Additive World MasterclassSophie Jones

5th March 2015

Session 1: Understanding AMWhat is Additive Manufacturing?

What is the difference between each process?

What are the business drivers for AM?

What are the barriers?

Session 2: Building a Business CaseThe business case process

Case Studies

What future developments can we expect?

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About Us

• Newly-founded Stratasys Strategic Consulting Division

• Part of Stratasys Services Group

• Formed from the acquisition of Econolyst – a specialist

consultancy with 12 years’ of experience helping companies

understand additive manufacturing and 3D Printing technology

We provide independent, expert consulting to help global brands

understand additive manufacturing and 3D Printing technology,

identify opportunities to use the technology and develop adoption

strategies.

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Some of our projects

• Helping Philips understand & modelling the current and future economics of using Additive Manufacturing to support volume production (2014)

• Helping FedEx understand the impact of Additive Manufacturing and 3D printing on their long term revenue steam as a global logistics business (2014)

• Helping BMW understand the capabilities and limitations of low cost consumer 3D Printers used within the professional design environment (2013)

• Helping the Intellectual property office understand the legal implication of online STL file sharing website and online product design services (2014)

WHAT IS

3D PRINTING?ARE ALL TECHNOLOGIES

THE SAME?

No Consumer 3D Printing is typically associated with people printing at home or in the community

Industrial 3D Printing is typically associated with production technologies & supply chains

BUT they both produce parts by the addition of layers

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AM/3DP Processes

3D Printing / AM processes are

automated systems that take

2-dimensional layers of computer data

and rebuild them as 3D solid objects

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Not all machines are the same

$200$35,000

$1,400,000

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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 – 3D Systems files US patent 4,575,330

• 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

• 2013 – 100,000 consumer & pro machines estimated

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7 Types of AM Technology

Additive Manufacturing

Binder Jetting

Vat Photo-polymerisation

Material Extrusion

Powder Bed Fusion

Sheet Lamination

Material Jetting

Directed Energy

Deposition

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Powder Bed Fusion

AKA. Selective Laser Sintering (SLS), Selective Laser Melting (SLM),

Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM)

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Vat Photopolymerisation

AKA. Stereolithography (SLA), Digital Light Processing (DLP)

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Directed Energy Deposition

AKA. Laser Cladding, Blown Powder, Wire Feed, Powder Feed, Hybrid

Manufacturing

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Sheet Lamination

AKA. Laminated Object Manufacture (LOM), Ultrasonic Consolidation

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Binder Jetting

AKA. 3D Printing, Sand Printing

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Material Jetting

AKA. Polyjet, Multimaterial Printing

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Material Extrusion

AKA. Fused Deposition Modelling

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What can we 3D print after 30 years?

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

Multimaterial – multifunctional systems

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And what are we making?

Rapid Prototyping – models for assessment

Rapid Casting – patterns

Rapid Tooling – cavities and moulds

Additive Manufacturing – end use parts

Why is AM becoming so important to manufacturers?

1. Low Volume Production

2. Design Complexity

3. Personalized Products

4. Part Functionality

5. Life Cycle Sustainability

6. Supply Chain Realignment

6 fundamental drivers

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1. Enabling Low Volume Production

Enables 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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2. Maximise 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

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Flow optimisation

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Flow optimisation

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Internal flow

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Flow optimisation

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3. Product Personalisation

Individual consumer centric

products, with customer

input (low volume & complex

geometry)

• Medical devices

• Consumer goods

• Cultural & emotional artefacts

• Online design tools

• Co-creation

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40,000 orthopaedic implants 12,000,000 hearing aid shells

17,500,000 dental aligners

Product Personalization

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4. Increasing Part Functionality

AM enables 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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5. Lifecycle 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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1kg weight saving = $3,000 fuel saving

annually**EADS quoted by The Telegraph

5. Lifecycle Sustainability

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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)

Lots of drivers, but there are still some big barriers…

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Barriers

• Part acceptance

─Mechanical property limitations

─Surface finish

─Part accuracy

─Process variance & quality assurance

─www.Epic3DPrintingFail.tumblr.com

• Product liability

• Limited materials available

• Data protection, IP control

THE MYTH“Manufacturers will make products using AM, and consumers will repair products using AM”

THE REALITY

I can only replace 17% (€44) of the BOM by value with AM Parts

83% of parts cannot be functionally replicated

Those 17% of parts would cost €9,524 to make using current AM processes

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Conclusions

• Additive Manufacturing offers great benefits,

especially for small, high-value, complex

parts

• The benefits have to be considered against

the economics

• You need to look at all the ways in which AM

can add value to a product

Next up…Building a Business Case With AM

There is no one-size-fits-all approach to deciding if AM is suitable for you

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Our Methodology

• What considerations are

important when you’re

building a business case?

• How do you select the

most appropriate process?

• How do you estimate cost

to print?

www.wi l l i t3dpr in t .com i

Let’s look at some case studies…

Acetabula JointsOrthopedic Implants for hips and knees

Average implant costs around $6,000

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Why Use AM?

Personalized Products

Increased Functionality

Implants require a special

surface to allow bone to

fuse. This is expensive and

surrounded by IP.

Implants can either be

patient-specific or made to

stock

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Alternatives to manufacture

- CNC Machining, followed by a

plasma coating process

- Manufacturing costs for a

traditional implant are $1,716

- The cost is driven by the

high cost of the coating

process

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Implants

Titanium

50 50 50

10

?

?

?

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Implants

Could be made nestable

In body – biocompatible,

Constant- and shock-loading

$1,716?

?

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Implant Considerations

SLM EBM MBJ FEED

Process needs to support titanium * * * * * - * *

Process needs to support overhanging structures * * * * * * * * * *

Process needs to be scalable to production volumes * * * * * * *

Parts need to be biocompatible * * * * * * *

Component needs excellent mechanical properties * * * * * * * *

Cost needs to be comparable or lower than $1,716 * * * * * * *

108 cups = 95 hours

7,470 per annum per machine

$150 - $200 per stock cup

In-ear Hearing AidsPersonalized products

Commercialized by Siemens

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Why Use 3DP?

Supply Chain Realignment

Personalized Products

Part Functionality

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Alternatives to manufacture

- Originally made manually

- Wax impression taken

- Copy milled into moulds

- Resin cast into moulds

- Very expensive and skilled

process

- The industry faced a severe

labour shortage

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Hearing aids today

- 80% of the world’s hearing aid shells are manufactured

using Envisiontec

- Approximately 10million shells per year

- Shell costs less than $5

- Dedicated resins and machines now service market

- Optimized design featuring air vents

How will AM technology develop?

5 – 10 years outTechnology convergence & Consolidation of the Ecosystem

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Machine prices are tumbling…

SLA Viper Si2 - $250K

Formlabs Form 1 - $3.2K

Fortus MC400 - $106K

Makerbot - $6.5K

EnvisionTec

perfactory - $79K

B9 Creator - $3.5K

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…or capabilities are improving

1995

EOS M250

2015

EOS M400

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Technology Convergence

CAPABILITY

LowHigh

COST

Low

High

Not

good e

nough

Too expensive

Barriers to

technology

adoption

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Will manufacturing be disrupted?

Additive Manufacturing

Binder Jetting

Vat Photo-polymerisation

Material Extrusion

Powder Bed Fusion

Sheet Lamination

Material Jetting

Directed Energy

Deposition

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Will manufacturing be disrupted?

Additive Manufacturing

Binder Jetting

Vat Photo-polymerisation

Material Extrusion

Powder Bed Fusion

Sheet Lamination

Material Jetting

Directed Energy

Deposition

Thank youscd@stratasys.com