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Fortus 3D Production Systems

Fortus 3D Production Systems. Presentation for Rapid Made. NEXT. Agenda of needs. Reduce time-to-market Increased team productivity Reduce design & manufacturing costs Convenient & confidential in-house solution. NEXT SLIDE. Stratasys Incorporated. 20 years in the industry

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Fortus 3D Production Systems

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  1. Fortus 3D Production Systems Presentation for Rapid Made NEXT

  2. Agenda of needs Reduce time-to-market Increased team productivity Reduce design & manufacturing costs Convenient & confidential in-house solution NEXTSLIDE

  3. Stratasys Incorporated 20 years in the industry 7 year market leader* 43% of market share* +13,000 installations Financially stable * Source: 2009 Wohlers Report NEXTSLIDE

  4. Why Companies Choose Fortus Variety of durable thermoplastics Large capacity Versatile & configurable Low cost of ownership Facility friendly No geometry too complex Runs unattended NEXTSLIDE

  5. Fused Deposition Modeling (FDM) Dual Tip Technology Modeling Material Support Material Build Platform

  6. Primary Applications Traditional Applications(Design) Direct Digital Manufacturing (Manufacturing) To Slide:Thermoplastic Family

  7. Fortus Thermoplastics Family ABS-M30 ABS-M30i ABSi PC-ABS Polycarbonate PC-ISO ULTEM 9085 PPSF/PPU Soluble Supports* To Slide:Fortus Solutions

  8. FORTUS 360mc FORTUS 400mc FORTUS 900mc Click system image for more info. Click system image for more info. Click system image for more info. Performance • Envelope size • Materials • Accuracy • Resolution • Flexibility • Supports NEXT

  9. Thermoplastic Materials NEXT

  10. Materials: ABS-M30 • Unique Properties • Up to 70% stronger than ABS material • High tensile, impact, and flexural strength • More durable part than standard ABS • Versatile, good for form, fit and function • Variety of colors Back to Slide:Thermoplastic Family ABS-M30 Success Story

  11. Materials: ABS-M30 • Success Story • Simple fixture to aid in assembly process • Consistent height of post above plate • Integrated part number & description • Single vs. multiple piece construction • Time & cost savings • 15 vs. 01 days • $490 vs. $62 Back to Slide:Thermoplastic Family

  12. Materials: ABS-M30i • Unique Properties • Biocompatible (ISO 10993 certified) • Medical, pharmaceutical and food packaging • Sterilize using gamma radiation EtO • Best fit for good strength and sterilization Back to Slide:Thermoplastic Family ABS-M30i Success Story

  13. Materials: ABS-M30i • Success Story • Custom dental drill guide in hours • Contact with flesh - ISO-10933 • Designed from dental impression scan • Locks in and accurately positions drill • Tungsten bushing on wear surfaces • Fast, accurate, inexpensive tools Back to Slide:Thermoplastic Family

  14. Materials: ABSi • Unique Properties • Translucent material • Amber • Clear • Red • Ideal for automotive tail lens applications • Blend of mechanical and aesthetic properties Back to Slide:Thermoplastic Family ABSi Success Story

  15. Materials: ABSi • Success Story • After-market supplier bidding process • Wanted new design concept model • Concept model set apart from others • Design was chosen over others • Attributed to lighted concept model Back to Slide:Thermoplastic Family

  16. Materials: PC-ABS • Unique Properties • Best properties of PC and ABS • Mechanical props heat resistance of PC • Feature definition surface appeal of ABS • High impact strength Back to Slide:Thermoplastic Family PC-ABS Success Story

  17. Materials: PC-ABS • Success Story: New Stapler Design • Design objectives • Ergonomic & modern design • Reduce manufacturing cost • Consumer focus group • 8 design concepts evaluated • 3 month field testing • PC-ABS functional prototype • Good fit with high-impact strength • Improved design & profitability Back to Slide:Thermoplastic Family

  18. Materials: Polycarbonate (PC) • Unique Properties • Most widely used industrial thermoplastic • Superior mechanical properties • Accurate, durable, and stable • High heat resistant Back to Slide:Thermoplastic Family PC Success Story

  19. Materials: Polycarbonate (PC) • Success Story • Small scanner for research subjects • PC does not show up in imaging • Fortus system reduced time & cost • 14 days vs. 5 days (64% savings) • $1800 vs. $680 (62% savings) Back to Slide:Thermoplastic Family

  20. Materials: PC-ISO • Unique Properties • Biocompatible (ISO 10993 certified) • Sterilize using gamma radiation or EtO • Medical, pharmaceutical and food packaging • Applications requiring strength and sterilization Back to Slide:Thermoplastic Family PC-ISO Success Story

  21. Materials: PC-ISO • Success Story • Patient custom cutting & drilling guide • Designed from 3D MRI data • ISO 10993 Certification • Increased surgical accuracy • Reduced surgery and recovery time Back to Slide:Thermoplastic Family

  22. Materials: ULTEM 9085 • Unique Properties • FST (flame, smoke, toxicity) certified • High heat and chemical resistant • Ideal for commercial transportation • Highest tensile and flexural strength Demonstration of mechanical strength Ultem Success Story Back to Slide:Thermoplastic Family

  23. Materials: ULTEM 9085 • Success Story • New “eye-ball” air vent design required • Required for commercial aircraftapproval • Initially to test fitment and validate design • Certifications allowed commercial flight • Also use for low-volume manufacturing Back to Slide:Thermoplastic Family

  24. Materials: PPSF/PPSU • Unique Properties • Highest heat and chemical resistance • Mechanically superior, greatest strength • Sterilize using gamma radiation or EtO • Applications in caustic and high heat Back to Slide:Thermoplastic Family PPSF Success Story

  25. Materials: PPSF/PPSU • Unique Properties • Diesel vapor coalescer filter • Captures & re-burns oil, fuel, soot • Required by new emissions standard • Robust & functional prototype required • Testing +70hrs part survived • Validated design to OEM Back to Slide:Thermoplastic Family

  26. Materials: Soluble Supports • Unique Properties • Soluble material • Dissolves in detergent/water • Quick and hands free • Flush down drain • Easy to sand and polish • Soluble supports & cores Soluble Supports Success Story Back to Slide:Thermoplastic Family

  27. Materials: Soluble Supports • Success Story • Solution for complex tooling geometries • Composites • Investment Casting • RTV/Silicone Molding • Core dissolved after casting/molding • Prototype scooter engine radiator hose Back to Slide:Thermoplastic Family

  28. Success Stories Concept Models NEXT

  29. Concept Models GTRE Back to Slide:Primary Applications NEXTSLIDE To Slide: Materials

  30. Polaris Saves $60,000 In Mold Changes Injection molding for prototypes • Tooling changes common • Typical cost: $60,000 Installs Fortus system • Builds FDM prototypes in-house • PC-ABS provides 70% of production part strength FDM carrier rack • Used to perfect the design • Eliminated 3 mold revisions Time and cost savings • FDM cost $1200; saved $60,000 in mold fixes • Lead-time reduced from 70 days to 2 days NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  31. Needed time-to-market reduction Engine: 28 months to design and build Majority of prototypes were outsourced Fortus for in-house prototypes 2 alternative prototype engines built Nearly all from polycarbonate More holistic view of engine design Decreased design errors Sped up design process Time-to-market reduced 29% Engine designed and built in 20 months Prototyping costs also substantially reduced Ducati Cuts Development Time 20 Months NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  32. Instrument panel (IP)—fit and finish critical Need accurate prototype to detect flaws Complexity makes it difficult Fortus produced FDM prototypes Durability ideal for assembly and function testing Greatest deviation is 0.75 mm over 1382 mm length FDM IP prototype revealed many flaws Issues hard to see in CAD Most were minor but would have delayed project Fortus system operating at 91% capacity Paid for itself in under 30 months Plans to buy a second Fortus Hyundai’s Prototypes Reveal 27 Design Flaws NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  33. Previously made with conventional machining Took months and tens of thousands of dollars Time and expense limited use of prototypes Fortus now used for prototypes Many are complex assemblies Example is automotive clutch shown at right Prototype showed initial concept not good fit Avoided investing in on concept Jump start on new, successful concept Dramatic savings in time and cost Prototype cost reduced by 90% Lead-time reduced to days Dana Save Months In Engineering Time NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  34. Conduit prototypes normally cast aluminum 6 weeks; very expensive Epoxy rapid prototypes attacked by fuel and fluids Fortus produced functioning prototypes Polycarbonate and PPSF resist fuel and fluids Work well in functional testing FDM saved time in post-processing Other process: extensive labor FDM: remove supports and ready for use FDM reduced cost and development time Allowed more iterations than other processes Resulted in better-designed components Bell Helicopter: 6 WeekReduction NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  35. 2500 components needed for assembly 1 year estimated to machine parts CAD couldn’t portray piping runs clearly Fortus / FDM used to build parts Pipe interiors dissolved via WaterWorks Enabled modeling of full complexity of piping Huge time and cost savings $60,000 via CNC vs. $20,000 with FDM Lead-time reduced from 12 to 1. 5 months FDM caught flaws that CAD model wouldn’t Component interrelationships better understood Lighter engine, less time to validate and build. Gas Turbine Research Establishment 1 Year Compressed to 6 Weeks GTRE To Slide: Materials NEXTSLIDE Back to Slide: Concept Models Back to Slide:Primary Applications

  36. Success Stories Functional Prototypes NEXT

  37. Functional Prototypes Click on image to go directly to story: NEXTSLIDE To Slide: Materials Back to Slide:Primary Applications

  38. Prototypes need to withstand high pressures Other rapid prototypes don’t hold up Machining is costly; requires long lead-times Fortus makes functional prototypes Produced in a few hours PC meets mechanical requirements Design perfected for a fraction of the cost FDM prototypes of sprinkler shown here Engineers able to quickly test design ideas Dramatic savings over 2 years Product development time reduced by 283 weeks Tooling and service bureau costs cut $500,000 Toro Prototypes Withstand 100 psi NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  39. Problem with microphone boom Boom rotated past stops Broke electrical contacts Fortus’ functional prototypes ABS parts strong enough to handle like real parts Performed realistic tests Engineers solved problem Series of boom and stop designs tested Engineers select ideal design FDM prototypes help create better products Possible to prototype early in design process Test more designs; has better products Logitech: Headset Made 273% Stronger NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  40. ATM tested in rugged environments Rain, sleet, snow; 95oF, -5oF; 85% humidity Previous prototypes left much to be desired Fortus for functional prototypes Prototypes predictive of performance FDM used for 90% of all prototypes FDM parts perform well in battery of tests Survived a year’s environmental tests without failure Survived shipping that damaged cast urethane Plans include FDM for end-use parts Eliminate tooling cost on short-run parts Open new markets for custom ATMs Diebold ATMs Endure Extreme Conditions NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  41. Must resolve design problems faster Customers demanding shorter development cycles Accelerating development leads to flaws Fortus used to produce functional prototypes Strong and easy to modify Parts assembled into prototypes to confirm design Prototypes quickly identify root cause Check dimensions, fit, ease of assembly & practicality Engineers resolve problems before product launch Substantial cost savings Saved $830,000 in prototyping costs over 5 years Sped up product launches & improved quality Hanil E-Hwa Slashes Expenses by $830,000 NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  42. Working engine prototypes tough to make Molding /casting are time-consuming and expensive Epoxy rapid prototypes can’t take high temps or fuel Fortus makes PPSF prototypes Emissions filter for functional testing Withstands heat & petroleum FDM part takes the punishment Mounted on V8 diesel valve cover Collected 160oF blow-by gases with oil and fuel FDM reduced costs and development time Allows more iterations than other processes Results in better-designed components Parker Hannifin Runs FDM Filter 78 Hours NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  43. Surgeons unhappy with implant fastening tools 2 tools required to fasten set-screws Results was often a violent impulse Fortus used to produce functional prototype Combined 2 existing tools Strong enough to fasten stainless screws Prototype enabled design improvements Surgeons used prototype in hospital Found tool could be improved by rotating handle Benefits of in-house prototyping Speed and communications lead to better products Substantial cost savings Medtronic Tests Surgical Instrument NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  44. Outsourcing took too much time Wait for contractor to build prototypes Only time to build a few designs Invested in Fortus machine Now builds FDM prototypes in-house Engineers build and test every idea Boosted engineers’ capacity to innovate Resulted in better quality end products Time and cost savings Component lead-time reduced to hours Snap-fit components cost reduced by 90% Spacelabs Healthcare Buys Some Time NEXTSLIDE Back to Slide: Functional Prototypes Back to Slide:Primary Applications

  45. Success Stories Manufacturing Tools NEXT

  46. Manufacturing Tools Click on image to go directly to story: NEXTSLIDE Back to Slide:Primary Applications

  47. Oreck Reduces Fixture Costs 65% 40-50 assembly fixtures per vacuum • Made by molding and casting • Expensive and long lead-times Fortus machines make fixtures • Fixtures produced in-house • Holds tolerances of 0.003 inch FDM provides large cost savings • Typical cost reduced by $65,000 • Machine paid for itself in a few projects FDM reduces downtime • Fixture components quickly replaced • Manufacturing process is re-started faster NEXTSLIDE Back to Slide: Manufacturing Tools Back to Slide:Primary Applications CONSUMER PRODUCTS

  48. Sandwich composites for wind turbine components Strength to weight ratio critical Cores increase stiffness and bending strength Fortus thermoplastic cores Withstand lay-up and curing process +250°F / 50 psi Support lay-up and curing without tooling Composite parts up to 30% lighter Process improvements for composite parts Design flexibility; closed internal passages Changes & custom parts made faster First article produced in 6 days Reduced lead-time by 67% Reduced costs by 52% Method Cost Time Conventional fabricating $27,000 18 days Direct Digital Manufacturing $13,000 6 days Savings $14,000 (52%) 12 days (67%) Aviradyne Cuts 52% in Composite Production Cost NEXTSLIDE Back to Slide: Manufacturing Tools Back to Slide:Primary Applications

  49. Machining fixtures took a week Production sometimes stopped Product releases were delayed Fortus now used to make fixtures Thermoplastics meet durability requirements FDM process holds 0.005 inch accuracy Fixtures shown used for keypad 1st positions privacy shield during assembly 2nd holds part during machining operation Time and cost savings vs. machining 1/4 the time 1/5 the cost Diebold Saves 80% on Fixture Cost NEXTSLIDE Back to Slide: Manufacturing Tools Back to Slide:Primary Applications

  50. Plasma-cutter “goo-guns” needed rack Leaked expensive, sticky material Ergonomics were poor Fortus makes rack fixtures Originally purchased to build prototypes May not have built racks without Fortus Fixture positions gun & captures material Assembly sped up Costs reduced with waste reduction DDM faster and less expensive 6 fixtures produced in 4 vs. 7 days traditionally FDM saved about $10,000 Thermal Dynamics: Fixture in Under a Day NEXTSLIDE Back to Slide: Manufacturing Tools Back to Slide:Primary Applications

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