3D printing for Development Hack Day in Bucharesy

3D printing for Development Hack Day in Bucharesy

• 1.
  Dr Phil Reeves- Managing Director, Econolyst Ltd, UK The 3D for Development Challenge -Bucharest - www.econolyst.co.uk Friday 22nd June 2012 - Romania
• 2.
  Session 1 –the background (1-hour +) • Personal introduction • What is 3D Printing & Additive Manufacturing • What is the current state-of-the-art in 3DP/AM • What drives companies to use this technology – Economics, geometries, environment, personalised products, increased functionality, new supply chains • The growth of low-end / home consumer 3DP Slide 1 of 62
• 3.
  About Econolyst • Econolystis a UK based consultancy dedicated to the Additive Manufacturing & 3DP sector • Established 2003 • Built on almost 20-years of AM experience • Clients in the UK, Western Europe, Scandinavia, Benelux, USA, Israel, India, Middle East & Far East, Africa Slide 2 of 62
• 4.
  What we doat Econolyst • Help companies implement 3DP & AM technology (from design to retail) • Deliver AM focused training & conferences • R&D project management & delivery • AM software development — Establishing supply chain Carbon footprints — Developing AM part cost and value models Slide 3 of 62
• 5.
  Things that keepmy office busy • Helping the world largest jet engine maker (GE) use AM • Helping a global sports brand (Nike) to use AM • Helping India's largest jewellery retailer (Tanqish) implementing direct metal printing of precious metal into 150 shops • Advising one of the worlds largest chains of high street chemist (Boots) on how to use 3DP (glasses, hearing aids, drugs) • Advising VC’s and Private Equity companies on investment in AM • Advising the UK government on investment strategies to support AM R&D • Advising the UK Ministry of Defence on AM/3DP capabilities to support security and warfare out to 2030 Slide 4 of 62
• 6.
  So what is3D Printing & additive manufacturing? Slide 5 of 62
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  Agreeing terms –setting the context Additive Manufacturing is the manufacture of ‘end-use’ component parts using Additive Layer Manufacturing processes Slide 6 of 62
• 8.
  What is a3D printing systems 3DP processes are automated systems that take 2-dimensional layers of computer data and rebuild them into 3D solid objects Slide 7 of 62
• 9.
  Agreeing terms –what’s in a name • AM is also refereed to as: – Generative Manufacturing – Germany – eManufacturing - Germany – Constructive Manufacturing - Germany – Additive Layer Manufacturing (ALM) – Scandinavia & EADS – Direct Digital Manufacture (DDM) – USA – Freeform Fabrication (FFF)– USA – Solid Freeform Fabrication (SFF) – USA – 3D Printing (3DP)- Global – Rapid Manufacturing – Global (historic) Slide 8 of 62
• 10.
  How does the3D Printing process chain work? • Start with a 3D geometry • Generate STL file • Orient parts to optimum build direction • Generate support structures • Slice part & supports Link to Video horizontally • Consolidate, deposit or cut out layer • Index machine down (or up) by one layer thickness Slide 9 of 62
• 11.
  How does ALMdiffer 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 (1984 – Californians) Slide 10 of 62
• 12.
  So what isthe current state of the art in 3DP/AM in 2012? Slide 11 of 62
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  We have anever increasing range of technologies High end Mid range – Stereolithography IPro (3D) – 3D Printing (Voxeljet) – Selective Laser Sintering (3D & EOS) – Stereolithography Viper SLA (3D) – FDM Fortus (Stratasys) – Polyjet Eden (Objet) – Connex (Objet) – 3D Projet (3D systems) – Perfactory XE (Envisiontec) – Perfactory (Envisiontec) Lower end (desk-top) Very low end (home users) – 3D Printing (Z-Corp) – Ultimaker – Ultra Z-Printer (Envisiontec / Z-Corp) – Bits-from-Bytes (3D) – 24/30 (Objet) – MakerBot – FDM Dimension (Stratasys) – UP personal printer – UPrint (HP / Stratasys) – Fab@Home – Laminated Objet Manufacture (Mcor) – PrinterBot – V-Flash (3D Systems) Slide 12 of 62
• 14.
  Today we havea ‘pallet’ of around 200 materials Organic Ceramic Polymeric Metallic materials materials materials materials Waxes Alumina ABS Aluminium Tissue / cells Mullite Polyamide (nylon) Tool Steel Zirconia Filled PA Titanium Silicon Carbide PEEK Inconel Beta-Tri calcium Phosphate Thermosetting epoxies Cobalt Chrome Ceramic (nano) loaded epoxies Copper Silica (sand) PMMA Stainless steel Plaster Polycarbonate Gold / platinum Graphite Polyphenylsulfone Hastelloy ULTEM Aluminium loaded polyamide Slide 13 of 62
• 15.
  So what drivescompanies to adopt Additive Manufacturing (or be interested)? Slide 14 of 62
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  The core businessdrivers to AM adoption 1. Economic low volume production 2. Increased geometric freedom 3. Increased part functionality 4. Product personalisation 5. Improvised environmental sustainability 6. New supply chains and retail models Slide 15 of 62
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  Lets consider thesedrivers with some case studies Slide 16 of 62
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  1. Enabling lowvolume production • Enabled the economic manufacture of low volume complex geometries and assemblies – Reduces the need for tooling (moulds / cutters) – Reduced capital investment & inventory – Simplifies supply chains & reduced lead times Slide 17 of 62
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  Example – unitvolumes of 1 • Bentley is a subsidiary of Volkswagen • Vehicles from $250K - $1M • In-house polymeric and metallic AM capacity Slide 18 of 62
• 20.
  Example – Lowvolume production • Problem – customer with limited mobility needed a reversed dashboard • Production substrate produced by RIM • Manual modification time consuming • Solution – Laser Sintered AM part with leathers and veneers veneers Images courtesy of Bentley Slide 19 of 62
• 21.
  Example – Lowvolume production Images courtesy of Bentley Slide 20 of 62
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  2. Maximising designcomplexity & capability • AM enables the production of highly complex geometries with little if no cost penalty – Re-entrant features – Variable wall thicknesses – Complex honey combs – Non-linear holes – Filigree structures – Organic / genetic structures Slide 21 of 62
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  Example – DelphiDiesel Pump • Conventional product manufactured by cross drilling an aluminium die casting • Multiple machining operations • Multiple post processing ops (chemical deburring, hole blanking, pressure testing) • Final product prone to leakage Slide 22 of 62
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  With AM -Design the product around the holes Slide 23 of 62
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  Example – conceptualDiesel Pump • Produce the part as one piece using Selective Laser melting on Aluminium Slide 24 of 62
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  3. Increasing partfunctionality • AM enabled multiple functionality to be manufactured using a single process – Replacing surface coatings & textures – Modifying physical behaviour by designing ‘mechanical properties’ – Embedding secondary materials (optical / electrical) – Grading multiple materials in a single part Slide 25 of 62
• 27.
  Example – surfacedesign for bone ingress Material: Ti6Al4V Build time: 16 cups in Implants (production) 18 hours • Accetabular cups Images Courtesy of ARCAM – www.arcam.com Slide 26 of 62
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  Example – Heatdissipation surfaces Slide 27 of 62
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  Example – Energyabsorption Slide 28 of 62
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  4. Product Personalisation •Individual consumer centric products, with customer input – Medical devices – Consumer goods – Cultural & emotional artefacts – Online design tools – Co-creation Slide 29 of 62
• 31.
  Case study -Hearing aids • Produced using personal data from each individual patient – Produced using scan data – 20 million made every year by 3DP – Lower cost than traditional – Every one is different – Improved fit for the user – Lots of medical applications using bdy scan data, CT & MRI data Slide 30 of 62
• 32.
  The personalisation canbe by the consumer • www.makielab.com Slide 31 of 62
• 33.
  The Internet letseveryone become designers • Some web offering allow us to become the designer in an AM supply chain – Digital Forming.com – Jujups.com This is a pall point pen – Sculpteo.com – Landprints.com This is a bedside light This is a lemon squeezer Slide 32 of 62
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  There are lotsof new interfaces Google Sketch UP Slide 33 of 62
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  There are lotsof new interfaces Slide 34 of 62
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  5. Life cyclesustainability • Product lifecycle improvements in economic and environmental sustainability – Reduced raw material consumption – Efficient supply chains – Optimised product efficiency – Lighter weights components – Reduced lifecycle burden Slide 35 of 62
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  Case study –aerospace cabin component Slide 36 of 62
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  A very differentapproach to design Slide 37 of 62
• 39.
  Design optimisation forAM production Topologically optimised Machine from solid billet Complex lattice Slide 38 of 62
• 40.
  Example – Howdoes the weight compare Scenario 1 – Machined from solid (0.8Kg) Scenario 2 – Selective Laser melted lattice (0.31 kg) Scenario 3 – Selective Laser melted optimised design (0.37 Kg) Slide 39 of 62
• 41.
  To establish sustainability you have to establish life cycle boundary conditions Slide 40 of 62
• 42.
  Environmental benefit overproduct lifecycle Process Raw Manufacture Distribution Usage Life cycle Materials CO2 CO2 CO2 Kg CO2 CO2 Machining 100Kg 2 Kg 5 Kg 43,779 Kg 43,886 SLM lattice 16 Kg 5 Kg 1 Kg 16,238 Kg 16,260 SLM optimal 18 Kg 7 kg 2 Kg 20,339 Kg 20,366 • Example based on 90M km (Long haul) application Slide 41 of 62
• 43.
  So how doour lifecycle CO2 compare Scenario 1 – Machined from solid (100%) Scenario 2 – Selective Laser melted lattice (37%) Scenario 3 – Selective Laser melted optimised design (46%) Slide 42 of 62
• 44.
  Sunday Times 13thFeb 2011 Slide 43 of 62
• 45.
  Example – lifecycle economic benefits • 0.49Kg saving per monitor arm • $1,500 per annum in fuel savings (today's prices) • $45,000 over 30-year aircraft life • Product life span 5-7 years (estimate) • Life-cycle economic saving $6.5K - $9K • Machined part - $500 • SLM Part - $2,500 • Capital investment repaid in 2-years….  Slide 44 of 62
• 46.
  This is astep change in design thinking Slide 45 of 62
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  6. Supply chainrealignment • New lean yet agile business models and supply chain – Distributed manufacture – Manufacture and the point of consumption – Demand pull business models – Stockless supply chains – Chainless supply chains (home manufacture) Slide 46 of 62
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  Stockless supply chains– low barriers $50.00 each 60,000 month $36M P/A Slide 47 of 62
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  Integration with otherdata sources $6.2-million (6-machines) Slide 48 of 62
• 50.
  There are onlineprinting portals to buy & sell Slide 49 of 62
• 51.
  These portals havevolume traffic $44 average price of products Slide 50 of 62
• 52.
  So what arepeople designing & sharing Slide 51 of 62
• 53.
  But what doyou do with the data? – Home 3D Printing Makergear Start-up Growing Established Slide 52 of 62
• 54.
  MakerBot – the‘market leader’ • Less than 3-years old • Business based on open source • 6700 machines sold in 2011 • $1,749 per machine • 20,000 machines this year Slide 53 of 62
• 55.
  So what arepeople making Slide 54 of 62
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  These machines arebased on open-source Slide 55 of 62
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  Other supply chainopportunities for all Slide 56 of 62
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  Is there amarket? 1985 – 2010 = 45,000 machines 2011 = 15,000 machine 2012 = 45,000 machine 2013 = 200,000 machines 2014 = 800,000 machines 2015 = 3.2-million Moore's law? Slide 57 of 62
• 59.
  The money willalso be in the data & content Slide 58 of 62
• 60.
  So is AMthe new Manufacturing revolution for the digital age? Slide 59 of 62
• 61.
  Not yet -the harsh reality • Of the 200+ products, components, parts & business models we have looked at over the last 7-years, 90% were not immediately suited to AM. – Piece part economics – Production throughput – Mechanical property limitations – Surface finish Next session – Part accuracy – Process variance – Quality assurance & validation Slide 60 of 62
• 62.
  BUT…. We candream ……. Slide 61 of 62
• 63.
  Dr Phil Reeves- Managing Director, Econolyst Ltd, UK Questions Econolyst Ltd The Silversmiths Crown Yard Wirksworth Derbyshire, UK DE4 4ET +44 (0) 1629 824447 phil.reeves@econolyst.co.uk www.econolyst.co.uk Friday 22nd June 2012 - Romania