This is presentation of winner of case study competition conducted by GE at SIOM Nashik. The topic evolved around Additive Manufacturing/3D Printing and its commercial application.

1. Advanced
Manufacturing
Fantastic4
Varun Patel Parth Lunia
Utkarsh Gupta Aditya Sharma

2. Market Research
1 2 3 4 5 6 7 8 9 10 11 12
306
163
86
49 44
0
50
100
150
200
250
300
350
Stratasys EOS 3D Systems SLM Solution Concept Lasers
Machine Sold (Million $)
35%
19%
10%
6% 5%
0%
5%
10%
15%
20%
25%
30%
35%
40%
Stratasys EOS 3D Systems SLM Solution Concept Lasers
Global Share
Source :- http://www.prnewswire.com
Top 5 Vendor 3D Printer Market by Revenue from Machines shipped, Global Industrial/Professional 3D
Printers, YTD 2016 (Q1-Q3)
Top Players

3. Driving Best In Class AM
NASA
•Zero-G 3D printer designed to operate in
zero gravity launched in 2014 for made in
space components.
GE Aviation
•3D printed fuel nozzles for LEAP engine
Rocketdyne
•12 additively manufactured production
nozzle extensions for Orion spacecraft
Lockheed Martin
•3D parts have flown in space JUNO - a set
of eight titanium waveguide brackets
RUAG
•Antenna Bracket – Weight reduced from
1.6kg to 940gm.
Low and high temperature fasteners
Discs, hubs, spacers, seals
Compressor blades
Structural parts
Complex turbine engine components
Blisks
Cases, rings
Exhaust parts
1 2 3 4 5 6 7 8 9 10 11 12

4. Driving Best In Class AM
Fluid Handling
• Pumps
• Valves
Manufacturing Process
• Prototyping
• Customized Tooling
Exhaust
• Cooling Vents
Exterior
• Bumper
• Wind Breakers
Interior
• Dash Board
• Seat Frames
DUCATI
Prototyping Ducati cut 20 months from the
development process of the engine designed for its
Desmosedici race bike
Local Motors
-Fully 3D printed LM3D Swim
EOS technology
-The volume of the battery housing was reduced by
half, and the weight by 40 %
Blade Car
•3D printed chassis.
BMW
•3D-printed water pump wheel.
•10000 parts for Rolls Royce phantom.
Toyota
•3D printed car seats.
1 2 3 4 5 6 7 8 9 10 11 12

5. Driving Best In Class AM
muRata
•Pacemakers
•Invasive Pressure measurement
•Non-invasive Pressure Measurement
Metamason
•3D printed mask customized for each customer
Organovo
•Liver Tissues
•Kidney Tissues
3D OPS
•Convert MRI and CT scan to 3D model for pre-surgical
planning.
Osteo3d
•Cranial Helmets – Price ₹20000. US price ₹1.5 lakh.
•Guides For Dental Implants
•Custom Surgical Guides & Fixtures
Dental & Orthopedic Implant
Prosthetic Devices
Personalized Drugs
Anaplastology
Medical Sensor
Bioprinting
1 2 3 4 5 6 7 8 9 10 11 12

6. Future of Raw Materials Advance Manufacturing
42%
18%
26%
13%
0%
1%
0%
2%
2015
Photopolymer Thermoplastic Filament Thermoplastic Powder
Metal Powder Binder Welding Wire
Sand
38%
13%
23% 25%
0%
1%
0%
2%
2025
Photopolymer Thermoplastic Filament Thermoplastic Powder
Metal Powder Binder Welding Wire
Sand
1 2 3 4 5 6 7 8 9 10 11 12

7. Scope Of Applicability For Different Material
•Aerospace: Gas turbine and airframe parts
•Power Generation: Gas turbine parts
•Parts for petrochemical applications
•Industrial furnace components
•Structural components
Nickel-Chromium-Iron-
Molybdenum Alloy
•Tools and dies
•Plastic injection molds
•Light metal and pressure die casting
•Cold extrusion tools `
Maraging Steel
•Aerospace applications
•Chemical processing equipment
•Nuclear applications
•Oil and petrochemical refining equipment
•Food processing equipment
•Surgical parts
High Strength Stainless
Steel
•Aerospace: Gas turbine and airframe parts
•Power Generation: Gas turbine parts
Inconel 718 and Inconel
625
•Aerospace and defense
•Automotive and racing
•Maritime applications
•High-end sports equipment
•Medical and dental
•Jewelry and art
Titanium Alloy
1 2 3 4 5 6 7 8 9 10 11 12

8. Scope Of Applicability For Different Material
PLASTICS
• ABS - acrylonitile butadiene styrene or
'lego' plastic
• PLA - polylactic acid
• PVA - polyvinyl alcohol
• PC – polycarbonate
• SOFT PLA - polylactic acid
• Nylon 12
• Glass filled nylon
• Epoxy resin
• Wax
• Photopolymer resins
• PEEK (Polyetheretherketone)
• PEKK (Polyetherketoneketone).
CERAMICS
•Silica/Glass
•Porcelain
•Silicon-Carbide
•Fused Silica
•Zirconium Oxide
•dental restorations,
thermal barrier coatings
and aesthetic purposes
such as jewelry.
•Aluminum Oxide
•catalysis, water
purification, electronics
and medical implants,
such as hip replacements.
Others
• Binders
• Biomaterials
• Conductive – inks,
pastes,photopoylmers
• Carbon Fibre
• Wood
• Graphene
• Full Color Sandstone
• Full Color Sandstone
1 2 3 4 5 6 7 8 9 10 11 12

9. Scale of Manufacturing
.
3D printing is an effective manufacturing technique for goods which
are slowing moving and are produced only during special demands. For an
industry which functions on the principle of Make-To-Order or Assemble-To-
Order, 3D printing is especially beneficial since the inventory in stored and be
practically kept Zero as the inventory can be produced right in the vicinity of
Assembly line or Production line.
As can be seen from the adjacent graphs, the cost per unit of goods
is lesser when produced in batch of small quantities in comparison to an
industry where Fast moving goods are made and the lead time post setup
required is less. In order to reduce this setup time and start the production
quicker, multiple 3D printers can be deployed.
Installing multiple 3D printers will incur a one time installation cost
but the production system will become adaptive. Since no dedicated moulds
or dies need to be made for 3D printing, the change over for any setup is not
required and different components can be produced. It will also avoid need for
dedicated manufacturing line hence the production system can be aligned to
produce any component in demand.
Source - Impact of 3D Printing on Global Supply Chains by 2020 by:
Varun Bhasin & Muhammad Raheel Bodla
Source - Breakeven Point for High-Pressure Die-Casting and
Selective Laser Sintering, Atzeni and Salmi (2011)
1 2 3 4 5 6 7 8 9 10 11 12

10. Cost Effectiveness & Commercialization
Consider the above production schedule for an year. To commercialize the 3D printing technology in a cost
effective manner, it needs to produce goods in small quantity. Deploying a mix of traditional manufacturing along with
additive manufacturing techniques can provide a cost effective measure which will reduce the time required to cater to
customer demands and keep the working capital rolling.
0
50
100
150
200
250
300
350
400
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Production
In order to do so, one needs to identify a baseline, not necessarily level production, based on the cost
effectiveness of 3D printed parts and scheduling the production of goods above the baseline to be done on 3D printer. This
setup will help avoid stressing the traditional set up and still cater to surges in the demand due to seasonality or events.
Source : Preliminary Investigation into the Influence of 3D Printing on Sustainable Manufacturing Carter Keough, Ola
Harrysson, Ron Aman, Harvey West, Russell King, Tim Horn
1 2 3 4 5 6 7 8 9 10 11 12

11. Cost Effectiveness & Commercialization
Source : Preliminary Investigation into the Influence of 3D Printing on Sustainable Manufacturing Carter Keough, Ola
Harrysson, Ron Aman, Harvey West, Russell King, Tim Horn
Consider a Ti6Al4V C130 Hinge component, used in aerospace
sector, which is not available from OEM. The adjacent table shows a basic
comparison between traditional manufacturing approach and Electron
Beam Melting approach. The lead time includes the die building and testing
time, proto sampling time and finally the product building time.
As it can be seen, for limited production, the cost for
manufacturing is drastically less for EBM than traditional manufacturing.
The time period to obtain the finished component is also lesser for EBM
Lead Time Cost
Traditional 18-24months $60k - $100k
EBM 22hours $2.5k
Cost
Saved
Lead time
Reduced
1 2 3 4 5 6 7 8 9 10 11 12

12. Cost Effectiveness & Commercialization
A PwC analysis of 3D printers adoption by the
global aerospace industry’s MRO parts market,
estimates a $3.4 billion annual savings in
material and transportation Costs alone,
assuming a scenario in which half of that
industry’s MRO parts are 3DP manufactured.
In fact 70% of
manufacturers we
surveyed in the PwC
Innovations Survey
believe that in next
three –five years, 3DP
will be used to produce
obsolete parts, 57%
believe it will be used
for after-market parts
Snippets from-
3d Printing And The New Shape Of Industrial Manufacturing,
PwC Report, June 2014
22% of the survey respondents said that more than 10% of the
spare parts they keep in stock are obsolete or do not
contribute positively to margins and the majority of
respondents believe that at least 3% of their spare parts stock
loses money.
1 2 3 4 5 6 7 8 9 10 11 12 13

13. Cost Effectiveness & Commercialization
‘3DP creates the flexibility to manufacture products according
to the “Lot Size One” Principle – that is, individually – without tools or
changeovers, while maintaining production capacity.’
- EY Global 3D Trends Report, 2016
The spare parts for any industry is a huge cost. The major portion of this
cost is the logistics and the opportunity cost the customer bears due to machine
downtime caused while waiting for spare parts. The industries under observation
are Health, Defense and Aerospace.
Capitalizing upon the ‘Lot Size One’ principle by building 3D printer hubs
across country at strategic locations in order to cater to spare parts demand of
customer in a shorter time frame, at lesser transportation cost and to insource back
of the crucial value added processes.
With the above concept, the inventory carrying cost at customer and
supplier reduces. The threat of obsolescence of inventory due to shift towards
better technology is reduced. Spare parts are produced as and when required
hence judicious use of materials saves material cost.
Adjacent map shows the tentative locations of 3D printer hubs
1 2 3 4 5 6 7 8 9 10 11 12

14. Presentation By:
Varun Patel Parth Lunia Utkarsh Gupta Aditya Sharma