Aarthi Janakiraman Senior Industry Analyst Chemicals and Materials (91) 044-66814102 aarthij@frost.com Aravind Chander V Industry Manager Materials & Coatings (91) 044-66814103 achander@frost.com 19 Angie Montoya Global Webinar Marketing Coordinator Marketing 210-247-2435 amontoya@frost.com