Demystifying 3D Printing & Additive Manufacturing presentation for Steve Hatten – TechHelp Brian Hoffmann – Intermountain3D
TechHelp and Intermountain 3D …are working together to: • Empower Idaho’s manufacturing sector with knowledge and access to high-technology additive manufacturing tools and processes • Accelerate growth and adoption rate of additive manufacturing and rapid prototyping tools and processes in Idaho • Raise awareness and educate Idaho’s manufacturing sector on high-efficiency manufacturing tools and processes through jointly held events and seminars • Create opportunities for current Idaho students to build skills in the high-tech manufacturing sector which are in demand
3D Printing: Wiki View 3D printing (or additive manufacturing, AM ) is any of various processes used to make a three- dimensional object. In 3D printing, additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source.
3D Printing: Mainstream Media View • Manufacture at home on your own desktop!
3D Printing : Additive Manufacturing View Aviation Manufacturing Direct Metal 3D Printer (EBM-Electron Beam Melting) LEAP Fuel Nozzle (19/engine) CFM LEAP Turbine Engine • • Single piece titanium print 15% reduction in fuel & CO2 emissions • • 18 piece assembly reduced to 1 part > $1.5 million in annual fuel savings/plane • • 25% lighter Lightweight composite & AM materials • • Simpler, 5X more durable/reliable > 99.98% dispatch reliability • GE plans to manufacture over 100K aviation parts by 2020
Gartner 2014 Hype Cycle Consumer 3D Printing 3D BioPrinting Commercial 3D Printing Commercial 3D Printing/Additive Mfg. has 5-10 year lead on consumer 3D printing. This is why you should care about Additive Manufacturing now!
Additive Manufacturing Design Cycle Design Cycle Desired Revision Count Prototype Early/Inexpensively Typical Revision Count Cost per Change Revise Without Retooling Concept Build / Manufacture / Detail Design Development Test Ship Time
Design Revision Cost Rule of Thumb F ACT Changes later frequently cost 10x the previous stage 1 1 Reinertsen, D. (2009) Principles of Product Development Flow. Celeritas Publishing
Key Additive Manufacturing Benefits • Faster time to market for product introductions and revisions • End-to-end design cycle cost savings – Concept phase: Inexpensive concept modeling – Design phase: Design verification & 3D fitment check – Build/Test phase: Prototyping materials that mimic production parts – Mfg. phase: Elimination of part/job specific tooling and their own development cycles
Key Additive Manufacturing Benefits • New design freedoms vis-à-vis elimination of many manufacturing limitations – Parts that can only be built via AM techniques • Improved product performance & quality, affordable continuous improvement • Quick design cycles = more ideas = more breakthroughs = improved designs • Improved communication = improved decision making & efficiency
Basic Truths About Additive Manufacturing GE announces first FAA • There is no single 3D Printing approved 3D-printed technology that does everything best engine part – April 2015 • Each technology has strengths and weaknesses, e.g. material properties, speed, equipment cost, post-processing • 3D printer choice should primarily be driven by intended APPLICATIONS The T25 housing is located inlet to the high-pressure compressor and protects the sensor electronics (Photo: GE Aviation) 11
Basic Truths About Additive Manufacturing • Many companies rely on multiple 3D printer platforms for different applications or they will outsource for applications that their printer fails to satisfy • A great 3D printer is not a cure for poor CAD design practices – CAD training, architecture, review, validation, etc. are important for successful AM Early Melni Connector Concept 12
3D Print Technologies Roadmap • Resolution • Engineering applications Powder-Metal • Material properties • $$$ Cost Powder-Thermoplastic Liquid Plastic Photopolymer-UV Laser Paper-Cut/Laminated Ceramic-Extrusion Liquid/Gel Photopolymer-Piezo Jetting Printhead Powder-Gypsum/Plastic-Jetting Binder Sugar/Chocolate-Extrusion Thermoplastic Filament-Extrusion Concept Build / Manufacture / Detail Design Development Test Ship
Case Study – Consumer Products • Project: Series of tests to correlate material properties of production parts to 3D printed parts • Outcomes: High correlation resulted in change in “go to market” strategy • Before: Destructive testing with SLA, SLS • After: Destructive testing with SLA, later SLS Production Seat SLS Seat
Investment Casting • Investment casting is the use of a pattern to create a single use direct-pour metal mold.
I3D Case Study Custom Jewelry Manufacture (Process: Investment Casting) CAD Assemble Wax Cast Before After • 4 hours per/mold • 2 hours for 7 ring molds • $1 material cost/mold • $0.5 cost/mold • Setup time (~1 hour) • Setup time (10 minutes) • Capacity: 5-10 rings/wk • Capacity: 50+ rings/wk • Superior detail in parts
Melni Connector - 3D Printing Applications • Early Prototypes • Product Testing • Investor presentations
Questions?
BACKUP
CONCEPT PHASE EXAMPLE APPLICATIONS
CONSUMER ELECTRONICS RAPID DESIGN ITERATION Courtesy of Cisco Consumer Business Group, Denmark • Create models in hours instead of weeks, at one- fifth the cost • Keeps the development cycle humming • More refined, elegant products “We get prototypes quickly, we refine them quickly, we create new ones, and we derive our elite designs…” -- Eskild Hansen, Head of Cisco’s European Design Centre
STAMPS AND WRITING INSTRUMENTS RAPID DESIGN ITERATION Courtesy of Shachihata, Japan • Time to market reduced by half • Faster, better, more innovative products development • Improved production efficiency
FOOTWEAR DESIGN ITERATIONS Courtesy of Timberland, USA • Dramatic reduction in prototype costs and turnaround time, resulting in more prototyping, better communication, better designs and increased revenue “3D Systems printers have done exactly that for us, compressing our design cycles, lowering our costs and helping us produce better products for our customers.” – Toby Ringdahl, Computer Aided Design Manager, Timberland Company
ENGINEERING COMMUNICATION MODELS Courtesy of Pratt & Miller, USA • Evaluation models to match timeline and quality standards • Marketing models for more effective decision making Finite Element Result - Corvette GT2 Spindle Stress Colored and Deformation x1000
LARGE MACHINE SCALED SALES & MARKETING MODELS Courtesy of Spirax Sarco, USA • Reduced time and costs for tradeshows displays • Powerful sales tool make the difference • Compressed design cycle by 25 to 30% This model weighs This 1/3 scale 3D A $600,000 sale was closed six pounds instead printed model of with this 3D printed scale of 40, making it the PTF4 model of the EasiHeat heat easy for sales Condensate Pump exchanger persons to tote to saves tradeshow customer calls labor time and costs
Clash Detection Courtesy of Shinryo and Team-S, Japan • Use color to check interferences and remaining space Plant model – MEP Systems
DETAILED DESIGN PHASE EXAMPLE APPLICATIONS
3D Printing Applications – Design Verification Models • Check Fitment • Validate CAD Data • Identify functional design revisions early • Test form, fit and assembly • Hands-on feedback 28
Detailed Design Models Courtesy of Andrew Chary Architect • Color and texture for faster approval of details “BIM doesn’t reach its full persuasive potential on a computer screen. The model comes to life when you hold a 3D print in your hands.” - Andrew R Chary, Andrew Chary Architect PLLC
TRANSMISSION TOWER DETAILED MODELS Courtesy of Nippon Katan Corporation, Japan • Better customer understanding with 3D printed models for presentations and communication Catenary pole brackets and insulators
FORM & FIT TESTING Courtesy of Trinity Products “ Our ProJet x60 Printer has been the single biggest step we’ve taken to improve the way we refine concepts, develop products, communicate with our suppliers and market our products” - Mike Wood Chief Engineer, Trinity Products 3D printed hi-flow exhaust pipe and manifold installed onto the vehicle to ensure that the shape of the configuration was exactly the right fit
ASSEMBLY TEST OF WATCH HOUSINGS Courtesy of Citizen • Inhouse prototyping: keeps developments confidential • Higher Quality • Flexible use: directly produce assembly fixtures "With the high-precision 3D printed mock-ups of our wristwatch designs, we improved quality and saved three times the installation costs of our ProJet 3500 HD within six months." - Mr. Naito Product Development, Citizen Watch
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