![Complex Components
Rocket Engine Injector
“This type of [rocket engine] injector
manufactured with traditional
processes would take more than a
year to make but with these new
processes it can be produced in less
than four months, with a 70 percent
reduction in cost.”
Source: NASA
Minimize number of components:
This injector had only two parts, whereas a similar
conventionally manufactured injector had 115
parts. Fewer parts require less assembly effort,
which means complex parts made with 3-D
printing have the potential for significant cost
savings.](https://image.slidesharecdn.com/cscmpconferencepresentationfinal-140924152617-phpapp01/85/CSCMP-2014-3D-Printing-for-the-Rest-of-Us-12-320.jpg)
CSCMP 2014 3D Printing for the Rest of Us
- 1. 3D Printing for the Rest of Us
- 2. Session Outline • Introductions • 3 D Printing (Additive Manufacturing): State of the Industry • Areas of disruption… and opportunity • Q/A
- 3. Introductions Ed Elsbury, Liberty Advisor Group, Business and Technology Advisory Firm eelsbury@libertyadvisorgroup.com Ben Elrod, Liberty Advisor Group, Business and Technology Advisory Firm belrod@libertyadvisorgroup.com Kim Brand, 3D Parts Manufacturing, 3D Printing Service Bureau kim.brand@3dpartsmfg.com
- 4. 3D Printing (“Additive Manufacturing”) • Radical new method for manufacturing objects • Technology has been around since early 80’s • Over hundred materials currently available for 3D Printing • Already used in scale manufacturing
- 5. Materials available for 3D Printers • Metals available for 3D Printing – Tool steels – Stainless Steel (including 17-4PH) – Titanium (including 6-4 Medical Grade) – Titanium & Aluminum Alloys – Aluminum (6061 to 6061-T6) – Nickel-based Alloys – Cobalt-chromium Alloys – Copper-based Alloys – Gold, Silver & other precious metals
- 6. Industry is growing as functional parts become economical Functional parts now most prevalent Source: Wohler Associates, Stratasys, 3Discovered analysis Based upon 2012 data, 43% of parts manufactured are Production quality: Functional Parts, Tooling, and Casting Patterns.
- 7. Increased availability and precision support further growth 20 micron resolution & tolerance of 100 microns Post processing to a roughness average of 1 micron To print 100k finished components annually by 2020 80k 3D Printers; ~$1Bn in Service Bureau Sales. Over 800 Service Bureaus in the USA. 8,000 industrial 3D Printers sold in 2012
- 8. Client Experiences / Applications • Toyota – Turnaround • Nexxt Spine – Part Consolidation • Lilly – Lot size one • Walmart + IUPUI – No Alternative (Plastic molds) • Parker-Hannifin – Rapid Iteration • Rolls Royce – Geometry/Turnaround/Tooling • Zip Speed Weaponry – Turnaround • Diamond Chain – Marketing Demo • Delta Faucet – New Product Development
- 9. Client Experiences / Applications
- 10. Client Experiences / Applications
- 11. Finished Parts General Electric Co. LEAP Jet Turbine Fuel Nozzle 3D Printed in Titanium in a single run • Formerly 20 pieces welded together > less labor and waste for production • 25% lighter & 5x more durable > longer life & reduced maintenance • 15% more efficient spray > Several million in fuel savings annually per plane • Full turbine 450kg lighter > Up to $3,000/kg annual fuel savings
- 12. Complex Components Rocket Engine Injector “This type of [rocket engine] injector manufactured with traditional processes would take more than a year to make but with these new processes it can be produced in less than four months, with a 70 percent reduction in cost.” Source: NASA Minimize number of components: This injector had only two parts, whereas a similar conventionally manufactured injector had 115 parts. Fewer parts require less assembly effort, which means complex parts made with 3-D printing have the potential for significant cost savings.
- 13. 3D Printing Drama • Gravity is not your friend • New material qualification very expensive, risky? • Radical geometry is free but sloooow (8 hr/in) • Metal printing is a team sport • Machine technology frenzy • New tools = new rules
- 14. Disruption 1. One printer makes many shapes >> No retooling 2. Small footprint manufacturing >> Production possible anywhere 3. No lead time from design to production >> Accelerated speed-to-market 4. Skill is in design, not manufacturing >> Anyone can make everything 5. Only make what’s required, when required >> No waste, no inventory 6. Reduced assembly >> Combine sub-assemblies into a single part 7. Infinite blends of materials >> Better products 8. Duplicate, edit, copy physical objects >> Make what you design 9. Unlimited design space >> Think it, make it! 10. The printer does it all >> Manufacturing complexity is free Source: Melba Kurman: 10 Principles of 3D Printing, 3Discovered
- 15. What products/parts? NOW SELECTIVE LATER • Low relative production volume, high value • Customized objects • High logistics costs • Complex construction/assembly • Tools & Molds • Hand-crafted/ hand assembled products and components • High inventory cost & demand uncertainty • Tools • Molds • Large form factor & dimensions (e.g. steel beams & plates) • Simple/low cost logistics • Low inventory costs • Predictable demand patterns • Esoteric materials TRADE-OFF point Volume (# Units) Total Cost
- 16. Manufacturers are starting slow by piloting specific cases 1. Economic Feasibility 2. Pilot Program 3. Roll-out Assessment Quantify and compare value chain economics for existing objects • Identify potential object (products, parts, tools) candidates. • Analyze value added costs and metrics. • Identify and analyze alternative 3D Printing processes. • Quantify opportunity in $, time, and organizational impact. Test for quality, cost, complexity, and scalability • Controlled, small scale, outsourced test production • Monitor and evaluate results • Make adjustments: Design & Processes Plan for implementation • Revise/quantify production, logistics, net investment, and switching costs • Plan and execute organizational changes • Integrated manufacture & design planning • Develop budget; change & steady state
- 17. Longer term changes to sourcing and manufacture are being planned Design for 3d Printing New Economics Organizational Change Leverage new possibilities rather than replacing existing processes • Develop new parts that take advantage of unique 3D Printing features • Simplify multi-part assemblies into single parts • Premium features from customization flexibility • Potential crowdsourcing of designs, and product requirements Product Innovation and increased value-added • Monetize retired/aftermarket objects, parts, and designs • Print molds, castings, & tooling on demand • Repair vs. replacement will impact pricing and customer relationships • Evaluate need for dedicated production facilities vs. outsourcing Design to manufacture requires new organizational models • Evaluate core strengths – design v. production? • Merging product design and manufacturing engineering teams • Business Process Reengineering - Collaboration & planning between R&D & Manufacturing - Customization > closer, collaborative engagement with customer needs
- 18. Over time the impact on the Supply Chain will be significant Conventional Supply Chain • Products mass produced (China/Globally) • Goods ‘pushed out’ and distributed through warehouse network to customers • Long lead times • High transportation costs • Large carbon footprint • Scale > large facilities 3D Print Supply Chain • Customized production (onshore) • ‘Pulled’ by end customer demand • Locally printed and distributed • Short lead time • Lower transportation costs • Lower carbon footprint • Experience > smaller facilities Design Mfr. Distr. Design Mfr. Distr.
- 19. Don’t Forget to Complete the Evaluation! Download the conference app and rate this session. Start by choosing: “Cornerstones and Tracks” on the main menu and follow the prompts to this session’s landing page.
- 20. Liberty Advisor Group Liberty Advisor Group is a management and technology advisory firm that specializes in identifying and executing high priority business and technology initiatives that quickly improve operating income. Clients engage us when faced with complex business and IT challenges to design and execute strategic initiatives that are both practical, positively impact the bottom line, and align top-down business needs and bottom-up operational capabilities. Technology Strategy • IT Strategy & Architecture • System and ERP Planning, Prioritization and Roadmaps •Master Data Management • IT/Business Alignment Assessment •Multi-channel architecture M&A Services • Operations and IT Due Diligence • Merger Integration • Carve Out Planning and Execution • System and ERP Rationalization and Consolidation • IT Strategy and Roadmaps Business Transformation • End to End Business Process Improvement • Supply Chain Optimization • 3D Printing • ERP Implementation Optimization and Rescue • e-commerce and m-commerce Data Mining & Analytics • Operating Income Improvement •Margin Improvement • Customer & Product Profitability • Sales Effectiveness • Indirect and Direct Spend Improvement •MRO Spend Improvement
- 21. 3D Parts Manufacturing • Founded 1/2013 • $2M Investment in downtown Indianapolis • Service Bureau: DMLS (Metals), PolyJet (Digital Plastics,) SLA (Resins,) FDM (ABS/PLA)