Inside3DPrintingSantaClara_TylerReid
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This document discusses 3D printing (3DP) and its growing industrial applications. It provides an overview of the benefits of 3DP such as iterative design, increased part complexity, and on-demand tooling. Examples are given of 3DP applications in tooling, end-use parts, aerospace, automotive, and more. The document also outlines the expanding 3DP market and discusses barriers to further adoption as well as promising future applications as speeds and volumes increase.
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Inside3DPrintingSantaClara_TylerReid
- 1. Indus t r ia l 3DP Digital Manufacturing
- 2. Agenda Introduction Unique Benefits of 3DP Applications Tooling End Use Parts What’s Next?
- 3. 3DP Market Outlook Growing market: hardware sales estimated to reach $6.6B in 2017, up from $2.2B in 2012 85% of that figure will be from industrial machines Driving Markets: • Aerospace • Defense • Automotive Copyright Taylor-Deal Aviation
- 4. 3DP Adoption Small and large firms are adopting additive manufacturing Uses range from prototyping to end use parts
- 5. Why 3D Printing? Iterative, purpose-driven, and adaptive design Improved design validation Low cost, on-demand tooling Increased part complexity Distributed Manufacturing
- 6. Iterative Design “Free” design changes • Cost of iteration reduced • Changes to production parts with less impact
- 7. Adaptive Design 3DP allows for design adaptability, mass customization, and reconfigurability
- 8. Purpose-Driven Design Parts are designed from end-goal backwards Complex, ergonomic shapes are created without increased difficulty
- 9. Design Validation Prototypes for physical and/or destructive testing can supplement FEA and CFD analysis Prototypes tested for: Function Form, Fit, & Assembly Ergonomics
- 10. Part Complexity 3DP simplifies BOM by combining parts Parts are optimized for “needs” rather than “creation”
- 11. Distributed Manufacturing Shift in supply chain from traditional model Manufactured -> Inventoried -> Distributed from different locations 3DP enables parts to be created on location
- 12. Rapid Tooling Tooling applications often overlooked points of ROI Jigs/fixtures Casting patterns (investment, sand, urethane) Thermoforming patterns Composite tooling (positive molds, clam shell, soluble core) Sheet metal forming tools Injection molding tools
- 13. Jigs & Fixtures Assembly Inspection Transportation • Trim templates • Drill guides • Masking • Positioning • Assembly aids • Testing • Measuring • Go/No-Go • Carrier trays • End of arm tooling • Cooling
- 14. Assembly Fixtures Drill Guides • Drill accurately positioned and oriented holes without CNC machinery • High conformity to workpiece contours • Bushings increase longevity • Popular in mechanical & medical fields
- 15. Inspection Fixtures Measuring • Primary concerns are accuracy & repeatability • Consolidation of parts eliminates fasteners • Design around CMM contact points • Easily include text for part numbers, SKUs, or QA instructions
- 16. Casting Patterns Investment Casting Metal parts from printed parts Silicone Molding Castable plastics (urethane, silicone) Sand Casting Traditional green sand mold or directly printed molds
- 17. Thermoforming Forming tools for creating thin, plastic parts. FDM tools can be built with internal structure Designed with internal porosity and stiffness in mind Ideal for complex shapes Perform as-well or better than traditional tooling ¼” Kydex® (acrylic/PVC alloy)
- 18. Composite Tooling Used in lay up, cored, and hybrid processes Proven processes: • Carbon, glass, kevlar fiber • Epoxy, polyester resins • <350˚F (177˚C) cure temp • <100 psi cure pressure
- 19. Composite Tooling – Lay Up Boeing FDM stiffener Out of Autoclave (OoA) application Printed in Ultem 9085 Large, complex shape is printed in pieces Production time and cost reduced
- 20. Composite Tooling – Soluble Cores Wash-out cores made from support material: • Temps up to 180˚F (SR-30) or 250˚F (SR-100) and 80psi Ideal for trapped-core applications
- 21. Injection Molding Directly print mold tooling Digital ABS material available on Connex series Short run production Low quantity runs Mid-sized parts Mid-sized press Create parts in non-printable materials (PP, PE, PS, TPE, POM, PA)
- 22. End-Use Parts Final products used or sold in their printed form. • Post-processing is acceptable • Excludes manufacturing tools (jigs, fixtures, molds, etc) Source: Sebastian Errazuriz Studio
- 23. Joint Replacements Models generated from CT scans are used to design bespoke joint replacement parts Surgeries are faster and less error-prone, while recovery is quicker Jigs are also printed and used during surgery Cost is comparable due to low inventory
- 24. UNYQ Prosthetic Fairing Fashionable protective covers for prosthetic limbs Customized to each individual to restore symmetry and reflect personal style
- 25. normal Headphones “One size fits none” Personalized 3D printed headphones ABS with soft-touch coating Shape developed from user-submitted photos, delivery within 48 hours Photo credit: The Verge
- 26. Production Components Kelly Manufacturing Company (KMC) created the M3500 “turn and bank” indicator from Ultem 9085 • Replaced urethane casting • 500 part batches • 3 day lead time • Per-piece savings of 5% • Held 0.003” tolerance
- 27. What’s Next? Companies investing in 3DP hardware and talent are benefiting from better R&D, quicker launches Early adopters are crossing threshold from tinkerer and prototyper to final product producers Companies are anticipating saves from reduced material usage and transportation costs ($B)
- 28. What’s Next? Increases in speed and volume will enable further applications Heavy R&D in materials by all top hardware manufacturers
- 29. What’s Next? Top barriers to 3DP: Material concerns Lack of expertise Printer expense See no application Printer speed Education and R&D needed in coming years
- 30. GoEngineer provides design and manufacturing tools with Expertise that enables Customers to reduce the cost, risk and time required to go live with new technologies and ultimately new product introductions. More Information: Tyler Reid treid@goengineer.com
Editor's Notes
- create specialty fluid and air handling parts in hours rather than weeks, while meeting the latest industry regulations for flame, smoke and toxicity. This collaboration showcases SABIC’s deep understanding of aviation industry challenges and its proactive efforts to enable new strategies that lead to customer success. Key benefits of this unique new use of ULTEM 9085 resin with FDM include enhanced design flexibility, cost-effective low production runs, accelerated cycle times and compliance with the Federal Aviation Administration (FAA) and OEM flame-smoke-toxicity regulations.
- About half a million knee replacement surgeries are currently conducted every year. Current implants require a number of cuts to the femur and/or tibia to fit the device. Additionally, many of the products that are currently on the market are off-the-shelf devices that come in a few sizes, so surgeons have to slice off even more bone in order to get them to fit. This can lead to long surgeries and increase the discomfort of recovery as well as the time it takes to get back to normal, usually six to eight weeks. This software takes the CT data of the patient’s knee, hip and ankle to create models that account for the unique anatomy of the patient’s entire leg. These models are used to create both the implants and the tools to install them. These tools, called jigs, are the exact same shape as the implants, so they align perfectly to the patient’s knee, but they also have placement and cutting guides that allow the surgeon to make precise cuts to remove minimal amount of bone. With these tools, inserting the implant is a bit like snapping a Lego piece into position exactly where it belongs, resulting in much less manual effort and hence less errors from the surgeon. Cost-wise, custom-made implants are twice as expensive to manufacture, but ConforMIS does not have to maintain the same massive inventory as competitors, so they can offer the implants at comparable prices to other knee replacement devices. These acetabular cups were built using electron-beam melting. The technique allows the printing of cups tailored for individual patients receiving hip replacements. The integrated trabecular structure improves osseo-integration.
- "Until World War II, when the process of fabricating prosthetics was industrialized, all prosthetics were handmade but too expensive to scale due to details of the craftsmanship." notes Bender. "Thanks to its proprietary technique, UNYQ can now, affordably, revive personalization and handcraft innovative 3D printed prosthetic covers -- or fairings -- that mirror the shape of the amputee's sound leg." Established in 2014 and with studios in San Francisco, California and Seville, Spain, UNYQ is a direct-to-consumer site that invites amputees to design stunning 3D printed custom fairings and other ornamentations for their prosthetic legs.
- “I had the problem of uncomfortable earphones and was trying to figure out what else was on the market,” Nikki Kaufman, Normal founder, told ABC News. After looking into the process of getting earphones custom made, the doctor’s appointment, silicone mold, three-week wait and $2,000 price tag seemed a little much. Yes, it’s a real place! Located on the elf-ear-shaped island of Manhattan. Stop by and see our 3D printers in action. Craft your Normals right then and there. Hear the bliss.