HP Multi Jet Fusion 3D PrintingThe HP Jet Fusion 300/500 Printer will use140+unique MJF parts
Transcript of HP Multi Jet Fusion 3D PrintingThe HP Jet Fusion 300/500 Printer will use140+unique MJF parts
HP Multi Jet Fusion 3D Printing How to complement CNC machining with Multi Jet Fusion
1 © Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
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About HP
© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.
HP ships 1 printer
every second 430Powering
HP’s Commercial PCs
rank #1 or #2 in 50 of the top
54 countries
HP ships 1.7 PCs
every second
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HP’s Printing
ranks #1 or #2 in 51 of the top 55
countries (ink + laser)
of the Global Fortune 500 companies
Print & PC leadership
By disrupting manufacturingWe intend to lead in 3D printing too
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The HP Jet Fusion 3D 4200prints dozens of its own plastic parts
The HP Jet Fusion 300/500 Printerwill use 140+ unique MJF parts
140+ unique
3d printed parts
Technology Overview
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HP Multi Jet Fusion Technology (HP MJF)How it works
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FusionApply energyApply agentsMaterial spreading
Fused
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Modularity enables continual printing
HP Jet Fusion 3D Printing Solution
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Day 1 Day 28:00 am8:00 am 12:00 pm 8:00 pm
HP Jet Fusion 3D Build UnitHP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station
Build
Software & PluginsJob preparation & submission
Printer UtilitiesPrinter management
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Cool
10.5h print 10h cool1.7h
10.5h print 10h cool1.7h
10.5h print1.7h
8:00 pm12:00 pm
Prep
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How it works (cont.)
HP Multi Jet Fusion Workflow
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300 & 500 Series do all of thesePre-process
Loading Build Unit
Printing
E2E HP Jet Fusion Solution
Secondary process
Surface finishing
Color dyeing
Post-process
Fast Cooling
Mixing
Cleaning
Bead blasting
Water jetting
Dry ice
Surface finishing
Color dyeing**Not needed for
380 & 580
Why ConsiderAugmenting CNCWith HP Multi Jet Fusion?
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Why consider HP Multi Jet Fusion?
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4 Main Reasons
Economic advantage
Time Performance increase
NewValue
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CNC Machining vs. HP Multi Jet FusionCNC Machining
Part Development
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Layout Design3D Print
Part
IterateDesign
Test ManufactureHP Multi
Jet Fusion
CNC
Layout DesignCNC Machine
Part Test
IterateDesign
Manufacture
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NewValueNew
ValuePart Development
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CNC Machining vs. HP Multi Jet Fusion
HP Multi Jet Fusion enables part designs not achievable with
CNC machining
Performance increase
TimeEconomic advantage
Performance increase
TimeEconomic advantage
Days to weeks
$$
Days$
Potential Time-to-Market Advantageor
Part Design Optimization Time
Quality of CNC’ed plastic parts≠HP MJF because ofmachined in stresses
HP Multi Jet Fusion parts = production parts
Layout DesignFabricate
Part
CNC
IterateDesign
Test Manufacture
Layout Design3D Print
Part
IterateDesign
Test ManufactureHP Multi
Jet Fusion
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This benefit accrues every
design iteration
NB: The delta increases per iteration
NewValueNew Value Example
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Ficep S3—Automatic Paint Machine
Company background:
• FICEP Steel Surface Systems (S3) is a high tech engineering and research & development company which operates worldwide within the FICEP group.
• HP Multi Jet Fusion technology was used to overcome challenges typically faced with traditional production methods.
With HP MJF they can:
• Improve the design of an automatic paint machine arm - it is now extremely lightweight
• Optimize geometry with DFAM (design could not be machined or molded)
• Improve the machine arm performance and help enable savings for the end customer
• Reduce the height of the entire machine, as well as the volume of air that needs to be filtered, and in turn the size of the filter station.
HP MJF printed Machine Arm for FICEP S3 DaVinci
Paint Machine
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Performance increase
TimeEconomic advantage
Result:FICEP S3 aims to replace as much as 40% of the machine’s traditionally manufactured parts with HP MJF technology.
NewValue
Printed assembly
New Value Example: Cartridge Adapter for 4200 printer
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Performance increase
TimeEconomic advantage
Traditional Assembly Multi Jet Fusion Assembly
Operating Position Folded for production
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NewValueNew
ValueCartridge adapter
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Performance increase
TimeEconomic advantage
CNC production workflow
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CNC job-shops Today
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CNC Production is complex - it requires skilled and experienced operators
Part DesignCustomer
DFX & Prod PlanningTechnical Office
ProductionCNC Operator
CNC Machine Shop employee CNC Machine Shop employeeCustomer
2 3
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Print & MonitorPlan BuildDesign Parts
From Design to production in one step with HP MJF
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CNC Machining Service Provider
Technology comparison
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CNC Machining
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Associated costs
These costs are magnified as a percentage of costs for short runs common for low volume production
• Programming of cutter paths
• Building jigs to hold parts being machined
• Fabricating custom cutters
– For when standard sizes cannot create desired geometry
• Wasted material
– Machined chips
• Set up for machining
– Multiple Machines needed to cover all operations
• Break down of machining set-ups
• Storage of jigs
Performance increase
NewValue
TimeEconomic advantageEconomic advantage
$
$$
$$
$
$
$
$
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0
0
0
-
0
-
0
-
0
0
HP MJF
CNC Machining vs HP Multi Jet Fusion
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Associated costsCNC
HP Multi Jet Fusion has none of these costs
Performance increase
NewValue
TimeEconomic advantageEconomic advantage
$
$$
$$
$
$
$
$
• Programming of cutter paths
• Building jigs to hold parts being machined
• Fabricating custom cutters
– For when standard sizes cannot create desired geometry
• Wasted material
– Machined chips
• Set up for machining
– Multiple Machines needed to cover all operations
• Break down of machining set-ups
• Storage of jigs
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This time is directly proportional to the quantity ordered
CNC Machining
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Lead Time
• Programming of cutter paths ………………..………………..….….
• Building jigs to hold parts being machined……………..……….
• Fabricating custom cutters……………………………………..…...….
– For when standard sizes cannot create desired geometry
• Scheduling of multiple machines ………………..………..……..….
• Set up for machining..…………………………………………..….………
– Multiple Machines needed to cover all operations
• Machining one part at a time.…………………….……………..…..…
– Includes:
• Cutting
• Tool exchange
• Transfer to other set-ups
Performance increase
NewValue
TimeEconomic advantage
Time
These times are magnified as the part design becomes more complex
hours
hours/days
hours/days
hours/days
hours/days
mins/hours
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CNC Machining vs HP Multi Jet Fusion
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Lead Time
Performance increase
NewValue
TimeEconomic advantage
Time
HP Multi Jet Fusion has none of these delays
• Programming of cutter paths ………………..………………..….….
• Building jigs to hold parts being machined……………..……….
• Fabricating custom cutters……………………………………..…...….
– For when standard sizes cannot create desired geometry
• Scheduling of multiple machines ………………..………..……..….
• Set up for machining..…………………………………………..….………
– Multiple Machines needed to cover all operations
• Machining one part at a time.…………………….……………..…..…
– Includes:
• Cutting
• Tool exchange
• Transfer to other set-ups
hours
hours/days
hours/days
hours/days
hours/days
mins/hours
HP Multi Jet Fusion can print multiple parts of multiple designs simultaneously
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NewValueCNC Machining
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Process limitations
Performance increase
TimeEconomic advantage
Performance increase
A
A Section A-A
Geometry impacted by machine constraints
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• Need to hold part
• Depth of cut limited by diameter of cutter
• Sharp internal corners cannot be machined
• Dimensions and shape of undercuts
• Feature formation depends on access availability for cutter
Machining process part quality issues
• Stress concentrations from removal of material by cutting
– Strength concern
• Warpage from machined in stresses
NewValueCNC Machining vs HP Multi Jet Fusion
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Process limitations
Performance increase
TimeEconomic advantage
Performance increase
Geometry impacted by machine constraints
HP Multi Jet Fusion can reduce or eliminate issues associated with these machining limitations
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• Need to hold part
• Depth of cut limited by diameter of cutter
• Sharp internal corners cannot be machined
• Dimensions and shape of undercuts
• Feature formation depends on access availability for cutter
Machining process part quality issues
• Stress concentrations from removal of material by cutting
– Strength concern
• Warpage from machined in stresses
NewValue
Other issues to consider
CNC Machining
Machining limitations may require breaking a part into multiple pieces to achieve desired functionality
Performance increase
TimeEconomic advantage
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• Inventory management complexity
• Assembly costs
• Performance impacts
Complexity of part design increases number of machining operations
• Time and cost implications
– Increased set up time and/or number of machines
Scheduling of multiple CNC machines for short runs
CNC Machining vs HP Multi Jet Fusion
HP Multi Jet Fusion can reduce or eliminate issues associated with these machining limitations
NewValue
Other issues to consider
Machining limitations may require breaking a part into multiple pieces to achieve desired functionality
Performance increase
TimeEconomic advantage
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• Inventory management complexity
• Assembly costs
• Performance impacts
Complexity of part design increases number of machining operations
• Time and cost implications
– Increased set up time and/or number of machines
Scheduling of multiple CNC machines for short runs
But CNC Machining…
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Can meet some requirements that HP MJF cannot
Surface finish
Feature precision
Dimensional accuracy
Material range
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Provide optimal output qualityCertified for
HP Jet Fusion 3D Printers
HP Branded Powder HP Certified Powder Any Powder (Fully Open)
Bringing down the barriers to advance widespread 3D printing adoption across industries through materials innovation with the HP Multi Jet Fusion “Open Platform”
OPEN PLATFORM
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HP Open PlatformBringing down the barriers to advance widespread 3D printing adoption across industries through materials innovation
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HP MJF + CNCOne + One > Two
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Combine the advantages of both to achieve new value
HP Multi Jet Fusion + CNC Machining
HP Multi Jet Fusion
• Enable designs not achievable with CNC alone
• Consolidate production of multiple parts of same or multiple designs
• Create near net shape parts to feed CNC finishing
• Eliminate time and costs associated with low value features
– Programming cutters
– Set-up
– Material waste
CNC Machining
• Focus CNC machines on high value features
– Surface finish
– Feature precision
– Dimensional accuracy
• Make parts not achievable by either MJF or CNC alone
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Part Development
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Using Hybrid CNC/HP Multi Jet Fusion production
Layout Design3D Print
Part
IterateDesign
Test Manufacture
MJF
CNC
Layout DesignCNC Machine
Part Test
IterateDesign
Manufacture
Layout Design 3DP Test
IterateDesign
HP Multi Jet
Fusion+
CNC
ManufactureCNC
Finish
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HP Multi Jet Fusion enables part designs not achievable with
CNC machining
Days to weeks
$$
Days$
Potential Time-to-Market Advantageor
Part Design Optimization Time
Quality of CNC’ed plastic parts≠ HP MJF because ofMachined in stresse
MJF/CNC parts = production parts
This benefit accrues every
design iteration
NB: The delta increases per
iteration
NewValueNew
ValuePerformance
increaseTimeEconomic
advantagePerformance
increaseTimeEconomic
advantage
Summary
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Advantages of augmenting CNC Machining with HP Multi Jet Fusion
Schedule
– Faster TtM or more time for design optimization
Development cost
– Less expensive parts for development and production
Design freedom
– Combine multiple parts into one
– Make parts that cannot be made by machining only
• e.g. lightweight lattice structures
Reduce assembly cost
– Print parts already in assembled state
Plastic Part Quality
– Multi Jet Fusion parts do not have the machined in stresses that machined plastic parts have
Performance increase
NewValue
TimeEconomic advantage
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Hypothetical ExampleLow-volume,
Low-load Bearing Parts
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Select Eq. Program Set-up Calibrate Produce
Equipment dedicated
CNC Part Production
30 50
CUSTOMER ORDER
75
Technical Office
What’s the best machine, Is it available?
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CNC ProductionSequential
CNC Part Production
Machine Ready for Next Job
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50u
75u
30u
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CNC Part Production
CNC Part Production
Parts Frequently require
more than 1 pass to machine different planes
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Part 2Plane B
Part complexity has consequencesLonger Lead-times or more machines
Part 1 – Plane A
Part 1 – Plane B
Part 1Plane A
Part 2 – Plane A
Part 2 – Plane B
Part 2Plane A
Part 2Plane B
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Part 3Plane A
Part 3Plane B
Part 2 – Plane A
HP Multi Jet Fusion Production
Preflight Load Print Cool Clean
HP Jet Fusion 3D part production
75u
30u
50u
Nest all the parts in 1 unique build
155uHP JET FUSION 3D Printing
Machine Ready for Next Job
Equipment dedicated
Consolidated
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High Dimensional Accuracycan be achieved withHybrid Production
High Precision is frequently not required on all sides
Accuracy > 0,2mmAccuracy < 0,2mm
But Multi Jet Fusion may not meet all requirementsCNC needed to finish parts
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Hybrid ProductionMore efficient use of machines and faster delivery of parts
Printer Ready for Next Job
155u
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HP JET FUSION 3D Printing
+Critical Features
Critical Features
Critical Features
Actual HP ExampleLow-volume,
Low-load Bearing Parts
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Real HP parts CNC machined during product development
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3 Parts of different complexity
Duct
Feet
ActuatorSupport
Simple Medium Complexity Difficult
Actual quotes to CNC machine these HP parts
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HP spent this time and money
$1760 $2340 $65,140Cost:
2 Weeks 2 WeeksTime: 4 weeks
Duct
Feet
ActuatorSupport
9 (3 sets of 3)Qty: 3080
Considering the entire order
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That’s ~$582 per part
Duct
Feet
ActuatorSupport
Total Qty: 119 Total Cost: $69,240 Time to Parts: 4 Weeks
Few (if any) features require CNC
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The rest could be printed
Duct
Actuator SupportHole diameters and locations require high precision and accuracy
FeetNo features require CNC machining
Duct:Surface finish and flatness of sealing surface
Three HP MJF builds
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All 119 (near-net-shape) parts
60 ActuatorSupports & 9 Feet
(3 sets of 3)
15 Ducts &10 Actuator
Supports
15 Ducts &10 Actuator
Supports
Assuming Fast Print Modeand Fast Cooling
6.9h cool
All 119 near-net-shape parts in <2 days
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First parts ready for CNC finishing in less than one day
HP Jet Fusion 3D Build Unit
HP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station
Build
Cool
Prep
* If have only one processing station, then third partial build will cool naturally for 1.8 hours until processing station is available
4.17h cool1.7h
1.7h Ready to CNC10.25h print 9.75h cool
1.7h Ready to CNC10.25h print 9.75h cool
6.25h print Ready to CNCInQueue* <6.9h cool
Conservative estimate from HP TCO tool
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An average of $24.22 per near net shape part
$970.9025 parts
$970.9025 parts
$940.5869 parts
Total Qty: 119 Total Cost: $2,882 Time to Parts: <2 days
Delta available to CNC critical features based on conservative estimate
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Potential for significant savings in time and money
Duct
Feet
ActuatorSupport
CNC Total Cost: $69,240 Time to Parts: 4 Weeks
MJF Cost: $2,882 Time to net-shape parts: 2 Days
Delta: $66,358 Delta: 26 Days
Assuming Balanced Print Modeand Natural Cooling
All 119 near-net-shape parts in 3 days
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First parts ready for CNC finishing in <2.5 days
HP Jet Fusion 3D Build Unit
HP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station
Build
Cool
Prep
Ready to CNC1.7h 14. 8h print
Ready to CNC1.7h 14. 8h print
Ready to CNC9h print1.7h 22.5h cool
38.75h cool
38.75h cool
Conservative estimate from HP TCO tool
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An average of $30.72 per near net shape part
$1,230.0325 parts
$1,230.0325 parts
$1,195.7469 parts
Total Qty: 119 Total Cost: $3,656 Time to Parts: 3 days
Delta available to CNC critical features based on conservative estimate
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Potential for significant savings in time and money
Duct
Feet
ActuatorSupport
CNC Total Cost: $69,240 Time to Parts: 4 Weeks
MJF Cost: $3,656 Time to net-shape parts: 3 Days
Delta: $65,584 Delta: 25 Days
Delta available to CNC critical features based on conservative estimate
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Potential for significant savings in time and money
Duct
Feet
ActuatorSupport
CNC Total Cost: $69,240 Time to Parts: 4 Weeks
MJF Cost: $3,656 Time to net-shape parts: 3 Days
Delta: $65,584 Delta: 25 Days
Summary of opportunities if hybrid CNC/HP MJF fabrication used
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Faster, Cheaper, More robust
Actuator Support<1 week delivery
instead of 4
FeetNo machined in stresses
enables earlier qualification testing
Duct:Part cost reduced
order(s) of magnitude down from >$2K
PotentialHP MJF Applications
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Potential HP MJF applications from CNCLow volume production of low load bearing parts
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Prototypes
Visual modelsFunctional prototypes
Manufacturing Aids
Jigs & Fixtures
New products
Interior parts: supports & bracketsGrippers/end effectors
Fluid vessels
Spare parts
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HP Example: Drill extraction shoeManufacturing process tooling application
POST PROCESSINGBead Blasting
DIMENSIONSX: 3.91 in / 9,93 cm Y: 3.72 in / 9,45 cmZ: 2.68 in / 6,82 cm
TOTAL COST PER PARTCNC Machined part: $450HP 3D MJF part: $18
95% Overall cost reduction
WEIGHT REDUCTIONCNC Machined part: 575 g.HP 3D MJF part: 52 g.
90% Overall weight reduction
DELIVERY TIMECNC Machined part: 3-5 DaysHP 3D MJF part: 24 h.
MATERIALHP 3D High Reusability PA 12
Turbulent flow
Laminar flow
DESIGN OPTIMIZATION
HIGH REUSABILITY: HP Jet Fusion 3D print solution with HP 3D High Reusability PA 12 has the highest post-production surplus powder reusability with 80% reusability vs any other powder based 3D printing technology using PA 12 material. Consistent performance with only 20% powder refresh rate
CNC MACHINED ASSEMBLY MULTI JET FUSION PART
Assembly unification(from 7 parts to 1)
&Topology optimizaton
Flow optimization
Process to analyze business opportunity using HP Multi Jet FusionCan be applied to: New products, Manufacturing Aids, Spare Parts
Engineering analysis
Plastic partsMetal parts with low load requirements
Can it work
Does it make sense
Opportunity size
Size/Weight Mechanical Properties
part #’s addressable to HP MJF
Materials
3D Part cost better than alternatives Design-for-AM (Several Parts combined into one)
part #’s: based on ROIFinancial analysis
Where to look
Account for benefits of time-to-market Design flexibilityPostponing tooling of unstable design
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Application
Possible CNCpost-process
68
Surface FinishDimensional Accuracy
reasons
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to consider investing in
HP Jet Fusion 3D printing
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To consider adding HP Multi Jet Fusion to your tool box
Four Reasons
Diversify and grow your businessFocus CNC investment on value added features not achievable by HP Multi Jet Fusion
Improve delivery timesConsolidated manufacturing of HP Multi Jet Fusion combined with accuracy of CNC
Reduce costReduce costs associated with programming, machining and materialPrototype the final part before cutting it to minimize errors
Add valueDeliver parts unachievable with CNC aloneHelp customers to solve design problems
Thank you
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