www.econolyst.co.uk Tuesday 12th June 2012

Dr Phil Reeves - Managing Director, Econolyst Ltd, UK

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3D Printing & Additive Manufacturing

“Extending your printing capability in true 3D”

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• Introduction

• Background to 3D Printing

• The state-of-the-art in 3D Printing

• Supporting prototyping, casting & tooling

• The move to part production & AM

• The importance of design in an additive world

• Democratising manufacture

• Future trends and conclusions

Agenda (1-hour with questions)

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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

• Assessment & implementation of 3DP & AM technology

• Vendor business & technology strategies • AM focused training & conferences • R&D project management & delivery • AM software development

— Establishing supply chain Carbon footprints — Developing AM part cost and value models

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So what is 3D Printing?

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What is 3D Printing – what ARE 3D Printers?

3D Printers are automated systems that take 2-dimensional layers of computer data and

rebuild them into 3D solid objects

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Agreeing terms – history of manufacture

There are Four fundamental manufacturing principles:

• Subtractive - Material is successively removed from a solid block

until the desired shape is reached (2.6M BC – Paleolithic man)

• Fabricative - Elements or physical material are combined and

joined (6,000 BC – Western Asia, basket making)

• 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, investment casting)

• Additive - Material is manipulated so that successive pieces of it

combine to make the desired object (1984 – Californians)

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• 3D Printing is also refereed to as: – Direct Digital Manufacture (DDM) – USA

– Freeform Fabrication (FFF)– USA

– Solid Freeform Fabrication (SFF) – USA

– Fabbing – USA

– Layer Manufacturing (LM) – Scandinavia

– Constructive Manufacturing – Germany

– Generative Manufacturing – Germany

– eManufacturing - Germany

– Rapid Manufacturing - Global

– Additive Manufacturing - Global

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

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• This technology is a natural extension of the digital 3D design environment

• This technology bridges the virtual and the physical design space

• This technology is maturing at an almost exponential rate (something new to take away!)

• This technology is moving well beyond just Rapid Prototyping and is changing supply chains

• Design data is core to this new business model

Why 3DP at the Solid Edge University?

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

2012?

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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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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

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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What do these technologies do?

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)

– Solido

– Bits-from-Bytes (3D)

– MakerBot

– UP personal printer

– Fab@Home

Lower end (desk-top)

– 3D Printing (Z-Corp)

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

– 24/30pro (Objet)

– FDM Dimension (Stratasys)

– UPrint (HP / Stratasys)

– Laminated Objet Manufacture (Mcor)

– V-Flash (3D Systems)

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Objet Desktop – why?

Visualisation, appraisal & discussion (communication tools, just like

computer screens and paper print-outs)

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So why are desktop machines need?

• Reducing prototyping lead time (replacing bureau services & manual model making)

• Reducing the cost of sub-contract bureau services or manual model making

• Increasing the number of prototyping iterations during the early design stage “prototype early & prototype often”

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Design discipline Products Enabling

software

3D Prototype

demand

Interiors Lighting, door furniture MCAD / DCAD Medium – high

Exterior (architecture) Buildings, town planning ACAD Low – medium

Vehicles Cars, planes, boats, trains MCAD High*

Consumer goods Toys, jewellery, sporting goods DCAD / MCAD High

Household goods Furniture, cookware, tableware DCAD Medium - high

Consumer electronics TV, Laptop, desktop, IPod MCAD High

FMCG Razors, packaging, cosmetics MCAD Medium - high

Electrical goods Power tools, small appliances MCAD High

White goods Fridge, freezer, oven MCAD High- medium

Apparel Clothing, shoes, sports ware DCAD Medium – Low

Computer games War, fantasy & role-play games Mixed Low – medium

CGI animation TV and film character generation Mixed / DCAD Low - medium

Medicine Medical models CT/MRI Medium / low

So who is using desktop 3D printing

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What do these technologies do?

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)

– Solido

– Bits-from-Bytes (3D)

– MakerBot

– UP personal printer

– Fab@Home

Lower end (desk-top)

– 3D Printing (Z-Corp)

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

– 24/30pro (Objet)

– FDM Dimension (Stratasys)

– UPrint (HP / Stratasys)

– Laminated Objet Manufacture (Mcor)

– V-Flash (3D Systems)

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Objet – Connex technology

3D Printing of multiple materials simultaneously

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How Connex different to other high end systems

• All other high end processes produce a limited number of single material components

• SLS – Nylon, Polycarbonate

• FDM – ABS, PEI, PPSF

• Z-Corp – Gypsum

• SLA – Epoxy (photocurable)

• Voxeljet – PMMA, Polystyrene

• Envisiontec – Epoxy (photocurable)

• Connex - Multimaterials

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Why is material property so important?

• With Form & Visualisation prototypes the user only care about the look and the shape

• With Fit and assembly prototypes the user also cares about accuracy & resolution

• With Functional prototypes the user also cares about the material properties of the part

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So how do we create Multi-materials

• There are two kinds of Multi-material part

1. A part with two or more ‘different’ mechanical properties (currently Durometer & colour)

2. A part where two different materials are combined to create a new ‘third material’

1. 2.

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What does Multimaterial allow us to do today?

• Use the digital material approach we can already match or exceed the capabilities of single material RP processes • Simulate ABS

• Simulate higher temperature Polypropylene

• Simulate transparent polymers with shades & patterns

• Simulate rigid polymers with Opaque shades

• Simulate 6 levels of shore hardness rubber

• Print in full grey scale at 600 dpi

• Limited colour – just around the corner

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So where are the applications for 3DP?

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So what can we use parts for?

Prototypes (Rapid Prototyping)

Casting Patterns (Rapid Casting)

Tool cavities (Rapid Tooling)

Direct Parts (Additive Manufacturing)

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– Presentation & marketing models

– Architectural models

– Concept models for discussion

– Visualisation aids for engineers

– Quotation request models

– Visual aids for tool makers

– Fit & function models

– Assembly Models

– Ergonomic Studies

Rapid Prototyping applications are growing

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– Direct printing of sacrificial investment casting patterns (waxes & polymers)

– Direct printing of sand casting cores and cavities

– Direct printing of injection mould tools (in metals and plastics)

– Direct printing of forming tools (for carbon composite layups and aluminium pressings)

Rapid Casting & Tooling

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BUT…….

Why not just print the parts?

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Lots of companies are doing

• Automotive

– Passenger

– Commercial

– Motor sport

• Aeronautical

– Civil aero

– Space

• Production

– Machine parts

– Assembly aids

• Comm’s

– MiniSARS

– Sonar body

– Housings

• Consumer

– Fashion

– Jewellery

– lighting

– Furniture

– Toys

– Giftware

• Defence

– Land

– Air

– Marine

• Medical

– Implants

– Bone scaffolds

– Hearing aids

– Dental aligners

– Surgical guides

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So why are companies adoption AM for production

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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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

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Example – Heat dissipation surfaces

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Example – Energy absorption

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The next generation of systems - multifunctional

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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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www.makielab.com

• Internet based design tools

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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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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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• 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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Scenario 1 – Machined from solid (100%)

Scenario 2 – Selective Laser melted lattice (0.37%)

Scenario 3 – Selective Laser melted optimised design (46%)

So how do our lifecycle CO2 compare

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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 needs a step change in design thinking!

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BUT - We can go much further

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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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Rapid retailing - linking the internet to 3DP

$50.00 each

60,000 month

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Figure Prints – 4,000 per month

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Printing in the home - MakerBot

• Less than 3-years old

• Business based on open source

• 6700 machines sold in 2011

• $1,749 per machine

• Up to 20,000 projected this year

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MakerBot are not alone

Makergear

Start-up Growing

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Is there a market?

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

Moore's law?

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The money will be in the data & content

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A great time to be a CAD Designer

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So what do we know now?

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• 3D printing is a must have technology in the product development environment

• Technology is suited to many different user environments (from desktop to production)

• Technology is available for form, fit & functional prototyping, & beyond into production

• Think beyond design validation into the manufacturing supply chain

• Casting patterns, tool cavities & even parts

Conclusions

www.econolyst.co.uk 12th June 2012

Dr Phil Reeves - Managing Director, Econolyst Ltd, UK

Questions Econolyst Ltd

The Silversmiths

Crown Yard

Wirksworth

Derbyshire, UK

DE4 4ET

+44 (0) 1629 824447

phil.reeves@econolyst.co.uk

Thanks to