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.

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  • Additive Fabrication
    Preferred term (adopted by Stratasys) covering all technologies/applications
    Preferred replacement for RP
    Definition: 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 design
    Problem (that is solved)
    Reduce design cycle of new engine on Desmosedic motorcycle surpassing predecessors in power
    How used (solution)
    Brought work in-house (vs. service bureaus)
    Built complete engines (2 different designs) almost entirely in Polycarbonate
    twin-cylinder oval-piston configuration
    four pistons in L-shaped layout
    Benefit delivered (result)
    71 % reduction in time (concept to final engine design)
    8 months vs 28
    reduced outsourcing- Saved $1.5M
    Saved time and money by eliminating 83 design problems
    Complete engine made buy-in on vision for twin-cylinder design possible/easier
    Success with a major piston configuration design change
  • Example: Toro-Commercial Sprinkler Functional Prototypes
    Problem (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 testing
    Validate form, fit and function
    Benefit delivered (result)
    Over a 2 year period & many projects
    Reduced product development time by 283 weeks
    Reduced tooling costs by $500,000
  • Example: Logitech Mobile Bluetooth Headset
    Problem (that is solved)
    Philosophy: continuous improvement-flawless design
    Needed earlier functional testing
    Other AF too expensive/prone to breaking
    Only option-later in the cycle for injection molded parts
    expensive/long lead time
    So, very few iterations
    How used (solution)
    Problem with headset. Design flaw made unit prone to breaking.
    Used Fortus for ABS prototypes
    Multiple iterations to test/fin d the best design
    Benefit delivered (result)
    Discovered counterintuitive wedge stop design
    273% stronger than original
    Faster response and low cost resulted in more functional prototyping for more applications
    Design, manufacturing, marketing
    Which leads to better products and happier customers
  • Manufacturing applications—the “developing market”
    High-level benefits (primary)
    Broad since cover parts, jigs, patterns and tools
    But still, fundamentally, about
    Financial gain
    Lowering costs
    Costs to make tools, patterns, fixtures
    Increasing profits
    Profits from lower part costs, inventory costs, or direct labor expense
    Time advantages
    Decreasing time-to-market
    Faster production of tools, patterns and parts
    Decreasing cycle time
    Faster, more efficient production of finished goods
    Secondary advantages
    Design freedom
    Product redesign frequency
    Rapid response
  • Ideal solution when (note: try to explain why for each in a few words)
    Relative low volumes
    Short run production
    Bridge to tooling
    High part complexity
    Eliminate expensive tooling
    Reduce long lead times
    Part acceptable
    Aesthetics not critical
    Finishing processes feasible
    Physical 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 items
    Check Gauges
    Drill / Rivet Guides
    Go / No-Go Gauges
    Alignment Tools & Guides
    Tooling Masters & Patterns
  • Example: BMW
    Reduced weight-worker fatigue
    Better balance/ergonomics – worker productivity
    Better performance – organic shape to fit up/under bumper
  • Example: Oreck
    Problem (that is solved)
    Making 40 to 50 identical assembly pallets (fixtures) for every vacuum model
    Limits in producing new or replacement fixtures for use on assembly line
    Open 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 mind
    Fortus replace urethane castings/CNC milling
    Modular “pallets” in this case
    Also complete assembly fixtures, assembly tools, milling fixtures and test fixtures
    Benefit delivered (result)
    65% reduction in fixture project costs (up to $100,000 per project)
    Replacement fixtures in hours vs. weeks
    Nearly eliminated worker fatigue and injuries
    58% reduction in manufacturing related defects
    Fortus is also used extensively for functional prototyping

  • The last applications segment is end-use parts, another aspect of DDM
    The parts, subassemblies or products that are sold to a customer or put into service
    Primary Benefits
    Lower cost
    Because there is tooling
    Shorter lead time
    Because tooling is eliminated
    Design freedom
    Few DFM (constraints) (design for manufacturing)
    Change freedom
    Reduced warehouse space/inventory cost
    True JIT (just in time) manufacturing
    Mass customization
    Supports lean initiatives

    DST Control produces advanced embedded electromechanical products primarily for unmanned aerial and ground vehicles.

    The control system of DST’s gimbal eyes or cameras detects the motions of its carrier and corrects in real-time so that the camera remains stable and produces more accurate images.

    Manufacturing costs to produce increasingly complex parts with CNC machining was rising. Suppliers of CNC parts gave DST Control’s smaller orders a lower priority, resulting in slow turn around. Custom parts were very expensive using these methods.

    DST Control is using a Fortus machine to produce 20 different parts for its latest COLIBRI gimbal and also producing custom parts for other products.


    Parts are produced as needed so inventories have been reduced. Delivery time for custom units is four weeks compared to 10 to 12 weeks for competitors.

    Part cost has been reduced to one-third.

    DST is also using the Fortus machine to produce parts for customers’ products.
  • Example: ScriptPro
    Problem (that is solved)
    Manufacture parts for automated pill-dispensing systems
    Custom bezels manufactured to precise tolerances
    Many vials sizes
    They now support 56 sizes
    Need to accept only one vial size
    So, custom for each pharmacy
    How used (solution)
    Fortus to replace injection molded parts
    Produce parts, as needed, in a day or two
    Build, wash, install
    Aesthetics important, yet need no secondary ops
    Benefit delivered (result)
    Saving $25,000 (78%) on
    Engineering time
    Tooling / bezel
    Delivery 58 day reduction (97%)
    Design flexibility
    New product design without tooling
    Easy customization

  • Summary/conclusion
    Terminology (briefly state definition of each)
    3D Printer
    3D Production system
    Business segments
    On Demand (RedEye), 3D Printers (Dimension) and 3D Production Systems (Fortus)
    Product design (established market)
    Functional prototype
    Manufacturing (developing market)
    Manufacturing tools
    End-use parts
    Which we call DDM
    Reduce time, reduce cost (in real, tangible numbers)
    Improve product and process
  • Manufacturing the Future - How 3D Printers are Used for Design and Manufacturing

    1. 1. How 3D Printers and Rapid Prototyping Systems are Changing the Future of Product Development and Manufacturing MANUFACTURING THE FUTURE Stratasys, Inc.
    2. 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. 3. Additive Manufacturing Known by many names:  3D Printing  Rapid Prototyping  Rapid Tooling  Rapid Technologies  Rapid Manufacturing  Additive Fabrication  Advanced Manufacturing  Additive Layer Manufacturing  Direct Digital Manufacturing  Direct Manufacturing
    4. 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. 5. Primary Applications for Additive Manufacturing Established / Traditional (Design) Direct Digital Manufacturing (Manufacturing) Additive Manufacturing Conceptual Modeling End-Use Parts
    6. 6. Technology Assessment End-Use Parts 3D Printers 3D Production Systems Performance Requirements Increase
    7. 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. 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. 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. 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. 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. 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. 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. 14. Manufacturing Tools Examples:  Jigs  Fixtures  Check gauges  Drill / rivet guides  Go / no-go gauges  Alignment tools & guides  Tooling masters & patterns
    15. 15. Manufacturing Tools at BMW Emblem Headlight Alignment Cubing Device Gage Checker Bumper Reach
    16. 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. 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. 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. 19. End Use Parts at DST Control • 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 • FDM parts perform better  Lower weight  Better electrical insulation • Time and cost savings  Part cost reduced 66%  Custom part production time reduced 63% FDM reduces cost 66% & time 77% Method Cost Time Traditional Manufacturing €2,44 1 11 weeks Direct Digital Manufacturing €830 4 weeks Savings €1,61 1 (66%) 7 weeks (63%)
    20. 20. • Custom bezels manufactured  Accept only one vial size  Easy customization • Saving $25,000 on  Engineering time  Tooling / bezel • Design flexibility  New product design without tooling  Able to support new vile sizes  Unique competitive edge Automated Pill Dispensing System End Use Parts at ScriptPro Method Cost Time Traditional $31,650 60 Days Fortus $ 6,750 2 Days Savings $24,900 (78%) 58 Days (97%)
    21. 21. Summary • Terminology  AF  DDM  3D Printer  3D Production system • Business segments  On Demand  3D Printers  3D Production Systems • Applications  Product design • Concept models • Functional prototype  Manufacturing • Manufacturing tools • End-use parts
    22. 22. More Information Test it, Prove it.  Send 3D cad file and have Stratasys build it for you  Application Engineer consultation  Download Application Guides and White Papers  Fill out form to get benchmark built  Get FDM sample part  Request Consultation