Master's students use ideas from my (Jeff Funk) forthcoming book (Technology Change and the Rise of New Industries) to analyze the technical and economic feasibility of 3D additive printing. Manufacturing parts using additive fabrication techniques can enable on-demand local manufacturing and thus can eliminate complex value chains. See my other slides for details on concepts, methodology, and other new industries..

1. MT5009
ANALYZING HI-TECHNOLOGY OPPORTUNITIES
Chew Kuan K k Cl
Ch K Kok, Clement (A0076995E)
Espiritu Maricris Tolentino (A0076910E)
Le Quang Dung (A0077075Y)
Myo Kyaw
Myo Kyaw Thu (A0013741U)
Wong Yong Jin, Melvin (A0076844U)
1

2. 2D printing 3D images?
No color you like?
Dented bumper?
2

3. Lets watch a video …
3

4. 4

5.  Introduction to 3D Printing
d i 3 i i
 Technology Paradigm
 Value Propositions
Value Propositions
 Current 3D Printing Technologies
 Cost and Performance
Cost and Performance
 Comparison of 3D Printing Technologies
 Why 3D Printing Will Get Better
Why 3D Printing Will Get Better
 Potentials for Improvement – Technology Roadmap
 Entrepreneurial Opportunities – Opportunities of Applications
Potential New Businesses
 3D Printer Market at a Glance
 Conclusion
5

6.  3D printing is a form of additive
manufacturing in which components
are f b i
fabricated i an additive f hi
d in ddi i fashion
by adding successive layers of
material together
3D Printing
3D Printing
=
Additive Manufacturing
Additive Manufacturing
6

7. Conventional Manufacturing 3D Printing
Technology Technology
• Mass‐production • Allow customization and
on‐demand production
• Require tools to produce • Directly manufacture from
p
parts (hardware driven)
( ) CAD model (software driven)
( )
• Subtractive manufacturing • Additive manufacturing
7

8.  Fabrication on demand
 Shorter product development time due to rapid
prototyping
Timberland prototype
 Less reliance on logistics
Cost : $1200 $35
 Mass customisation Time required :1 week
90 mins
 Caters to each individual’s wants and needs instead
of mass production and consumption
8

9.  Opens up new
possibilities in design
ibili i i d i
 Complex geometries
 Eliminate constraints of
conventional
conventional
manufacturing processes
 Customised geometry and
geometry and
parts
 Avoids assembly issues
assembly issues
9

10.  Cost‐efficient in producing parts with complex
ff d h l
geometries and reduces waste
€770
€380
Material Subtracted by Machining to Produce Feature/Part
Material Subtracted by Machining to Produce Feature/Part
Material Added by 3D Printing to Produce Feature/Part
Source: Dr Hopkinson, Loughborough University
10

11.  Lowers barriers to entry for new businesses
f
otal cost of
production
To
Cost of conventionally
manufactured parts
p
ng
ost of toolin
Cost of part produced by
Cost of part produced by
Co
3D Printing
Break even
Break‐even Production
Production
Source: Terry Wohler’s Report 2006 volume volume
Illustration showing the total cost of production using
conventional manufacturing and additive fabrication 11

12.  Promotes Innovation
 Communicate design ideas
better through physical
models
 Allows user‐centered
innovation to take place
i ti t t k l
‐ Democratizing Innovation
12

13. Product Company Improvements
ICON Aircraft + Gained two to three weeks on the schedule
+ Saved $2,000
+ Saved $2 000
per part for tooling
Autodesk University Method Cost Estimate Time Estimate
Machining $900,00 9 months
FDM (3D Printing)
( g) $25,000 1.5 months
Savings $875,000 7.5 months
(97%) (83%)
Akaishi (Shizuoka, Japan) Method Cost Estimate Time Estimate
Traditional JPY 37,500 10 days
Prototyping
FDM Prototyping JPY 10,000 1 day
(3D Printing)
Savings $27,500 9 days
(73%) (90%)
13

14. Stereolithography (SLA)
 Process using
photosensitive
photosensitive
resins cured by a
laser that traces the
parts cross sectional
geometry layer by
layer.
14

15. Selective Laser Sintering (SLS)
 Process using a CO2
laser to sinter or
laser to sinter or
fuse a powder
material. The laser
traces the parts
cross sectional
geometry layer by
layer.
15

16. Improvement in Components (SLA/SLS)
 Laser system
› Improvement in speed of
curing/fusing process.
curing/fusing process.
› Higher intensity of the laser.
› Smaller laser beam spot size.
› D li i
Decline in cost of laser
t fl
technology.
 Scanning system
› Improvement in optical scanning
system (Digital Mirror System).
› Improvement in path scanning
p p g
algorithm.
16

17. Three‐Dimensional Printing (3DP)
Introduction:
 Ink‐jet based process that prints
the parts cross sectional geometry
on layers of powder spread on top
of each other.
Improvement in components:
 Inkjet print heads
› Improvement in the droplet
Improvement in the droplet
formation chamber.
› Multiple nozzles to enable multi‐
material deposition.
p
17

18. Fused Deposition Modeling (FDM)
Introduction:
 Process using molten plastics or
g p
wax extruded by a nozzle that
traces the parts cross sectional
g
geometry layer by layer.
y y y y
Improvement in components:
 Extrusion nozzle:
› Improvement in size of the tip
› Improvement in feed rate of
material
18

19. Source: Dr Hopkinson, Loughborough University
Illustration showing the break-even cost analysis of a small but complicated part
19

20. 4
3
2
1
0
SLA SLS FDM 3DP
Best for making Best for direct Best for functional
Best to produce
small lots of manufacture of testing, Rapid
fine feature details
complex, durable, structural tooling,
like hearing aid
hard‐to‐ components; Direct
p ; Prototyping, high
yp g, g
and jewelry
dj l
manufacture parts metal coasting heat applications
20

21.  Laser system
Laser system
 Scanning system
 Print head
Print head
 Extrusion nozzle
 Materials: Emergence of more types of material
Materials: Emergence of more types of material
which can be used. Application of
Nanotechnology.
gy
 3D CAD software: Improvement in speed,
accuracy and user interface.
21

22.  Technology improvements lead to cost reduction
of components and material.
 Open source community: Shared knowledge and
experiences (e.g. RepRap printers).
 As 3D Printing is getting better, demand for 3D
g g g
printing application increases significantly.
“Increase in demand will lead to reductions in
cost and i
t d improvements i performance” ‐
t in f ”
Christensen’s theory of disruptive innovation.
 High end vs Low end
High‐end vs. Low‐end.
22

23. 23

24.  Opportunities of Applications
 Potential New Businesses
24

25. “Design & Use” instead of “Buy & Use” 25

26. Prosthetics Dental solution
Artificial bone Limb
Printing Body Parts
P i ti g B d Pa t
Replicate human
anatomy easily 26

27. 1Kg = $3000 Fuel/ yr
COST SAVING
A380 landing-gear section
Titanium extraction
Save Energy 25X*
Source: www.airbus.com
27

28. Wind Tunnel Testing
Enhance Innovation & Creativity
28

29. Imagination Creation DIY 29

30.  US Military has projects to make spare parts for
Military equipments for in‐battle repairs
Mili i f i b l i
Time saved
30

31.  Artist creates a design but not the actual piece
 Some form of Arts will be democratized if not all
M Museum, Belgium
31

32. I want an
iPad cover
 Printing shops (Fab Lab) like yours,
but I like it
but I like it
 Printer Leasing thicker, and
 3D‐Printing solutions for self‐ pink
service customer kiosks
service customer kiosks
 On‐line printing services
32

33.  Self‐help books
 3D software learning institutes
 Web‐based trainings
 Website to showcase the
model files (like flickr)
model files (like flickr)
 Website where we can buy
and sell 3D‐model files (like
getty images, iTunes)
33

34.  Computers
 More powerful computers
 Higher resolution graphics
 Faster data transferring techniques [e.g USB3.0, HDMI, etc… ??]
 3D CAD software
3 f
 3D printer‐centric solid modeling software
 Easy to use interface
 Incorporated analysis software (e.g FEA, etc…)
d l f ( )
 Lasers
I
Improvement in lasers used to “cure” the materials quicker
ti l dt “ ” th t i l i k
 Material
I
Improved and new materials to cater the needs of 3D printers
d d t i l t t th d f 3D i t
(e.g Nano‐materials for better surface finish and strength)
34

35. 3D Printer Manufacturers
3D Printer Users
35

36. Figure 1: Growth of 3D-Printing industry Figure 2: Countries that have adopted the 3D-printing technology
*in millions of dollars. *cumulative systems installed by country through the end of 2008
2009 and 2010 are forecast
services
p oducts
products
Source: Terry Wohler Report 2010
36

37.  Price
› $ 10,000 ‐ $500,000 Range
› Low end machines with limited applicable materials
› Volume Vs Price (chicken and egg problem)
 Current Design Methodologies
› Heavily invested in existing technologies and tools
› Most design software are developed based on existing manufacturing
technologies
h l i
› Design Engineers / Designers are so used to with the existing manufacturing
technologies / constraints.
› Need to Un‐learn and Re‐Learn
Need to Un learn and Re Learn
 Still lack of common Industrial Standards for 3D printing
technologies
› Creates less confident on the technology by potential users
37

38.  What’s next for 3D‐printers?
Success of the 3D printers lies on:
› Further improvements in supporting technologies and
components
› Reduction in cost of 3D printers and consumables
› C
Consolidation and creating standards
lid ti d ti t d d
› Innovative and feasible business models
 Key to manufacturing will change from Economies
y g g
of Scale to Economies of Knowledge
 Mass production to mass customized products
 Greener production/consumption
 Good ideas can be shared even more rapidly with
3D printing
3D i ti
 Barriers to entry for new businesses will be lower
38

39. Is 3D printing
What would we
going to disrupt
need
the existing
g
manufacturers
f t
technologies
for if there is
machine that
can print a
machine
What will
happen to the Will everybody
ill b d
supply chain of own 3D printers
the one day
manufacturing
f
industry
39

40. … closing video.
40

41. 1. ADVANCES IN RAPID PROTOTYPING D18E © 2008 Frost & Sullivan
2. 3D Printer Benchmark: North American Edition, T. A. Grimm & Associates, Inc., June 2010
3. World Rapid Prototyping Equipment Markets N191‐30, © 2007 Frost & Sullivan
4. EMERGING INDUSTRIAL MANUFACTURING TECHNOLOGY‐‐ RAPID PROTOTYPING D273© 2004 Frost & Sullivan
5. FACTORY@HOMETHE EMERGING ECONOMY OF PERSONAL MANUFACTURING, OVERVIEW AND RECOMMENDATIONSA (HOD
LIPSON, Cornell University MELBA KURMAN, Triple Helix innovation), report commissioned by the US Office of Science and
Technology Policy, December 2010
6. The Wholer Report 2003, Terry Wholer Copyright 2003
7. The Wholer Report 2006, Terry
The Wholer Report 2006, Terry Wholer Copyright 2006
8. The Wholer Report 2010, Terry Wholer Copyright 2010
9. Roadmap for Additive Manufacturing, Identifying the Future of Freeform Processing, The University of Texas at Austin Laboratory
for Freeform Fabrication Advanced Manufacturing Center, Copyright 2009
10. Worldwide Trends in Additive Manufacturing, Terry Wohlers, RapidTech 2009: US-TURKEY Workshop on Rapid Technologies
11. “The impact on industrial design by the development of three‐dimensional printing technology from a technical perspective”,
“Th i t i d t i l d i b th d l t f th di i l i ti t h l f t h i l ti ”
Xing Liu, Xiaojiang Zhou, Hangzhou Dianzi University, Copyright 2010
12. Fused Deposition Modeling http://www.time‐compression.com/articles/html/fused_deposition.html
13. 3D printing technique applied to rapid casting by Elena Bassoli and Andrea Gatto Department of Mechanical and Civil
Engineering, University of Modena and Reggio Emilia, Modena, Italy
14. Direct Digital Manufacturing: Advantages & Consideration By Scott Crump, CEO, Stratasys, Inc.
15. Three Dimensional Printing by Professor Emanuel Sachs, Mechanical Engineering Department , MIT
16. Additive Manufacturing for mass customization by Phil Reeves, Chris Tuck, Richard Hague , Additive Manufacturing Research
Group Wolfson School of Mechanical and Manufacturing Engineering Loughborough University
17. Fab@home. http://www.fabathome.org
@ p // g
18. Reprap. http://www.reprap.org
19. Objet Technologies. http://www.objet.com
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