Franck Fabre Ingénieur commercial Europe du Nord Nicolas ... - Platinium 3D - 07_07_2016.pdf ·...
Transcript of Franck Fabre Ingénieur commercial Europe du Nord Nicolas ... - Platinium 3D - 07_07_2016.pdf ·...
3D printing : a fast growing market
From $4.2 billion to $21.8 billion in just a few years
195,000 units sold
15% of revenue
12,000 units sold
85% of revenue
Selling Price < $5K
Selling Price > $5K
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10
15
20
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2014 2016 2018 2020
$4,2b
$7,3b
$12,7b
$21,8b
USA40%
China9%
Japan 9%
Germany 8%
UK 4%
France 3%
Italy 3%
Key additive manufacturing markets
Aerospace
• Production of lightweight parts with complex geometries, e.g. fuel nozzles
• Stationary turbine components• Reworking of burners
Medical/dental
• Production of dental models, surgical guides and orthodontics
• Customized prosthetics such as head implants
Automotive
• Primarily used for rapid prototyping, especially for visual aids and presentation models
• Production of special components for motorsports sector (e.g. cooling ducts)
Consumer Products/Electronics
• Production of customized tools and manufacturing equipment
• Production of embedded electronics (e.g. RFID devices)
Industry & Business machines
• Mainly prototyping and tooling• Manufacturing of injection molds
Others
• Wide range of applications for architecture/research/military…
• Manufacturing of customized models and patterns
15%16%
17%
13%17%
22%
Part of Groupe Gorgé The culture and experience of an industrial group with constant focus on innovation
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Smart Safety SystemsECA
Industrial Projects & ServicesCLF Satrem AI Group, Van Dam, Cimlec Industries, CommercyRobotique, Tenwhil
Protection in nuclear environmentsNucleaction, Baumert
Seres Technologies
3D PrintingProdways
• A family-owned group in advanced industries
• 1500 employees
• Subsidiaries in 8 countries, global coverage
• Listed on NYSE-Euronext
• Industrial culture
An accelerated path to success
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90’ 2007 2013 2014 1H2015 2H2015
Dr Allanic PhD imagined a revolutionary new system of UV photo-polymerization
Creation of MOVINGLight®
technology and foundation of Phidias technology company
Creation of Prodways from the acquisition of Phidias technology by Groupe Gorgé
Acquisition of Deltamed, leader in material development for 3D printing
Partnership with CEA, Dreve and DSM Somos
Development of partner network in EMEA, Asia and USA
Creation of Prodways Americas subsidiary
Acquisition of Norge, manufacturer of 3D printing systems based on SLS technology,
Acquisition of Initial, main France service bureaux
Become 3rd
largest player in the world with an industrial multi-technology product range
R&D partnership with Hunan Farsoon on plastic & metal laser sintering technology
Launch of “Prodways powered by Farsoon” plastic laser sintering range
Investment in Varia3D, service provider in the USA with expertise on laser sintering
Service & R&D partnership with LSS, leading European service provider on laser sintering
Acquisition of Exceltec, manufacturer of powders for laser sintering
A complete offering of 3D printing solutions for industrial needs
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Industrial3D Printers & technologies
Materials R&D & Production
On-demand Parts Design & Production Services
Support & Investment
Aerospace Division
Prodways core values
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Innovation Customer focus
Open Materialstrategy
Strategic Industrial and R&D patnerships
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A constant focus on Innovation
170employees worldwide
4 sites : • Prodways HQ
in Les Mureaux• Prodways Materials
in Friedberg• Prodways Design &
Production in Annecy• Prodways Aerospace
division in Toulouse
High levelR&D partnerships
Innovation
Centerequipped with latest technologies
36R&D Engineers
Supported by an international network of experts
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Prodways Americas Headquarters
Minneapolis (MN)
Prodways Americas Tech Center
Austin (TX)
Prodways Group Headquarters,
Paris, France
Prodways Aerospace Division
Toulouse, France
Prodways Materials R&D - Manufacturing,
Francfort, Germany
Initial - Prodways Parts Design & ProductionAnnecy, France
Initial – Prodways Parts Design &
ProductionAn end to end solution to design & produce your parts on-demand
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05/07/2016
Product Design &EngineeringSolutions
3D Scanning & Inspection process qualification
On-Demand parts productionPlastic & Metal AMInjection molding & tooling
• 20 years 3D printing experience
• 30 machines (20 plastic, 10 metal)
• 150k plastic parts/ year
• 5 000 metal parts/ year
Prodways 3D printers & Technologies A multi-technology offering for industrial needs
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MOVINGLight® DLP Photopolymerisation
Premium Selective Laser Sintering
• Disruptive light-curing technology • Unequalled levels of resolution and speed• Acrylate & Hybrid resins and ceramic pastes
• High quality laser sintering technology with best thermal stability
• Game-changing open material strategy
Acrylate & Hybrid Resins
Ceramic pastes Plastic Metal (coming)
Prodways Premium Materials A wide range of premium, innovative materials
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Integrated Materials business unit
• Integrated R&D
• Production site in Germany
• Strategic partnerships
• Premium materials strategy
Large portfolio of Premium Materials
• Liquid resins for photo-polymerization
• Ceramic pastes
• Plastic powders for laser sintering
Prodways Entrepreneurs Support & Invest in 3D eco-system
Support 3D printing companies on the road to success
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Financial Solutions
• Invest in equity (taking non-controlling stakes)
helping companies to accelerate their
development
Operational Solutions
• Operationally support 3D companies in
delivering innovative products and services
Strategic Solutions
• Share its network of experts and benefits of its
partnerships with world-renowned institutions
Technical Solutions
• Access the latest 3D printing techniques and
innovations
MOVINGLight® Technology
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High power LED combined with DLP microchip (with water-cooling unit) to solidify UV curable material
Possibility to move one or two DLP LED heads on the build platform
MOVINGLight® technology from Prodways : a game changer
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Unequalledresolution
even on large parts
High throughputwith speeds up
to 10x faster
Process stability& parts accuracy
Wider range of premium materials
Key applications
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Dental Jewelry
Molds Casting Jigs & features
Medical
Industrial Ceramics
Prototyping
Key applications
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Dental Jewelry
Molds Casting Jigs & features
Medical
Industrial Ceramics
Prototyping
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Molding applications
ThermoformingComposite material
Molds Blow MoldingInjection Molding
Prodways Material suitable for molds application on L series:
Plastcure Rigid 10500
Additive Production of molds : Printing Guidelines
Objectives:
• Additive manufacturing for production of thermoforming / blow molding / injection molding molds
• Shorter lead-time than standard processes! (down to 2 days for an insert)
• Save tooling costs on low production volume runs
Applications:
• Validation of mold design, part functionality with the final material
• Validation of Pre-series, small series
Framework:
• Parts size : small to medium 50 to 100 tons injection molding machines
• Material injected influences tool lifetime
• Main competitor = aluminium mold!
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ProMaker printer L-series
PLASTCure resin Rigid 10500
Layer Thickness 50-100µm
Thermal Post-treatment might be applied to
increase thermomechanical propertiesTIP
Additive Production of molds: Mold fabrication
• Several technical options are available depending on the molding process. Hollow structure, reinforced hollow structure, backfiller, thermal postcuring, coatings, conformal cooling channels
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• Partnership with Initial and automotive group for injection molds development. Industrial partnership with leading companies for other molding technologies
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Thermoforming Molds
• Manufacturing process used for forming plastic sheet
• Technical Key points : Recommendation to use reinforced hollow structure
• Thermal absorption easier to control
• Vacuum easier to transfer to molding surface
• Less resin consumed
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Composite materials molds• Molds for Hand lay-up, Autoclave process (RTM)
• Same technical specifications as molds for Thermoforming.
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Injection Blow Molding• Process used for production of series hollow items (e.g. Bottles)
• Hollow items blown from a pre-form in an heated blower
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Injection Blow Molding: 50cl Bottle use case
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ProMAKER printer L5000
PLASTCure resin Rigid 10500
Layer Thickness 100µm
Build time 6,6h (two halves)
Finishing Support removalSand blasting
More than 250 bottles produced without any damage on the mold. (test stopped – requested quantity obtained)
Parting surface printed horizontally Part cavity as upfacing surface
Bonus: Extrusion Blow Molding
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• Conformal cooling @5°C
• Metallic backfiller
• Closing pressure of 30 bars
• Blowing pressure of 8 bars
Reducing time to market
Injection Molding
Overview
• Manufacturing process for producing parts by injecting material into a mold.
• Injection molding is the most common modern method of manufacturing plastic parts.
3D printed Mold use
• Capacity of producing between 1 and a few hundreds of parts, depending on the requested thermoplastic material and part design
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Injection Molding: Test box
Results
• Build time 2x faster than standard SLA (8,5 h)
• More than 250 parts injected in PP and POM (test stopped)
• 30 parts injected in PA 30%GlassFiber
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ProMAKER printer L5000
PLASTCure resin Rigid 10500
Layer Thickness 75µm
Build time 3,3h (two halves)
Finishing Support removalSand blasting
Key applications
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Dental Jewelry
Molds Casting Jigs & features
Medical
Industrial Ceramics
Prototyping
Metal Casting
• Process similar to jewelry casting but with bigger patterns.
• Traditionally wax models are used to create the ceramic mold for metal casting.
• 3D printed parts with castable resins open new design possibilities for the production of high tech metal components
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Metal Casting: 3D printing patterns
Burn-out process
• In a traditional mold building process, wax melts away.
• With the resin pattern, master has to be burned away.
Solution
• Special 3D preparation with hollow structures: Tetrashell ® Pattern
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Metal Casting: 3D Value offer
Why foundries are interested in 3D printing?
• Speed : Foundry obtains directly the pattern eliminating 2 steps
• Freedom of design : Rapid prototyping allows creating more complex shapes
• Polished casted parts : Resin parts allows a high finishing degree
Applications (by importance)
• Aeronautics and engine manufacturer
• Orthopedics implants (Titanium)
• Oil –Well drilling equipment
• Military equipment
• Artcasting
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Metal Casting
Tetrashell Pattern vs Wax
• Tetrashell is faster, more complex shapes
• 3D Material more expensive than wax
• Adaptation of foundry process required
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Tetrashell Pattern vs Voxeljet (binder jetting)
• Tetrahsell has better surface finishing & better dimensional stability
• Material is more expensive
Metal casting : Application CaseProduction of Turbo Wheel
Goal
Production of turbo wheels in titanium or inkonel for the after market
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ProMAKER printer L5000
PLASTCure resin ABS3650
Layer Thickness 75µm
Tetrashellparameters
Walls thickness: 0,7mm Leg thickness : 1mm Leg length : 3,5mm
Finishing Centrifugal CleaningSupport removalSand blasting
Metal casting : Application CaseProduction of Turbo Wheel
Fabrication Data:
• Production time for 20 wheels : 12h12
• Plateforme price : 109€ (including resin loss)
• Production time on SLA system : 16h00
• Production in wax (3d printed): 29h30 (less accuracy)
• Production in wax using molds : NA in this business case
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ProMAKER printer L5000
PLASTCure resin ABS3650
Layer Thickness 75µm
Part per platform 20