This document discusses lowering the entry barrier to metal 3D printing through Renishaw's Solutions Centres. The centres provide incubator cells for private development, access to additive manufacturing machines and finishing processes. They also offer pre-production capacity and integrated manufacturing capabilities to prove out and ramp up production processes. Renishaw aims to be a full-service AM partner, drawing on its expertise in machines, software, metallurgy and other areas to optimize solutions for customers' applications around the world.

1. Lowering the entry barrier to metal 3D printing
Marc Saunders
Director – Global Solutions Centres

2. Lowering the entry barrier to metal 3D printing
Getting the most from
additive manufacturing (AM)
Applying AM in series
production

3. Why everyone is interested in 3D printing…
Cast aluminium bike seat post bracket
and optimised titanium bracket.
A weight reduction of 44% was achieved
by optimising the design for AM.
Additive manufacturing (AM) benefits
Innovative product designs
Complex internal details
Lightweight, optimised forms
Efficient material usage with minimal waste
Improved cooling & heat transfer
Customisation for specific applications
Short lead times
Build from CAD with no special tooling

4. Low volume parts
made direct from CAD
Getting the most from AM
Rapid prototypes & tooling
Why use AM for prototype & tooling development?
• Prototypes help to de-risk system designs at low cost
• No intention to use AM to make production parts
• AM avoids tooling costs whilst the design is still in flux
• AM enables cost-effective manufacture of complex tooling
Benefit

5. Examples: Rapid prototypes & tooling
Complex bar
locators for part
handling
Prototype
exhaust
nozzle
Conformal
mould tooling for
rapid cooling

6. Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Getting the most from AM
Rapid prototypes & tooling
Direct part replacement
Why use AM for direct part replacement?
• Gain experience with AM in low risk applications
• Develop a supply chain for AM parts
Benefit

7. Example: Direct part replacement
Significant
waste
reduction
with AM
process
Note: some finish
machining still
required on AM
part
Example courtesy of GKN Aerospace

8. Complex parts that simplify
assembly & enhance reliability
Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Getting the most from AM
Rapid prototypes & tooling
Direct part replacement
Part consolidation
Why combine parts using AM?
• Simpler assembly & fewer joints / bonds
Higherbenefit

9. Example: Part consolidation
Single piece microwave guide reduces
weight and improves performance

10. New product designs that
1. Deliver lifetime benefits in use
2. Provide mass customisation
Complex parts that simplify
assembly & enhance reliability
Re-production parts, that avoid
complex manufacturing
Low volume parts
made direct from CAD
Getting the most from AM
Rapid prototypes & tooling
Direct part replacement
Part consolidation
DfAM
optimised
Highestbenefit

11. Examples: DfAM optimised
Customised
cranio-facial
implant
Increased
efficiency heat
exchanger
Light-weight,
efficient hydraulic
manifold

12. Lowering the entry barrier to metal 3D printing
Getting the most from additive
manufacturing (AM)
Applying AM in series
production

13. Few companies are using AM in series production – why?

14. Lowering the entry barrier for AM
Metal additive manufacturing
technology for industrial applications
Global network of Renishaw Solutions
Centres
Applications expertise in a wide range
of industries
Integrated manufacturing solutions

15. Global network of Solutions Centres
Stone
Pune
Shanghai
Toronto
Stuttgart
Dallas
Breda
Miskin
Chicago
Wotton
A mutually supporting
network of centres,
each with applications
specialisms to suit
local industrial
demand
Opening during 2015
and 2016
Renishaw location
UK
Europe

16. Solutions Centre services
Benchmark part:
benefits tangible
Concept embodies
AM benefits
Optimise process
& verify part
Demonstrate
process stability
AM & finishing processes
to make saleable product

17. Renishaw Solutions Centre
for Additive Manufacturing

18. Incubator cells to nurture your idea
Your private development facility,
including…
 Secure, access-controlled process incubator cell
 Dedicated AM250 additive manufacturing machine
 Materials choice & option to use your own powder
 Dedicated powder handling accessories
 No overheads & predictable costs
 Access to Renishaw engineers and technicians
 Optional access to finishing processes, metrology
and materials analysis

19. Incubator cell services
Partially supported
• Secure incubator cell & office
• AM operator support
• Initial consultancy on build
orientation & support design
• Assisted build removal
• Systematic build data capture
• Reserved access to:
– De-build
– Filter management
Fully supported
Partially supported plus…
• Application engineering
• DfAM knowledge transfer
• Reserved access to:
– Heat treatment
– Part removal (EDM, saw)
– Support removal
– Surface-treatment
Additional services
Fully supported process
development & operation of:
• 5-axis CNC machining
• CMMs
• Equator gauges
• Standard or AM-built custom
fixtures

20. Pre-production capacity to prove your process
Ramp up towards production
volumes…
Access to multiple AM machines
Metrology and finishing processes
as required
Contracted price per part
Support for process capability
studies
Business case preparation

21. Integrated manufacturing capabilities
Support removal
Build plate removal
Heat treatment
Surface treatment
Machining CMM inspection
Polishing Gauging

22. Oil & gas Consumer
Aerospace AutomotiveHealthcare
Mould & die
Industrial applications expertise

23. Why choose Renishaw as your AM partner ?
• FTSE 250 plc, c £500m revenue and >4,000 staff
• Develops all aspects of AM technology in-house
(machines, software, metallurgy, services)
• World-class metrology, process control,
machining, electronics and assembly expertise
• Optimised solutions for your application, not just
standard product that you have to adapt

24. Thank you
Your product
design
Renishaw
expertise
Your AM
process
Global
support