This presentation explored the foundation of ‘the next industrial revolution’ - how additive manufacturing systems such as 3D printers and 3D production systems are changing the future of product development and manufacturing. Mr. Fischer presented examples of how design engineers use 3D production systems for concept modeling and prototyping, but also how manufacturing engineers are now employing these technologies for various applications such as jigs, fixtures, check gauges, and even as a bridge-to-tooling and low-volume end-use parts. From the 2013 Taking Shape Summit: Additive Manufacturing: 3D Printing--Beyond Rapid Prototyping.

1. Keynote
Fred
Fischer
Stratasys

3. Additive Manufacturing 101:
3D Printing Past, Present & Future
Fred Fischer
Director of Materials & Applications Product Management

4. Passionate Believers
in a 3D World

5. Shaping the Next Industrial Revolution
AM helps designers perfect their
ideas.
AM helps manufacturers evolve the
way they make things.
AM transforms the way individuals,
teams and organizations work.

6. Additive Manufacturing Terminology
Known by many names:
•
3D Printing
•
Advanced Manufacturing
•
Rapid Prototyping
•
Additive Fabrication
•
Rapid Tooling
•
Additive Layer Manufacturing
•
Rapid Technologies
•
Direct Digital Manufacturing
•
Rapid Manufacturing
•
Direct Manufacturing

7. Terminology
Additive Manufacturing
• Term covering all technologies
• Term covering all applications
• Replacement for “RP” and “Additive
Fabrication”
Definition:
• Collection of technologies, directly driven
by CAD data, to produce 3-Dimensional
physical models and parts through an
additive process.

8. 3D Printing Impact
By noon today you will have been impacted by 3D
printing multiple times and you don’t realize it
Fortune 500 companies leverage 3D printing,
even those associated with the internet or
software
(i.e. Yahoo and Google)

9. 3D Printing Coverage

10. Real Possibilities
Obama touts 3D printing in push
to revive manufacturing

11. Real Possibilities
Obama touts 3D printing in push
to revive manufacturing

12. 3D Printing in Industries
Industrial
Consumer
Aerospace
Medical
Automotive
Dental
Military
Architecture
Jewelry
Education

13. Solution Classification
Additive Manufacturing
On-Demand Services
(Service Bureaus)
3D Printers
3D Production
Systems
LOWEST BARRIER TO
PARTS
MOST AFFORDABLE
SOLUTIONS
HIGHEST PERFORMANCE
SYSTEMS
• Distributed globally
• $10 -$50K USD
• $50-$500K & up USD
• 3 – 10 day turn around avg.
• Simple and easy to use
• Optimized for performance
• Almost all technologies
• Optimized for form, fit
some function
• Broad application solution

14. Typical Build Process
1- Pre-Process
2- Produce Part
3- Post Process
Output Materials
Plastics
Photopolymers
Metals
Others

15. Primary Applications for Additive
Manufacturing Technology
Additive Manufacturing
Concept
Models
Functional
Prototypes
Manufacturing
Tools
End-Use
Parts
Established / Traditional
Direct Digital Manufacturing
(Design)
(Manufacturing)

16. Typical Design Cycle
Design
Change
Design
Change

17. Prototype Early & Often to Minimize
Cost of Change
80% of Product cost finalized
10,000
Relative Costs
1,000
100
10
1
$
Concept
$
Engineering
$
Detail
Tooling
Source: Rosenberg, Boston University
Production

18. Ideal Design Cycle
Design
Change

19. Primary Applications for Additive
Manufacturing Technology
Additive Manufacturing
Concept
Models
Functional
Prototypes
Manufacturing
Tools
End-Use
Parts
Established / Traditional
Direct Digital Manufacturing
(Design)
(Manufacturing)

20. Conceptual Models &
Functional Prototypes
Direct benefits
• Reduce time to market
• Solidify design earlier
• Reduce late design changes
• Lower product development cost
• Design changes earlier in process
• Make mistakes early and often
Indirect benefits
• Facilitate communication
• Improve product design

21. Henk and I – Zodiac Pool Systems
Henk and I
Zodiac Pool Systems
Henk and I, an industrial design firm located in Johannesburg
Zodiac Pool Systems, a global leader in swimming pool products, based in San
Diego
Challenge
Design a pool cleaner with a low-speed, high-torque motor that reduces the
number of moving parts and potential for failure
Previous process was outsourcing models and prototypes
Solution
To work efficiently in the highly iterative design process, Henk and I required an
onsite 3D printer that could keep pace with its engineers’ ideas
“As we developed the concept, we built FDM parts to fully understand the design
and communicate our ideas. We also built aesthetic models and shared them with
Marketing to help them choose a design look.”
“By using our own in-house 3D printer, we were able to complete the design
process in about half the time”
– Henk van der Meijden

22. Toro Prototypes Withstand
100 psi
Prototypes need to withstand high pressures
•
•
Other rapid prototypes don’t hold up
Machining is costly; requires long lead times
Fortus makes functional prototypes
•
•
Produced in a few hours
PC meets mechanical requirements
Design perfected for a fraction of the cost
•
•
Engineers able to quickly test design ideas
Mold right the first time
Dramatic savings over 2 years
•
•
Development time reduced by 283 weeks
Tooling and bureau costs cut $500,000
Conventional
Machining
Fortus
Time savings
283 weeks
Cost savings
$500,000+

23. Design Precision at Trek
Bicycles
Innovative bicycle design
•
•
Ironman & Tour de France
Aerodynamics critical
Typical prototyping methods ~1 wk
•
•
Produced in a few hours
PC meets mechanical requirements
AM technology enabled engineers to
•
•
Experiment with more concepts
Reduce time to market
Award winning bicycle design
•
•
Leading frame design
Accelerated leadership position
“It gave our engineers and designers a whole other
world to work with...he said - just buy it” Mike Zeigle

24. Primary Applications for Additive
Manufacturing Technology
Additive Manufacturing
Concept
Models
Functional
Prototypes
Manufacturing
Tools
End-Use
Parts
Established / Traditional
Direct Digital Manufacturing
(Design)
(Manufacturing)

25. Manufacturing Applications (DDM)
Direct benefits
• Financial gain
• Lowering costs
• Increasing profits
• Time advantages
• Decreasing time-to-market
• Decreasing cycle time
Indirect benefits
• Design freedom
• Product redesign frequency
• Rapid response

26. Manufacturing Applications (DDM)
Best fit when:
Relatively 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

27. Manufacturing Tools
Examples:
• Jigs
• Fixtures
• Check gauges
• Drill / rivet guides
• Go / no-go gauges
• Alignment tools & guides
• Tooling masters & patterns

28. "FDM is taking on
increasing importance as
an alternative
manufacturing method
for components made in
small numbers.”

29. BMW Reduces Time & Cost to
Build Fixtures
Conventional fixture making
•
•
Cost and time requirements were high
Lack of design freedom reduced productivity
FDM used to produce fixtures
•
•
Have over 400 assembly fixtures
Several built on Fortus system
Method
FDM enhances ergonomics
•
•
Organic shapes maximize performance
Sparse fill cut weight 72%
Time and cost savings
•
•
Typical cost reduced from $420 to $176
Typical lead time reduced from 18 to 1.5 days
Cost
Time
CNC
Machining
Aluminum
$420
18.0 days
Fortus
system
ABS-M30
$176
1.5 days
Savings
$244
(58%)
16.5 days
(92%)

30. "Direct digital
manufacturing has become
a key revenue stream and
competitive differentiator
for our business. This
would not be possible
without Stratasys."

31. End-Use Parts
Direct benefits
•
Lower cost
• Shorter lead time
Indirect benefits
• Design freedom
• Change freedom
• Mass customization
• Supports lean initiatives
• True JIT (just-in-time) manufacturing
• Reduced warehouse space/inventory cost

32. ScriptPro: 79% Drop in LowVolume Part Costs
Custom machines require many bezel sizes


Difficult to forecast which bezels are needed
Cost of tooling would be very high
ScriptPro invested in Fortus system


Builds bezels as needed to customer orders
Meets precise tolerance requirements
Method
Elimination of tooling saves money


Injection molding would cost $31,650/year
FDM DDM costs $6,750/year
Cost
Time
Injection
molding
$31,650
60 days
FDM direct
digital mfg.
$6,750
1 day
Savings
$24,900
(79%)
59 days
(98%)
New or modified bezels don’t require re-tooling


Add new bezels at very low cost
Continually improve the product

33. Emma’s Story
3D printed “exoskeleton” lets a little girl lift
her arms and play.
Nemours
A Children’s Health System

34. Emma’s Story
Nemours
A Children’s Health System

37. Looking into the
FUTURE

38. +++
AM/3DP Market Segmentation & Growth Opportunities
# of Potential Parts / Design
Material Ma
Grow
Grow
(Future Capability)
(Future Capability)
AM Technology
Current Best Fits
Established AM Technologies
1s, 10s
10s to +100,000s
+
10s, 100s
IDEA
Concept Modeling
DESIGN
Design Verification
Functional Prototyping
PRODUCTION
Manufacturing Tools
End Use Parts

39. +++
Incumbent Technologies
PRODUCTION
Traditional
(Digital / 2D Printing)
Traditional
(CNC/Injection Molding)
Material Ma
All AM Technologies
+
Applications Satisfied / Material Volume
IDEA
IDEA
Concept Modeling
DESIGN
Design Verification
Functional Prototyping
PRODUCTION
Manufacturing Tools
End Use Parts

40. Future Trends
PRODUCTS
MATERIALS
WORKFLOW
WORKPLACE