3D printing for Development Hack Day in Bucharest, session 1

www.econolyst.co.uk Friday 22nd June 2012 - Romania

Dr Phil Reeves - Managing Director, Econolyst Ltd, UK

The 3D for Development Challenge -Bucharest -

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• Personal introduction

• What is 3D Printing & Additive Manufacturing

• What is the current state-of-the-art in 3DP/AM

• What drives companies to use this technology

– Economics, geometries, environment, personalised products, increased functionality, new supply chains

• The growth of low-end / home consumer 3DP

Session 1 – the background (1-hour +)

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About Econolyst

• Econolyst is a UK based consultancy dedicated to the Additive Manufacturing & 3DP sector

• Established 2003

• Built on almost 20-years of AM experience

• Clients in the UK, Western Europe, Scandinavia, Benelux, USA, Israel, India, Middle East & Far East, Africa

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What we do at Econolyst

• Help companies implement 3DP & AM

technology (from design to retail)

• Deliver AM focused training & conferences

• R&D project management & delivery

• AM software development — Establishing supply chain Carbon footprints

— Developing AM part cost and value models

http://images.google.co.uk/imgres?imgurl=http://www.p4store.co.uk/ekmps/shops/plant4print/resources/Image/CAT logo.jpg&imgrefurl=http://www.p4store.co.uk/wj31-proforce-professional-bomber-jacket-only-1495-280-p.asp&h=686&w=960&sz=37&hl=en&start=2&um=1&usg=__xbuMCpixk3BE1CApiDyqMZg_Wts=&tbnid=v8p4QwTg_Sg_QM:&tbnh=106&tbnw=148&prev=/images?q=caterpillar+logo&um=1&hl=en&rlz=1T4RNWN_enGB266GB267

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Things that keep my office busy

• Helping the world largest jet engine maker (GE) use AM

• Helping a global sports brand (Nike) to use AM

• Helping India's largest jewellery retailer (Tanqish) implementing direct metal printing of precious metal into 150 shops

• Advising one of the worlds largest chains of high street chemist (Boots) on how to use 3DP (glasses, hearing aids, drugs)

• Advising VC’s and Private Equity companies on investment in AM

• Advising the UK government on investment strategies to support AM R&D

• Advising the UK Ministry of Defence on AM/3DP capabilities to support security and warfare out to 2030

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So what is 3D Printing & additive manufacturing?

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Agreeing terms – setting the context

Additive Manufacturing is the manufacture of ‘end-use’ component parts using

Additive Layer Manufacturing processes

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What is a 3D printing systems

3DP processes are automated systems that take 2-dimensional layers of computer data

and rebuild them into 3D solid objects

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• AM is also refereed to as: – Generative Manufacturing – Germany

– eManufacturing - Germany

– Constructive Manufacturing - Germany

– Additive Layer Manufacturing (ALM) – Scandinavia & EADS

– Direct Digital Manufacture (DDM) – USA

– Freeform Fabrication (FFF)– USA

– Solid Freeform Fabrication (SFF) – USA

– 3D Printing (3DP)- Global

– Rapid Manufacturing – Global (historic)

Agreeing terms – what’s in a name

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How does the 3D Printing process chain work?

• Start with a 3D geometry • Generate STL file • Orient parts to optimum build

direction • Generate support structures • Slice part & supports

horizontally • Consolidate, deposit or cut out

layer • Index machine down (or up) by

one layer thickness

Link to Video

build animation.mpg

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There are Four fundamental manufacturing principles:

• Subtractive

– Material is successively removed from a solid block until the desired shape

is reached (2.5M BC – Hominids)

• Fabricative

– Elements or physical material are combined and joined (6,000 BC –

Western Asia)

• Formative

– Mechanical forces and, or heat are applied to material to form it into the

desired shape such as bending, casting and molding (3,000 BC – Egyptians)

• Additive

– Material is manipulated so that successive pieces of it combine to make

the desired object (1984 – Californians)

How does ALM differ from traditional manufacturing

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So what is the current state of the art in 3DP/AM in

2012?

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We have an ever increasing range of technologies

High end

– Stereolithography IPro (3D)

– Selective Laser Sintering (3D & EOS)

– FDM Fortus (Stratasys)

– Connex (Objet)

– Perfactory XE (Envisiontec)

Mid range

– 3D Printing (Voxeljet)

– Stereolithography Viper SLA (3D)

– Polyjet Eden (Objet)

– 3D Projet (3D systems)

– Perfactory (Envisiontec)

Very low end (home users)

– Ultimaker

– Bits-from-Bytes (3D)

– MakerBot

– UP personal printer

– Fab@Home

– PrinterBot

Lower end (desk-top)

– 3D Printing (Z-Corp)

– Ultra Z-Printer (Envisiontec / Z-Corp)

– 24/30 (Objet)

– FDM Dimension (Stratasys)

– UPrint (HP / Stratasys)

– Laminated Objet Manufacture (Mcor)

– V-Flash (3D Systems)

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Today we have a ‘pallet’ of around 200 materials

Waxes

Polyamide (nylon)

Organic

materials

Polymeric

materials

Ceramic

materials

ABS

Filled PA

PEEK

Thermosetting epoxies

Ceramic (nano) loaded epoxies

PMMA

Polycarbonate

Polyphenylsulfone

Tool Steel

Aluminium

Titanium

Inconel

Cobalt Chrome

Copper

Stainless steel

Mullite

Alumina

Zirconia

Gold / platinum

Silicon Carbide

Hastelloy

Aluminium loaded polyamide

Beta-Tri calcium Phosphate

Silica (sand)

Plaster

Graphite

ULTEM

Tissue / cells

Metallic

materials

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So what drives companies to adopt Additive

Manufacturing (or be interested)?

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The core business drivers to AM adoption

1. Economic low volume production

2. Increased geometric freedom

3. Increased part functionality

4. Product personalisation

5. Improvised environmental sustainability

6. New supply chains and retail models

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Lets consider these drivers with some case studies

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1. Enabling low volume production

• Enabled the economic manufacture

of low volume complex geometries

and assemblies

– Reduces the need for tooling (moulds /

cutters)

– Reduced capital investment &

inventory

– Simplifies supply chains & reduced

lead times

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Example – unit volumes of 1

• Bentley is a subsidiary of Volkswagen

• Vehicles from $250K - $1M

• In-house polymeric and metallic AM capacity

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Example – Low volume production

• Problem – customer with limited mobility needed a reversed dashboard

• Production substrate produced by RIM

• Manual modification time consuming

• Solution – Laser Sintered AM part with leathers and veneers veneers

Images courtesy of Bentley

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Example – Low volume production

Images courtesy of Bentley

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2. Maximising design complexity & capability

• AM enables the production of highly

complex geometries with little if no

cost penalty

– Re-entrant features

– Variable wall thicknesses

– Complex honey combs

– Non-linear holes

– Filigree structures

– Organic / genetic structures

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Example – Delphi Diesel Pump

• Conventional product manufactured by

cross drilling an aluminium die casting

• Multiple machining operations

• Multiple post processing ops (chemical

deburring, hole blanking, pressure testing)

• Final product prone to leakage

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With AM - Design the product around the holes

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Example – conceptual Diesel Pump

• Produce the part as one piece using

Selective Laser melting on Aluminium

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3. Increasing part functionality

• AM enabled multiple functionality to

be manufactured using a single

process

– Replacing surface coatings & textures

– Modifying physical behaviour by

designing ‘mechanical properties’

– Embedding secondary materials (optical

/ electrical)

– Grading multiple materials in a single

part

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Example – surface design for bone ingress

Implants (production)

• Accetabular cups

Material: Ti6Al4V

Build time: 16 cups in 18 hours

Images Courtesy of ARCAM – www.arcam.com

http://www.arcam.com/

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Example – Heat dissipation surfaces

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Example – Energy absorption

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4. Product Personalisation

• Individual consumer centric

products, with customer input

– Medical devices

– Consumer goods

– Cultural & emotional artefacts

– Online design tools

– Co-creation

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Case study - Hearing aids

• Produced using personal data from

each individual patient

– Produced using scan data

– 20 million made every year by 3DP

– Lower cost than traditional

– Every one is different

– Improved fit for the user

– Lots of medical applications using bdy

scan data, CT & MRI data

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The personalisation can be by the consumer

• www.makielab.com

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The Internet lets everyone become designers

This is a bedside light

This is a lemon squeezer

This is a pall point pen

• Some web offering allow us to become the designer in an AM supply chain

– Digital Forming.com

– Jujups.com

– Sculpteo.com

– Landprints.com

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There are lots of new interfaces

Google

Sketch UP

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There are lots of new interfaces

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5. Life cycle sustainability

• Product lifecycle improvements in

economic and environmental

sustainability

– Reduced raw material consumption

– Efficient supply chains

– Optimised product efficiency

– Lighter weights components

– Reduced lifecycle burden

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Case study – aerospace cabin component

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A very different approach to design

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Design optimisation for AM production

Machine from

solid billet

Topologically

optimised

Complex

lattice

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Example – How does the weight compare

Scenario 1 – Machined from solid (0.8Kg)

Scenario 2 – Selective Laser melted lattice (0.31 kg)

Scenario 3 – Selective Laser melted optimised design (0.37 Kg)

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To establish sustainability you have to establish life

cycle boundary conditions

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• Example based on 90M km (Long haul) application

Process Raw

Materials

CO2

Manufacture

CO2

Distribution

CO2

Usage

CO2

Life cycle

Kg CO2

Machining 100Kg 2 Kg 5 Kg 43,779 Kg 43,886

SLM lattice 16 Kg 5 Kg 1 Kg 16,238 Kg 16,260

SLM optimal 18 Kg 7 kg 2 Kg 20,339 Kg 20,366

Environmental benefit over product lifecycle

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So how do our lifecycle CO2 compare

Scenario 1 – Machined from solid (100%)

Scenario 2 – Selective Laser melted lattice

(37%)

Scenario 3 – Selective Laser melted optimised

design (46%)

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Sunday Times 13th Feb 2011

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• 0.49Kg saving per monitor arm

• $1,500 per annum in fuel savings (today's prices)

• $45,000 over 30-year aircraft life

• Product life span 5-7 years (estimate)

• Life-cycle economic saving $6.5K - $9K

• Machined part - $500

• SLM Part - $2,500

• Capital investment repaid in 2-years….

Example – life cycle economic benefits

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This is a step change in design thinking

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6. Supply chain realignment

• New lean yet agile business models

and supply chain

– Distributed manufacture

– Manufacture and the point of

consumption

– Demand pull business models

– Stockless supply chains

– Chainless supply chains (home

manufacture)

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Stockless supply chains – low barriers

$50.00 each

60,000 month

$36M P/A

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Integration with other data sources

$6.2-million (6-machines)

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There are online printing portals to buy & sell

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These portals have volume traffic

$44 average

price of

products

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So what are people designing & sharing

PL1Q Vampire, the 3d printed quadcopter - YouTube.flv

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But what do you do with the data? – Home 3D Printing

Makergear

Start-up Growing Established

http://www.origo3dprinting.com/

http://www.makergear.com/

http://www.makergear.com/

http://cdn.shopify.com/s/files/1/0030/7372/assets/Maker-Gear-logo-small-text_3_sm.png?100087

http://www.fablicator.com/

http://lebigrep.org/

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MakerBot – the ‘market leader’

• Less than 3-years old

• Business based on open source

• 6700 machines sold in 2011

• $1,749 per machine

• 20,000 machines this year

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So what are people making

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These machines are based on open-source

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Other supply chain opportunities for all

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Is there a market?

1985 – 2010 = 45,000 machines 2011 = 15,000 machine 2012 = 45,000 machine

2013 = 200,000 machines 2014 = 800,000 machines

2015 = 3.2-million

Moore's law?

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The money will also be in the data & content

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So is AM the new Manufacturing revolution

for the digital age?

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• Of the 200+ products, components, parts & business models we have looked at over the last 7-years, 90% were not immediately suited to AM.

– Piece part economics

– Production throughput

– Mechanical property limitations

– Surface finish

– Part accuracy

– Process variance

– Quality assurance & validation

Not yet - the harsh reality

Next session

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BUT…. We can dream …….

Disseny Hub Barcelona DHUB.mp4

www.econolyst.co.uk Friday 22nd June 2012 - Romania

Dr Phil Reeves - Managing Director, Econolyst Ltd, UK

Questions Econolyst Ltd

The Silversmiths

Crown Yard

Wirksworth

Derbyshire, UK

DE4 4ET

+44 (0) 1629 824447

[email protected]

3D printing for Development Hack Day in Bucharest, session 1

Technology

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