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Additive Manufacturing - Design Considerations Rapid Fire - OMTEC 2018

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Easing the Secondary Production Process During Design: The design stage is where the smart decisions are made in additive manufacturing — not only on ways to increase clinical outcomes and additive processes, but also to ease post-processing. In these areas, the process can be made efficient and cost-effective. Receive tips and tricks on orientation, supports, stock material and design features.

Enhancing Design through Engineering and Manufacturing Collaboration: Unlike conventional methods, additive manufacturing requires design and manufacturing teams to work closely together very early in the design phase. In a world where the pace of innovation is nearly vertical, it’s imperative to understand this concept early to make additive manufacturing work for you. This discussion lends a high-level overview of best practices when working with internal or external suppliers, and shows examples of the use of additive manufacturing to create innovative medical device designs.

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Additive Manufacturing - Design Considerations Rapid Fire - OMTEC 2018

  1. 1. Easing the Secondary Production Process During the Design Stage Maria Pettersson, Ph.D., Orthopedic Industry Specialist for GE Additive, will explain why the design stage is where the smart decisions are made in additive manufacturing — not only on ways to increase clinical outcomes and additive processes, but also to ease post-processing. In these areas, the process can be made efficient and cost-effective. Dr. Pettersson will offer tips and tricks on orientation, supports, stock material and design features.
  2. 2. Easing the Secondary Production Process During the Design Stage Maria Pettersson, Ph.D., Orthopedic Industry Specialist, GE Additive OMTEC, 13th of June, 2018
  3. 3. Not cleared or approved by the FDA.
  4. 4. Complex is Easy Not cleared or approved by the FDA.
  5. 5. Part design and build planning
  6. 6. Orientation Not cleared or approved by the FDA.
  7. 7. Porous structures
  8. 8. Features Not cleared or approved by the FDA.
  9. 9. Supports Not cleared or approved by the FDA.
  10. 10. Involve the whole manufacturing chain
  11. 11. Machining Not cleared or approved by the FDA.
  12. 12. Inspection Not cleared or approved by the FDA.
  13. 13. Finishing Not cleared or approved by the FDA.
  14. 14. Batch handling Not cleared or approved by the FDA.
  15. 15. Imagination at work
  16. 16. This presentation may contain confidential and/or privileged information. Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden. Enhancing Design Through Engineering & Manufacturing Collaboration Laura Gilmour Global Medical Business Development OMTEC Chicago June 12-14
  17. 17. EOS | 2 Medical Field: Early Adopters of AM Present:  Hearing aids  Dental applications  Porous acetabular cups 2-5 years:  Hip & knee replacements  Other common internal and external medical devices (e.g. instruments) > 5-10 years:  Bioprinting of living tissue for human transplant  Bioprinting for life sciences R&D Source: http://www.gartner.com/newsroom/id/3117917 and http://3dprintingindustry.com/2015/08/28/gartner-predicts-medical-3d-printing-to-become-mainstream-in-2-5-years/
  18. 18. EOS | 3 50% Expect >10% Increase in Medical AM Applications SME Medical AM3DP Annual Report, April 2018
  19. 19. EOS | 4 FDA Data on Additive Manufactured Medical Devices Medical Devices cleared as of Mid-2014a Breakdown by Device Typea Over 68% falling in the Division of Orthopedic Devices As of December 2017, over 100 FDA Cleared Additively Manufactured Productsb Source: aRicles et. al. RAPID May 2014; b“FDA Makes Statement Concerning the Future of 3D Printing in Medicine”, 3D Printing Industry, December 5, 2017
  20. 20. EOS | 5
  21. 21. EOS | 6 Silo Experience R&D R&D MD KOLKOL PD PM
  22. 22. EOS | 7 Silo Experience R&D R&D MD KOLKOL PD PM Metallurgy Innovative Shapes Exposure and Process Post- Treatments Manufacturing © Stefan Bindl Machining Supports & Orientation Design for Additive Manufacturing is about…
  23. 23. EOS | 8 Important to Establish Whole Process Chain Source: EOS, Instrumentaria Digital Design  CT/MRI based design  Optimization of part design  Use of design software to generate e.g. lattice structures Data processing Optimization with regard to  Part orientation  Placement  Usage of build area  Support structures  Layout Build process  Identification of critical parameters for application goal  Parameter optimization  Material characteristics Post processing  Heat treatment  Post-machining  Polishing  Cleaning DESIGN BUILD FINISH
  24. 24. EOS | 9 Important to Establish Whole Process Chain Source: EOS, Instrumentaria Digital Design  CT/MRI based design  Optimization of part design  Use of design software to generate e.g. lattice structures Data processing Optimization with regard to  Part orientation  Placement  Usage of build area  Support structures  Layout Build process  Identification of critical parameters for application goal  Parameter optimization  Material characteristics Post processing  Heat treatment  Post-machining  Polishing  Cleaning DESIGN BUILD FINISH
  25. 25. EOS | 10 Leveraging CM Experience in Design Phases for AM
  26. 26. EOS | 11 Risks of Implementing AM in Silo Environment Competitor innovates before you Redesign needed; adds to launch timeline CM & OEM expectations not aligned Device not economically buildable
  27. 27. EOS | 12 EOS-Design Process © EOS GmbH 1 Clarify Challenge Create Concepts Define Orientation Define Design Build final job Evaluation Test job Test job Test job
  28. 28. EOS | 13 Process Application Sprint/Redesign of Application Clarify challenge Define main functions Theoretical Evaluation Define final orientation Define redesign approach for each function Final Design (+ Parameters) Test for function 1 No Test for function 2 Test for function 3 N-Tests for n- functions Evaluation of each test Yes Test part building optional No Can a decision be made for design ? Test for design 1 Test for design 2 Test for design 3 N-Tests for n- designs Post processing optional Generate Concepts Define main goals Support Structures + pre processing Evaluation of each test Can a decision be made for orientation ? Yes Using methodic product development and design Evaluation
  29. 29. EOS | 14 Process Application Sprint/Redesign of Application Clarify challenge Define main functions Theoretical Evaluation Define final orientation Define redesign approach for each function Final Design (+ Parameters) Test for function 1 No Test for function 2 Test for function 3 N-Tests for n- functions Evaluation of each test Yes Test part building optional No Can a decision be made for design ? Test for design 1 Test for design 2 Test for design 3 N-Tests for n- designs Post processing optional Generate Concepts Define main goals Support Structures + pre processing Evaluation of each test Can a decision be made for orientation ? Yes Using methodic product development and design Evaluation
  30. 30. EOS | 15 Process Application Sprint/Redesign of Application Clarify challenge Define main functions Theoretical Evaluation Define final orientation Define redesign approach for each function Final Design (+ Parameters) Test for function 1 No Test for function 2 Test for function 3 N-Tests for n- functions Evaluation of each test Yes Test part building optional No Can a decision be made for design ? Test for design 1 Test for design 2 Test for design 3 N-Tests for n- designs Post processing optional Generate Concepts Define main goals Support Structures + pre processing Evaluation of each test Can a decision be made for orientation ? Yes Using methodic product development and design Evaluation
  31. 31. EOS | 16 Process Application Sprint/Redesign of Application Clarify challenge Define main functions Theoretical Evaluation Define final orientation Define redesign approach for each function Final Design (+ Parameters) Test for function 1 No Test for function 2 Test for function 3 N-Tests for n- functions Evaluation of each test Yes Test part building optional No Can a decision be made for design ? Test for design 1 Test for design 2 Test for design 3 N-Tests for n- designs Post processing optional Generate Concepts Define main goals Support Structures + pre processing Evaluation of each test Can a decision be made for orientation ? Yes Using methodic product development and design Evaluation
  32. 32. EOS | 17 Collaboration “Additive Minds is an applied engineering consulting team; designed to help your organization transform from prototyping to production with additive manufacturing.”
  33. 33. EOS | 18 Device OEM Contract Manufacturer Successful Product Innovation Affects Collaboration
  34. 34. EOS | 20 Shaping the Future of Manufacturing

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