HYB YB-MAN MAN Hybrid 3D manufacturing of smart products Ronald Maandonks, Rob van Asselt Signify Research November 21, 2018 www.hybman.eu Contact: info@hybman.eu 4-12-2018 1
THE HE CHA HALLENGE: LLENGE: EVOLVIN LVING G ELEC ECTR TRONI NICS S MARK RKET ET Electronics manufacturing is still heavily Industries like Signify and Bosch are facing: relying on mass production : • Demand for customized and personalized • Standard products and components, products leading to increased diversity rigid supply chains • Request for new product designs offering • High investment cost (tooling, R&D) improved functionality and form factors • Need for cost effective manufacturing of small • Long initial lead times (tooling, shipment) series . • Need faster response to changes in the market. Need for more flexible manufacturing methods No product specific tooling Design freedom Local/distributed Digital process Stock free → low investment Integration of manufacturing Digital design More flexible → short lead time functionalities supply chain 4-12-2018 2
THE HE SOLUTION: LUTION: HY HYB-MAN MAN The Hyb-Man project will develop hybrid 3D manufacturing methods to enable flexible first time right production of smart systems hybrid 3D manufacturing methods , combining: • additive manufacturing/3D printing • 3D electronic structure processing • 3D assembly & interconnect flexible first time right production smart systems 4-12-2018 3
HY HYB-MAN MAN APP PPRO ROACH ACH Design guideline activities to link relations materials-processes-products Product – process relations Design guidelines Materials Product architectures structural, electrical Product designs Processes and technologies AM 3DPE P&P FDM, SLA, dispense jet, dispense, FDM Complex set of activities • need to run in parallel • many mutual interactions Metrology • broad set of competences Control platform T , geometry, conductivity → drive for cooperation in Hyb-Man Sense Act Control platform to integrate processes and metrology 4-12-2018 4
HY HYB-MAN MAN ACTIV TIVITIES ITIES AND ND PARTNERS TNERS Product – process relations Design guidelines Materials Product architectures structural, electrical Product designs Processes and technologies AM 3DPE P&P FDM, SLA, dispense jet, dispense, FDM • Reden • Fraunhofer IFAM • Signify • Henkel Metrology Control platform • Technolution • Neotech AMT T , geometry, conductivity • TNO • Robert Bosch Sense Act • TU Eindhoven • Xenon • VSL 4-12-2018 5
HY HYB-MAN MAN RES ESULTS ULTS – 5-AXI XIS S PL PLATFORM TFORM & L & LED ED DE DEMONSTRA MONSTRATOR OR 3D product design: LED cube containing integrated tracks, LEDs and connection hybrid manufactured functional product Processing route for 5-axis FFF/FDM 1. Import Step file into Motion 3D CAD/CAM SW. 4. Base printed via FFF in PLA. 6. Main body printed with FFF. 2. Manufacture operations (FFF, P&P, printing 5. 4 LEDs in base added and then 7. Side wall circuits use 5 axis motion. circuits) programmed in single interface. Ag circuit printed to directly 8. 16 LEDs in walls mounted with 3. Output G-code via machine specific post contact. conductive adhesive. processor. 4-12-2018 6
HY HYB-MAN MAN RES ESULTS ULTS – HY HYBRID RID 3D D MA MANU NUFACT ACTURI URING NG PL PLATFORM TFORM Process and equipment development: • Baseline stereolithography 3D printing (SLA) • Modular • Pick & place of components • Interconnection by dispensing metal paste • Metrology & control Freeform gear shifter Hybrid 3D manfacturing platform 4-12-2018 7
HY HYB-MAN MAN RES ESULTS ULTS – THE HERMAL RMAL AND ND ME MECHA CHANICAL NICAL MO MODELING DELING Modular AM process simulation: • Prediction of internal stresses and warpage • Prediction of temperature field • Suitable for multiple AM techniques and materials G-code after release from build platform 3D printing simulation to predict temperature distribution (location and time) 4-12-2018 8
HY HYB-MAN MAN RES ESULTS ULTS – MA MATERIAL ERIAL AND ND PR PROCESS OCESS DE DEVELOPMENT VELOPMENT Additive manufacturing materials (polymers) with increased functionality → Filled materials with thermal/electrical conductivity Balancing properties Material optimization Optimized product properties PA hotmelt + multiple fillers Requires Results 1. Tuning polymer properties conductivity (high filler %) PA Hotmelts: highly amorphous low polarity processability (low filler %) 2. Optimization polymer/ filler composites • doubling of thermal conductivity • maintain good viscosity 4-12-2018 9
HY HYB-MAN MAN RES ESULTS ULTS AND ND OUT UTPUT PUT Models Know how Product designs Materials (Integrated) processes Equipment and tools Development platforms Methods and tools Manufacturing methods SW platform 4-12-2018 10
HY HYB-MAN MAN EX EXPLOIT PLOITATION TION OF PR PROJEC OJECT T RES ESULTS ULTS - Material sales - Product sales - Equipment sales - Manufacturing services - Simulation consultancy - Metrology consultancy - SW platform services - New partnerships - New funded projects All - Intellectual property 4-12-2018 11
HY HYB-MAN MAN IMP MPACT ACT ON N EU EU IND NDUSTR USTRY Opportunities Achievements up to Nov. 2018 Revenue Sales of products (LED lighting, automotive sensors), equipment, tools, materials. 3 R&D machines sold (> 500 k€) New products, faster introduction to the market and cost savings (tooling, development). (Universities and R&D product development) Economical Extend digital capabilities (modeling, metrology, process control). New markets Access to new markets, like healthcare, personal care, consumer electronics, aerospace. From high volume to low volume (personalized)/fast delivery. Requires digital supply chain (materials, equipment, inspection, packaging, transportation, …). New supply chain and New cooperation (funded) projects for universities and knowledge institutes. partnerships Bring manufacturing back to Europe (labor cost less dominant, complexity difficult to copy). Employment Grow in engineering/development and consultancy/services. Teach learnings from Hyb-Man, disseminate know-how (courses, conferences, papers) Education > 20 conference contributions Social Educate the future digital work force. 2 PhD students working in Hyb-Man Resources and materials use: on demand and local manufacturing. Societal challenges Health and well-being: e.g. personalized devices to monitor health at home. Innovative societies: include people in the design and manufacturing process. New end products (design, function, use); make on demand, make local New products/ Integrated process approach defined Innovation and New (integrated) equipment and tools technology services/ processes (Consultancy) services for simulation, metrology, control, manufacturing Pilots (HW and/or SW) for the products, equipment, metrology and control. Pilots & demonstrators First demonstrators available (HW, SW) SW tools (demonstrators) for product design and simulation. Hybrid 3D manufacturing is digital, thereby contributing to Industry 4.0 and Smart Industry. Manufacturing Hyb-Man linked to Fieldlab MM3D (NL) 4-12-2018 12
SUM UMMAR MARY Y AND ND CONCL NCLUSION USION Changing environment and customer demands drive the need for more flexible manufacturing methods smaller series, customized products – design freedom – faster response to changes Huge opportunities Many challenges • • product design technologies and materials • • manufacturing (local, on demand) industrial processes • • supply chain and business model first time right • • service offerings new product designs Multi-disciplinary approach and partnerships needed to move forward materials – processes – equipment – process control – product design – manufacturing – inspection and test 4-12-2018 13
ACKNO KNOWLEDGEMEN WLEDGEMENT Hyb-Man is a project labelled by the EUREKA Cluster PENTA, supporting innovation in micro- and nanoelectronics based components & systems 4-12-2018 14
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