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Manufacturing the Future - How 3D Printers are Used for Design and Manufacturing

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How to Utilize Additive Fabrication Machines for Direct Digital Manufacturing, 3D Printing and Rapid Prototyping.

How to Utilize Additive Fabrication Machines for Direct Digital Manufacturing, 3D Printing and Rapid Prototyping.

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  • Additive Fabrication Preferred term (adopted by Stratasys) covering all technologies/applicationsPreferred replacement for RPDefinition: collection of technologies, directly driven by CAD data, to produce 3-Dimensional physical models and parts through an additive process.NOTE: Additive manufacturing is on the rise as the catch-all term; there is little consensus in industry
  • With this understanding (of the classifications), we position these business segments as shown, 3D printers and 3D productions systems span the whole spectrum; it is just more likely that 3d printers used in concept modeling (and vice versa)And RedEye On Demand (and other bureaus) can satisfy the whole spectrum
  • Example: Ducati- Accelerating engine designProblem (that is solved)Reduce design cycle of new engine on Desmosedic motorcycle surpassing predecessors in powerHow used (solution)Brought work in-house (vs. service bureaus)Built complete engines (2 different designs) almost entirely in Polycarbonatetwin-cylinder oval-piston configurationfour pistons in L-shaped layoutBenefit delivered (result)71 % reduction in time (concept to final engine design)8 months vs 28reduced outsourcing- Saved $1.5M Saved time and money by eliminating 83 design problemsSecondaryComplete engine made buy-in on vision for twin-cylinder design possible/easierSuccess with a major piston configuration design change
  • Example: Toro-Commercial Sprinkler Functional PrototypesProblem (that is solved)Functional (performance testing) of multiple design iterations. Subjected to 100 psi water pressure.How used (solution)Built accurate functional prototype (for each design) within few hours for testingValidate form, fit and functionBenefit delivered (result)Over a 2 year period & many projectsReduced product development time by 283 weeksReduced tooling costs by $500,000
  • Example: Logitech Mobile Bluetooth HeadsetProblem (that is solved)Philosophy: continuous improvement-flawless designNeeded earlier functional testingOther AF too expensive/prone to breakingOnly option-later in the cycle for injection molded partsexpensive/long lead timeSo, very few iterationsHow used (solution)Problem with headset. Design flaw made unit prone to breaking.Used Fortus for ABS prototypesMultiple iterations to test/fin d the best designBenefit delivered (result)Discovered counterintuitive wedge stop design273% stronger than originalSecondaryFaster response and low cost resulted in more functional prototyping for more applicationsDesign, manufacturing, marketingWhich leads to better products and happier customers
  • Manufacturing applications—the “developing market”High-level benefits (primary)Broad since cover parts, jigs, patterns and toolsBut still, fundamentally, aboutFinancial gainLowering costsCosts to make tools, patterns, fixtures Increasing profitsProfits from lower part costs, inventory costs, or direct labor expenseTime advantagesDecreasing time-to-marketFaster production of tools, patterns and partsDecreasing cycle timeFaster, more efficient production of finished goodsSecondary advantagesDesign freedomProduct redesign frequencyRapid response
  • Ideal solution when (note: try to explain why for each in a few words)Relative low volumesShort run productionBridge to toolingHigh part complexityEliminate expensive toolingReduce long lead timesPart acceptableAesthetics not criticalFinishing processes feasiblePhysical properties acceptable (Mechanical props, Chem & Therm Resistance)
  • Manufacturing tools – the first DDM segment to be discussed.All items used to produce, inspect or manage/handle manufactured itemsExamples: JigsFixturesCheck GaugesDrill / Rivet GuidesGo / No-Go GaugesAlignment Tools & GuidesTooling Masters & Patterns
  • Example: BMWReduced weight-worker fatigueBetter balance/ergonomics – worker productivityBetter performance – organic shape to fit up/under bumper
  • Example: OreckProblem (that is solved)Making 40 to 50 identical assembly pallets (fixtures) for every vacuum modelAlsoLimits in producing new or replacement fixtures for use on assembly lineOpen to worker injury. Decreasing throughput/capacity of production. Increasing scrap rate.How used (solution)Simply design what needed and print/grow it.Basically a no brainer in Bill’s mindFortus replace urethane castings/CNC millingModular “pallets” in this caseAlso complete assembly fixtures, assembly tools, milling fixtures and test fixturesBenefit delivered (result)65% reduction in fixture project costs (up to $100,000 per project)Replacement fixtures in hours vs. weeksNearly eliminated worker fatigue and injuries58% reduction in manufacturing related defectsFortus is also used extensively for functional prototyping
  • The last applications segment is end-use parts, another aspect of DDMThe parts, subassemblies or products that are sold to a customer or put into servicePrimary BenefitsLower cost Because there is toolingShorter lead timeBecause tooling is eliminatedSecondaryDesign freedomFew DFM (constraints) (design for manufacturing) Change freedomReduced warehouse space/inventory costTrue JIT (just in time) manufacturingMass customizationSupports lean initiatives
  • Summary/conclusionTerminology (briefly state definition of each)AFDDM3D Printer3D Production systemBusiness segmentsOn Demand (RedEye), 3D Printers (Dimension) and 3D Production Systems (Fortus)ApplicationsProduct design (established market)ConceptFunctional prototypeManufacturing (developing market)Manufacturing toolsEnd-use partsWhich we call DDMBenefitsReduce time, reduce cost (in real, tangible numbers)Improve product and process


  • 1. MANUFACTURING THE FUTURE How 3D Printers and Rapid Prototyping Systems are Changing the Future of Product Development and Manufacturing Stratasys, Inc. www.Stratasys.com/Future
  • 2. Additive Manufacturing Objectives  Clear understanding of additive manufacturing market Content  Terminology  Types of additive manufacturing approaches  Application areas and benefits Importance  Foundation for identifying opportunities
  • 3. Additive Manufacturing Known by many names:  3D Printing  Additive Fabrication  Rapid Prototyping  Advanced Manufacturing  Rapid Tooling  Additive Layer Manufacturing  Rapid Technologies  Direct Digital Manufacturing  Rapid Manufacturing  Direct Manufacturing
  • 4. Terminology Additive Manufacturing  Preferred term covering all 3D printing technologies/ applications  Preferred replacement for rapid prototyping Definition:  Collection of technologies, directly driven by CAD data, to produce 3-Dimensional physical models and parts through an additive process.
  • 5. Primary Applications for Additive Manufacturing Additive Manufacturing Conceptual End-Use Modeling Parts Established / Traditional Direct Digital Manufacturing (Design) (Manufacturing)
  • 6. Technology Assessment 3D Printers 3D Production Systems Performance Requirements Increase End-Use Parts
  • 7. Conceptual Models & Functional Prototypes Primary Benefits • Reduce time to market  Solidify design earlier  Reduce late design changes • Lower product development cost  Make design changes earlier in process  Make mistakes early and often Secondary Benefits • Facilitate communication between teams and vendors • Improve product design
  • 8. Jay Leno’s Garage: Concept Models 1907 White Steam Car  D-Valve replacement needed  Not available at local automotive center Utilized multiple technologies  3D Scanning  Materialise - software  3D Printing From broken to fixed part - quickly 1. 3D scan broken D-Valve 2. Concept model produced 3. Validated design
  • 9. Concept Models at Ducati Design of Desmosedici Engine  Saved over $1.5M in outsourcing costs  Concept to final engine design in 8 months vs. 28 months (71% time savings)  Eliminated 83 design problems Major piston design change  Started with twin oval piston  Final design a four round side-by-side “To keep Ducati at the forefront of engine design, we sought a technology that could make accurate, durable prototypes quickly.” Piero Giusti, Ducati
  • 10. Functional Prototyping at Toro Commercial & Residential Sprinklers Prototyped in few hours for testing  Validated form, fit and function  Pressure testing at +100 psi Working prototype made for each new design Over a 2 year period & many projects  Reduced product development by 283 weeks  Reduced tooling costs by $500,000
  • 11. Functional Prototypes at Logitech Bluetooth Headset • Headset failure  Many iterations of functional prototypes  Gave to focus groups for evaluation • Found new, counterintuitive design fix  273% stronger • Faster response, lower cost  More functional prototypes  Better products, satisfied customers
  • 12. Direct Digital Manufacturing Applications Primary benefits  Lowering costs  Increasing profits  Decreasing time-to-market  Decreasing cycle time • Secondary advantages  Design freedom  Product redesign frequency  Rapid response
  • 13. Direct Digital Manufacturing Applications Best fit when: • Relative low volumes  Short run production and bridge to tooling • High part complexity  Eliminate expensive tooling  Reduce long lead times • Part acceptable  Aesthetics not critical  Finishing processes feasible  Physical properties acceptable
  • 14. Manufacturing Tools Examples:  Jigs  Fixtures  Check gauges  Drill / rivet guides  Go / no-go gauges  Alignment tools & guides  Tooling masters & patterns
  • 15. Manufacturing Tools at BMW Emblem Headlight Alignment Bumper Reach Cubing Device Gage Checker
  • 16. Jigs & Fixtures at BMW Manufacturing Jigs and Fixtures with FDM • Automobile assembly & testing tools  Over 400 jigs & fixtures / vehicle  Many produced on Fortus system • Benefits to workers and processes:  Improved productivity  Design optimized for worker comfort  Increased process ease-of-use  Greater process repeatability AUTOMOTIVE
  • 17. Manufacturing Tools at Oreck Repeatable & accurate assembly • Custom vacuum assembly pallets • Requirements  40 – 50 / model  5 – 10 models in production • Benefits  65% reduction in fixture costs  $100,000 / fixture savings (up to)  58% reduction in manufacturing defects  Replacement fixtures in hours vs. weeks  Nearly eliminated worker fatigue & injuries
  • 18. End-Use Parts • Primary Benefits  Lower cost  Shorter lead time • Secondary  Design freedom • Few design for manufacturing constraints  Change freedom  Mass customization  Supports lean initiatives  True JIT (just-in-time) manufacturing  Reduced warehouse space/inventory cost
  • 19. End Use Parts at DST Control FDM reduces cost 66% & time 77% • Gimbal eye or camera  For unmanned aerial and ground vehicles  Stable images from unstable carriers • Fortus machine produces 20 different parts  Meet accuracy and quality standards  Reduce delivery time for custom products Method Cost Time Traditional €2,44 11 • FDM parts perform better Manufacturing 1 weeks  Lower weight Direct Digital €830 4 weeks  Better electrical insulation Manufacturing Savings €1,61 7 weeks • Time and cost savings 1 (63%) (66%)  Part cost reduced 66%  Custom part production time reduced 63%
  • 20. End Use Parts at ScriptPro Automated Pill Dispensing System • Custom bezels manufactured  Accept only one vial size  Easy customization • Saving $25,000 on  Engineering time Method Cost Time  Tooling / bezel Traditional $31,650 60 • Design flexibility Days  New product design without tooling Fortus $ 6,750 2  Able to support new vile sizes Days  Unique competitive edge Savings $24,900 58 (78%) Days (97%)
  • 21. Summary • Terminology • Applications  AF  Product design  DDM • Concept models  3D Printer • Functional prototype  3D Production system  Manufacturing • Manufacturing tools • Business segments • End-use parts  On Demand  3D Printers  3D Production Systems
  • 22. More Information Test it, Prove it.  Send 3D cad file and have Stratasys build it for you  Application Engineer consultation www.Stratasys.com/Future  Download Application Guides and White Papers  Fill out form to get benchmark built  Get FDM sample part  Request Consultation