Dr Philip Reeves Rapid Manufacturing Eco-innovation in the context of recession TITLE Innov_ex09

Dr Philip Reeves Rapid Manufacturing Innovation in the outdoor industries in the context of recession and the environment ALTERNATIVE & TRUTHFUL TITLE Innov_ex09

Dr Philip Reeves Rapid Manufacturing Innovation & sustainability in the outdoor industries irrespective of recession ALTERNATIVE & TRUTHFUL TITLE Innov_ex09

Rapid Manufacturing – what is it Recession – what are the business driver Environment – how can RM contribute Innovation – how does RM enable Outdoor Industries – where does RM fit Outdoor Industries – where could RM fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment – how can RM contribute

Innovation – how does RM enable

Outdoor Industries – where does RM fit

Outdoor Industries – where could RM fit

Questions

Rapid Manufacturing – what is it Recession – what are the business driver Environment– how can it help Innovation – how does it support it Outdoor Industries – where does it fit Outdoor Industries – where could it fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment– how can it help

Innovation – how does it support it

Outdoor Industries – where does it fit

Outdoor Industries – where could it fit

Questions

Rapid Manufacturing is the manufacture of ‘ end-use ’ component parts using Additive Layer Manufacturing processes WHAT IS RAPID MANUFACTURING? AGREEING TERMS

Rapid Manufacturing is the manufacture of ‘ end-use ’ component parts using Additive Layer Manufacturing processes

There are Four fundamental manufacturing principles: Subtractive Material is successively removed from a solid block until the desired shape is reached (2.5M BC – Hominids) Fabricative Elements or physical material are combined and joined (6,000 BC – Western Asia) Formative Mechanical forces and, or heat are applied to material to form it into the desired shape such as bending, casting and molding (3,000 BC – Egyptians) Additive Material is manipulated so that successive pieces of it combine to make the desired object (1985 – Californians) How does ALM differ from traditional manufacturing

There are Four fundamental manufacturing principles:

Subtractive

Material is successively removed from a solid block until the desired shape is reached (2.5M BC – Hominids)

Fabricative

Elements or physical material are combined and joined (6,000 BC – Western Asia)

Formative

Mechanical forces and, or heat are applied to material to form it into the desired shape such as bending, casting and molding (3,000 BC – Egyptians)

Additive

Material is manipulated so that successive pieces of it combine to make the desired object (1985 – Californians)

ALM processes are automated systems that take 2-dimensional layers of computer data and rebuild them into 3D solid objects WHAT IS AN ALM PROCESS AGREEING TERMS

ALM processes are automated systems that take 2-dimensional layers of computer data and rebuild them into 3D solid objects

ALM MATERIAL OPTIONS MATERIALS Waxes Polyamide (nylon) Organic materials Polymeric materials Metallic materials Ceramic materials ABS Glass filed Polyamide Composite loaded PA Thermosetting epoxies Ceramic (nano) loaded epoxies PMMA Polycarbonate Polyphenylsulfone Tool Steel Aluminium Titanium Inconel Cobalt Chrome Copper Stainless steel Mullite Alumina Zirconia Gold / platinum Silicon Carbide Hastelloy Aluminium loaded polyamide Beta-Tri calcium Phosphate Silica (sand) Plaster Graphite ULTEM

Prototypes (Rapid Prototyping) Casting Patterns (Rapid Casting) Tool cavities (Rapid Tooling) Direct Parts (Rapid Manufacturing) ALM IS THE ENABLER – RM IS THE APPLICATION AGREEING TERMS

Prototypes (Rapid Prototyping)

Casting Patterns (Rapid Casting)

Tool cavities (Rapid Tooling)

Direct Parts (Rapid Manufacturing)

Rapid Manufacturing – what is it Recession – what are the business driver Environment– how can it help Innovation – how does it support it Outdoor Industries – where does it fit Outdoor Industries – where could it fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment– how can it help

Innovation – how does it support it

Outdoor Industries – where does it fit

Outdoor Industries – where could it fit

Questions

THE PRIMARY BUSINESS DRIVERS RM reduced the need for tooling (moulds / jigs) Risk mitigation Enables the manufacture of low volume production (no fixed asset amortizations) Simplifies the supply chain & reduces capital investment Enables complicated assemblies to be built in one piece

RM reduced the need for tooling (moulds / jigs)

Risk mitigation

Enables the manufacture of low volume production (no fixed asset amortizations)

Simplifies the supply chain & reduces capital investment

Enables complicated assemblies to be built in one piece

Enabling low volume complex part manufacture? CASE STUDIES

Rapid Manufacturing – what is it Recession – what are the business driver Environment (sustainability) – how can RM help Innovation – how does it support it Outdoor Industries – where does it fit Outdoor Industries – where could it fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment (sustainability) – how can RM help

Innovation – how does it support it

Outdoor Industries – where does it fit

Outdoor Industries – where could it fit

Questions

Increased process & supply chain efficiencies Less raw material usage Less waste production & recycling Less energy used in processing Less transportation in the supply chain Lighter weight more efficient products SUSTAINABILITY DRIVERS?

Increased process & supply chain efficiencies

Less raw material usage

Less waste production & recycling

Less energy used in processing

Less transportation in the supply chain

Lighter weight more efficient products

A holistic approach SOLUTION

TITANIUM ICE SCREWS SUSTAINABILITY 15,000 KWh per ton to extract 160 KWh per ton to CNC machine 8:1 – waste ratio Don’t machine from solid – sinter from powder!

Rapid Manufacturing – what is it Recession – what are the business driver Environment– how can it help Innovation – how does RM enable it Outdoor Industries – where does it fit Outdoor Industries – where could it fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment– how can it help

Innovation – how does RM enable it

Outdoor Industries – where does it fit

Outdoor Industries – where could it fit

Questions

THE PRIMARY BUSINESS BENEFITS OF RM RM enables complex geometries manufacture RM enabled added functionality RM enables optimised geometries RM enables personalised products RM enables distributed manufacture Enables true just-in-time Lean & agile = Legile

RM enables complex geometries manufacture

RM enabled added functionality

RM enables optimised geometries

RM enables personalised products

RM enables distributed manufacture

Enables true just-in-time

Lean & agile = Legile

(1) Images courtesy of Phonak www.phonak.com Design freedoms & personalized part manufacture? CASE STUDIES 1 2 3 4 5 6

OBSERVATION “ Most current successful RM applications and business models are people-centric and driven by societal wants and needs ”

Rapid Manufacturing – what is it Recession – what are the business driver Environment– how can it help Innovation – how does it support it Outdoor Industries – where does RM fit Outdoor Industries – where could it fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment– how can it help

Innovation – how does it support it

Outdoor Industries – where does RM fit

Outdoor Industries – where could it fit

Questions

Low volume High value Customised Personalised Niche OUTDOORS

Low volume

High value

Customised

Personalised

Niche

PETZL TECHNICAL ICE AXE EXAMPLE

ECONOMICS & SUSTAINABILITY EXAMPLE PETZL TECHNICAL ICE AXE

ERGONOMICS & PERSONALISATION EXAMPLE PETZL TECHNICAL ICE AXE

BURTON SNOWBOARD BINDING EXAMPLE

BURTON SNOWBOARD BINDING EXAMPLE ERGONOMICS, PERSONALISATION & MARKET DIFFERENCIATION

PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE

PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE ERGONOMICS, PERSONALISATION & PERFORMANCE

PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE

Images courtesy of Liverpool University www.liv.ac.uk IMPACT ABSORBANCY EXAMPLE

Images courtesy of Liverpool University www.liv.ac.uk

CUSTOM FOOTWARE EXAMPLE

CUSTOM FOOTWARE EXAMPLE ORTHOTICS & PERFORMANCE

CUSTOM ORTHESIS EXAMPLE

CUSTOM ORTHESIS EXAMPLE PERFORMANCE, COMFORT & INCLUSIVITY

Rapid Manufacturing – what is it Recession – what are the business driver Environment– how can it help Innovation – how does it support it Outdoor Industries – where does it fit Outdoor Industries – where could RM fit Questions Agenda

Rapid Manufacturing – what is it

Recession – what are the business driver

Environment– how can it help

Innovation – how does it support it

Outdoor Industries – where does it fit

Outdoor Industries – where could RM fit

Questions

Agenda OPPORTUNITIES + =

Agenda OPPORTUNITIES + =

Agenda OPPORTUNITIES + =

Many successful applications of RM exist today The best applications are people centric Supporting consumers wants and needs High value, low volume, Niche Customize & Personalise Product differentiation & competitive advantage Sustainability & resource efficiency Not so many current applications in the Outdoor Industries I am sure the opportunities exist – talk to me if you have ideas! SUMMARY

Many successful applications of RM exist today

The best applications are people centric

Supporting consumers wants and needs

High value, low volume, Niche

Customize & Personalise

Product differentiation & competitive advantage

Sustainability & resource efficiency

Not so many current applications in the Outdoor Industries

I am sure the opportunities exist – talk to me if you have ideas!

QUESTIONS, OBSERVATIONS, DISCUSSION END Dr Philip Reeves Econolyst Ltd The Silversmiths Crown Yard Wirksworth Derbyshire, UK DE4 4ET +44 (0) 1629 824447 [email_address] www.econolyst.co.uk www.rm-masterclass.com

QUESTIONS, OBSERVATIONS, DISCUSSION