Additive Manufacturing

The Automotive Industry

Alejandro | Gianmarco | Julia | Keyang | Quentin | Stefan | Verena

Team C Digital Solutions

Agenda

Introduction

Advantages

Drawbacks

Expenses

AM in 2020

Recommendation

What is Additive Manufacturing?

Introduction

• Briefly: 3D Printing

• Definition: It is a process of adding ultrathin layers of material(metal, plastic, etc.) one by one to create a raw material or a product

Introduction

Advantages

“For the automotive industry, these advances have opened doors for newer designs; cleaner, lighter and safer products;

shorter lead times; and lower costs”.Deloitte University Press

Advantages: New Design

The ability of producing different type of items for specific customers and market demands.

Example: Customized Dashboard

Competitor: Bentley

Possibility of customizing items

Advantages: New Design

The ability to create lighter, safer, cleaner and more efficient products.

Example: Hand tools used in testing and assembly

Competitor: BMW

BMW: ”The new tools reduced project time by 92 %”

1st stage: Creating better quality items

Advantages: New Design

2nd Stage: Creating better quality items

Example: Reducing the weight of a car without changing the

main structure

Competitor: None

The ability to create better quality items, that will change the industry.

Industry is not enough developed for this stage.

Advantages: Shorter Lead times

The time between the initiation and completion of a production process.

Example: Prototyping process

Competitor: Ford

Ford: ”Prototyping usually took 4 years.

Now with AM it takes 4 days”

Advantages: Lower costs

Capital vs. Scale

Reduction of capital required to achieve the same amount of products.

Example: Lowering the costs of production

Competitor: Ford & BMW

Ford: ”Prototyping cost decreased from 500,000 $ to

3000 $”

BMW: ”The new tools reduced the cost by 58 %”

Advantages: Lower costs

Capital vs. Scope

Increase in scope of products with the same amount of capital.

Example: Increase in the variety of products portfolio

Competitor: None

Industry is not enough developed for this stage.

Drawbacks

“The automotive industry still has challenges ahead

related to manufacturing of large parts; talent shortage;

intellectual property and materials variety.”Deloitte University Press

Drawbacks: Manufacturing large parts

Printed products size is limited

Oak Ridge National Laboratory: No size restriction

Research

Materialise: Has build a machine to produce big components

Drawbacks: Talent Shortage

Not enough AM specialist

Trainings

AM service providers and end-user industries areconcentrated to create a stable program for a capableworkforce.

Drawbacks: Intellectual Property Concerns

Expansion of AM will lead to expansion of copying

Patents

• Patenting of produced products through AM can solvethis problem.

• Patent protection qualification should be clear

Drawbacks: Limited materials

Materials for production are either limited or expensive

Example: Titanium powder (200-400 $ for 1 kg)

Competitor: Jaguar with Metalysis

Jaguar: Buying powder from Metalysis

with 75% lower price for AM

2020 (5 years later)

Current

Fluid handlingApplications: Pumps, valves

Exterior TrimApplications: Bumpers, wind breakers

Manufacturing ProcessApplications: Prototyping, customizing Exhaust emissions

Applications: Cooling vents

Future

Interior & SeatingApplications: Dashboards, seat frames

Wheels, Tires & SuspensionApplications: Hubcaps, tires, suspension springs

ElectronicsApplications: Sensors, panels, etc.

Frame, body, doorsApplications: Body panels

Powertrain, drivetrainApplications: Engine components

Expenses

Cost can be cut by 50% within 5 years

Investment EUR Direct Cost EUR

Machine Cost 500,000 Steel Powder price per kg 89

Technical Rate Energy per kWh 11

Utilization rate 86% Hourly labour 25

Monitoring 5% Yearly rent for 28 3,640

What should Porsche do?

Important Factors

•Technology is not fully developed yet

•The Industry is very interested in development

Recommendation

Implement AM in prototyping

Be always aware about the innovation in AM

Try to use this technology with the current technology

Invest right now in order not to be outsider in the future

Questions?