Additive manufacturing (3D printing) provides several advantages for the automotive industry, including new design possibilities, lighter and safer products, shorter lead times, and lower costs. However, challenges remain around manufacturing large parts, a lack of talent, intellectual property concerns, and limited materials. The automotive industry's use of additive manufacturing is expected to grow significantly by 2020 to include more interior, exterior, and powertrain components. For companies like Porsche, the recommendation is to start implementing additive manufacturing now for prototyping while continuing to monitor innovations, in order to integrate the technology and stay competitive in the future as it develops further.

1. Additive Manufacturing
The Automotive Industry
Alejandro | Gianmarco | Julia | Keyang | Quentin | Stefan | Verena
Team C Digital Solutions

2. Agenda
Introduction
Advantages
Drawbacks
Expenses
AM in 2020
Recommendation

3. What is Additive Manufacturing?

4. Introduction
• Briefly: 3D Printing
• Definition: It is a process of adding ultrathin layers of
material(metal, plastic, etc.) one by one to create a raw
material or a product

5. Introduction

6. Advantages
“For the automotive industry, these advances have opened
doors for newer designs; cleaner, lighter and safer products;
shorter lead times; and lower costs”.
Deloitte University Press

7. Advantages: New Design
The ability of producing different type of items for specific
customers and market demands.
Example: Customized Dashboard
Competitor: Bentley
Possibility of customizing items

9. Advantages: New Design
The ability to create lighter, safer, cleaner and more efficient
products.
Example: Hand tools used in testing and assembly
Competitor: BMW
BMW: ”The new tools reduced project time by 92 %”
1st stage: Creating better quality items

10. Advantages: New Design
2nd Stage: Creating better quality items
Example: Reducing the weight of a car without changing the
main structure
Competitor: None
The ability to create better quality items, that will change the industry.
Industry is not enough developed for this stage.

12. Advantages: Shorter Lead times
The time between the initiation and completion of a production
process.
Example: Prototyping process
Competitor: Ford
Ford: ”Prototyping usually took 4 years.
Now with AM it takes 4 days”

13. Advantages: Lower costs
Capital vs. Scale
Reduction of capital required to achieve the same amount of
products.
Example: Lowering the costs of production
Competitor: Ford & BMW
Ford: ”Prototyping cost decreased from 500,000 $ to
3000 $”
BMW: ”The new tools reduced the cost by 58 %”

14. Advantages: Lower costs
Capital vs. Scope
Increase in scope of products with the same amount of capital.
Example: Increase in the variety of products portfolio
Competitor: None
Industry is not enough developed for this stage.

15. Drawbacks
“The automotive industry still has challenges ahead
related to manufacturing of large parts; talent shortage;
intellectual property and materials variety.”
Deloitte University Press

16. Drawbacks: Manufacturing large parts
Printed products size is limited
Oak Ridge National Laboratory: No size restriction
Research
Materialise: Has build a machine to produce big components

17. Drawbacks: Talent Shortage
Not enough AM specialist
Trainings
AM service providers and end-user industries are
concentrated to create a stable program for a capable
workforce.

18. Drawbacks: Intellectual Property Concerns
Expansion of AM will lead to expansion of copying
Patents
•Patenting of produced products through AM can solve
this problem.
•Patent protection qualification should be clear

19. Drawbacks: Limited materials
Materials for production are either limited or expensive
Example: Titanium powder (200-400 $ for 1 kg)
Competitor: Jaguar with Metalysis
Jaguar: Buying powder from Metalysis
with 75% lower price for AM

20. 2020 (5 years later)
Current
Fluid handling
Applications: Pumps, valves
Exterior Trim
Applications: Bumpers, wind breakers
Manufacturing Process
Applications: Prototyping, customizing Exhaust emissions
Applications: Cooling vents
Future
Interior & Seating
Applications: Dashboards, seat frames
Wheels, Tires & Suspension
Applications: Hubcaps, tires, suspension springs
Electronics
Applications: Sensors, panels, etc.
Frame, body, doors
Applications: Body panels
Powertrain, drivetrain
Applications: Engine components

21. Expenses
Cost can be cut by 50% within 5 years
Investment EUR Direct Cost EUR
Machine Cost 500,000 Steel Powder price per kg 89
Technical Rate Energy per kWh 11
Utilization rate 86% Hourly labour 25
Monitoring 5% Yearly rent for 28 3,640

22. What should Porsche do?

23. Important Factors
•Technology is not fully developed yet
•The Industry is very interested in development

24. Recommendation
Implement AM in prototyping
Be always aware about the innovation in AM
Try to use this technology with the current technology
Invest right now in order not to be outsider in the future

25. Questions?