Additive Manufacturing: 3D Printing--Past, Present, and Future
13 likes5,305 views
The document discusses the impact and evolution of additive manufacturing (3D printing), highlighting its benefits for various industries, including faster prototyping, reduced costs, and enhanced design capabilities. It presents case studies such as those at Zodiac Pool Systems and Trek Bicycles, illustrating how companies leverage 3D printing to improve product development and manufacturing efficiency. The text emphasizes the potential for additive manufacturing to reshape production processes and create custom solutions across multiple sectors.
Additive Manufacturing: 3D Printing--Past, Present, and Future
- 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)
- 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)
- 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
- 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
- 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