The development & application of Additive Manufacturing & 3D Printing

1. The development & application of Additive Manufacturing & 3D Printing -looking to the past to inform the future- Stockholm, Sweden – 19th September 2013 Dr Phil Reeves – lead consultant, Econolyst

2. Contents (50-minutes) • A personal introduction • Agreeing terms (AM or 3DP) • The principles of layer manufacturing explained • Technology applications and trends • The business drivers to technology adoption (users) • Looking at the consumer 3D Printing Eco-system (suppliers) • Projecting out the future

3. About Econolyst • Econolyst is a UK based consultancy & research firm dedicated to the 3DP & Additive Manufacturing • Established 2003 • Team of Engineers, designers, economists, mathematician, software developers, retail & HR people • Partnership with Nottingham University for technology development & materials characterisation • Work across the Western Europe, Scandinavia, USA, the Middle East & Far East • Fortune 500 client base

4. What do we do • Help companies ideate & embed AM/3DP products into their brands, value chains & supply chains • Help AM software, technology & materials vendors with their technology & market strategy • Advise public & private sector investors on the dynamics of the AM/3DP market place Point Lobos Capital

5. Current stuff that keep us busy! • Modelling the 10-year convergence of 3D Printing, open source electronics & robotics on the consumer electronics industry • Investigating the long terms innovation benefits for the wide scale adoption of consumer 3D printing in a professional automotive design environment • Modelling the current and future economics for the use of 3D Printing to support volume manufacturing • Technology mapping for the re-shoring of ‘digital footwear’ – technology & data pathways

6. The development & application of Additive Manufacturing & 3D Printing -looking to the past to inform the future-

7. Q) Is 3D Printing the same as Additive Manufacturing?

8. Q) Is 3D Printing the same as Additive Manufacturing? • YES, but: • 3DP is typically associated with people printing at home or in the community • AM is typically associated with production technologies & supply chains • BUT they both produce parts by the addition of layers

9. What is Additive Layer Manufacturing 3DP processes are automated systems that take 2-dimensional layers of computer data and rebuild them into 3D solid objects

10. Why is this layer thing so different • Subtractive • Material is successively removed from a solid block until the desired shape is reached (2.5M BC – Hominids) • Fabricative • Elements or physical material are combined and joined (6,000 BC – Western Asia) • 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) • Additive • Material is manipulated so that successive pieces of it combine to make the desired object (1984 – Californians)

11. This is not a new concept • 1902 - Peacock patent for laminated horse shoes • 1952 - Kojima demonstrated layer manufacturing benefits • 1967 - Swainson files US patent for dual light-source resin system • 1981 - Kodama publishes 3 solid holography methods • 1982 - Chuck Hull experiments with SLA • 1984 - Chuck files US patent 4,575,330 • 1986 - 3D Systems formed, others follow • 1987 - Rapid Prototyping became a commercial reality • 1990 - Layer manufactured parts used as casting patterns • 1995 - Layer manufactured parts used as tools • 2000 - Layer manufactured parts used as production parts • 2011 – 45,000 ALM machines globally (in total since 1984) • 2012 – 45,000 new machines sold in 1-year

12. Wire feed Infrared Jet & Flash Solvent jetting Laser spot E-Beam Photocurable Powder bed DMD/DLP Binder jetting Laser Powder feed Extruded Jetting How do ALM process build layers Thermally Cut from stock How to make a layer Chemically

13. Commercial ALM systems in 2013 • Sintermask • High Speed sintering • 3D Systems - SLS • EOS - LS & DMLS • Phenix, Concept Laser, Realizer, Renishaw, SLM Solutions - SLM • Arcam EBM • Sciaky EBM3 • Stratasys – FDM • MakerBot clones • Optomec – LENS • Accufusion - LC • Solidscape • 3D Invision DP • Objet – Polyjet • 3D Invision HR/XT • Voxel Jet – PM • 3D Systems – SLA • Nextfactory – Digiwax • DMEC - SLA • Solidica – Ultrasonic compaction • Mcor Matrix • CAM-LEM CM100 • Z-Corp – 3DP • ProMetal • F-Cubic • EnvisionTEC – Perfactory • EnvisionTEC – Vanquish • 3D systems – Vflash • DWS – Micro SLA • Asiga - Pica

14. Metallic materials Polymeric materials Ceramic materials Organic materials Aluminium Tool Steel Polyphenylsulfone Polycarbonate PMMA Ceramic (nano) loaded epoxies PEEK Titanium Filled PA ABS Polyamide (nylon) Cobalt Chrome Thermosetting epoxies Inconel Copper Aluminium loaded polyamide ULTEM Graphite Plaster Silica (sand) Stainless steel Beta-Tri calcium Phosphate Hastelloy Silicon Carbide Gold / platinum Zirconia Alumina Mullite Tissue / cells Waxes So what can we print after 29-years?

15. 3DP is just an enabler – many applications Prototypes (Rapid Prototyping) Casting Patterns (Rapid Casting) Tool cavities (Rapid Tooling) Direct Parts (Additive Manufacturing)

16. But what about the value Rapid Prototyping $$ Rapid Casting $ Rapid Tooling $ Additive Manufacturing $$$$$$

17. Why is AM becoming so important to manufacturers (I want to be a user!)

18. The core business drivers to AM adoption • Economic low volume production • Increased geometric freedom • Product personalisation • Improvised environmental sustainability • New supply chains and retail models • Increased part functionality

19. 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

20. Example – unit volumes of 1 • Bentley is a subsidiary of Volkswagen • Vehicles from $250K - $1M • In-house polymeric and metallic AM capacity

21. 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

22. Example – Low volume production Images courtesy of Bentley

23. 2. Maximising design complexity • 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

24. 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

25. Design the product around the holes

26. Example – conceptual Diesel Pump • Produce the part as one piece using Selective Laser melting on Aluminium

27. 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

28. surface design for bone ingress Material: Ti6Al4V Build time: 16 cups in 18 hours • Implants (production) • Accetabular cups Images Courtesy of ARCAM – www.arcam.com

29. Example – Heat dissipation surfaces

30. Example – Energy absorption

31. Multifunctional technology platforms

32. 4. Product Personalisation • Individual consumer centric products, with customer input • Medical devices • Consumer goods • Cultural & emotional artefacts • Online design tools • Co-creation

33. www.makielab.com • Children engage with technology

34. There are many new interfaces

35. 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

36. Case study – aerospace cabin component

37. Design optimisation for AM Topologically optimised Machine from solid billet Images courtesy of Loughborough University Complex lattice

38. 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)

39. Lifecycle environmental benefit • Example based on 90M km (Long haul) application

40. Sunday Times 13th Feb 2011

41. Example – life cycle economic benefits • 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…. 

42. This is a step change in design

43. BUT - We can go much further

44. 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)

45. Rapid retailing linking the internet to 3DP $50.00 each 60,000 month $36M P/A

46. Figure Prints – 4,000 per month $6.2-million (6-machines)

47. “But what about consumer 3D Printing?” (I want to be a supplier BUT - It’s all just Hype!)

48. There is certainly a lot of hype 

49. “you can print anything” “A new world order” “Bigger than the internet” The hype debunked

50. “Bigger than the internet” Bigger than the internet……………..