final3dpnaderasnafi23nov2016 · 2016-11-25 5 nader asnafi 13 nader asnafi the new koenigsegg agera...

2016-11-25

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Nader AsnafiNader Asnafi2016-11-25 1

3D Printing/Additive Manufacturing from

Product Creator & Tool Maker Perspectives in the Automotive Industry

Professor Nader Asnafi

Tel: 070 ‐ 311 00 74

E‐post: [email protected]

Nader AsnafiNader Asnafi

Contents

Introduction:Brief status report related to 3D printing

Current 3D printing examples and applications

Future applications and required development

2

Nader AsnafiNader Asnafi3

0%

10%

20%

30%

40%

50%

60%

Criterionrankedfirstin

Decision‐Making‐Process

A/B

C/D

E/F

MPV

C: VW Golf , Ford FocusD: Volvo S60, BMW 3 series

E: Mercedes E class, Audi A6F: BMW 7 ‐series, Mercedes S Class

A: Citroën C1B: VW Polo, Ford Fiesta

MPV: Renault Escpace,Ford C‐max, VW Touran

Decision Criteria in Car Purchase

Source: Peters & de Haan, 2012

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Product Creation/Development &

Production/Manufacturing

2 0 1 6 ‐1 1 ‐2 5 2 9

Time

Product Development Production/Manufacturing


Product Development: Duration and Cost

5


Competitive Factors

from Product Creation Process Perspective

Investment Costs for Production

Product creation Lead Time (Time‐To‐Market/Time‐To‐Production)

Hit rate: product targets such as emissions, fuel efficiency, weight,

production/manufacturing costs, …

…

6

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Lead Time (or Time to Market) Reduction

Volvo Cars Target

Courtsey of Volvo Cars

7


Competitive Factors – the product perspective

• Safety

• Driving experience

• Styling/design

• Quality (both functional and perceived)

• Delivery precision

• Environmental friendliness

• Fuel efficiency

• Price

• …

8


The Importance of Different Criteria in

Car Buyers’ Purchasing Process*

9

* According to the global automotive executives

2016-11-25

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Quality

DeliveryCapacity

Cost Efficiency

Flexibility

Competitive factors from a

Product and Manufacturing Perspective


Car Production

11

Car bodycomponents

BodyShop

PaintingFinal

Assembly

Powertrain

Interior

Customer


Supply and Distribution

2 0 1 6 ‐1 1 ‐2 5 2 9

Suppliers’ suppliers

Suppliers Producer(OEM)

Retailers Customers

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www.va-automotive.com13


The new Koenig segg Ag era One:1 has a 3d pr inte d t urbo hou sing, pr inte d in

one p iece, with no furt her a ssem bly r equ ire d. stra ight fr om the pr inter tothe engine.

The new Koenig segg Ag era One:1 has a 3d pr inte d4 00 grams ti tanium exhau st

pipe end.

The first production car that offers a 1:1 power to weight ratio — it weighs 1340kg and produces 1322bhp(1340 metric horsepower).

Five (5) units of the One:1 have been produced, retailing for around $2 million (€1.45 million).

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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &

ManufacturingTryout Production

Product Development/Creation

15 Source: Divergent3D, www.divergent3d.com

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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


16

Source: Divergent3D, www.divergent3d.com



Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


17




Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


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Source: 3D Printing Industries, 3dprintingindustry.com


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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


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Source: 3D Printing Industries, 3dprintingindustry.com



Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


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Source: Local Motors, www.localmotors.com/3d‐printed‐car



Local Motors LM3D Swim

• Electric car• Made up of 80% plastic and 20% Carbon Fiber. • It’s light yet strong as a traditional car. Being tested right now.• Big Area Additive Manufacturing printers at a variety of locations around

the world.• To pump out 250 highly customized cars a year. • Price = $53,000/car.

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Local Motors 3D Swim

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It took Local Motors 44 hours to print this car body (including the seats) in carbon fiber reinforced thermoplastic or ABS.


Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


23 Source: Local Motors, www.localmotors.com/3d‐printed‐car



Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


24 Source: Local Motors, www.localmotors.com/3d‐printed‐car


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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


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http://3digiprints.b logspot.se/2 014 /11 /the‐t op‐best‐ sls‐3d‐p rin ted‐object s.html


Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


Unsplit and split styling respectively

26



Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


Citroën Hypnos

Functional testing

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https://www.wired.com/201 1/0 2/t he‐secre t‐world‐ of‐pr int ing‐conce pt‐cars‐in‐3d /

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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


Functional testing and more

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Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &


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Source: http://blogs.yahoo.co.jp/fuj i8888/29831664.html

3D Printed Metallic Tire Mold Segments

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Source:Mold & Die World,http://www.mouldanddiewor ld.c om/

3D Printed Metallic Tire Mold Segments


Illustrative Applications of AM/3DP in an Automobile


Car Production

33

Car bodycomponents

BodyShop

PaintingFinal

Assembly

Powertrain

Interior

Customer

2016-11-25

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FOCUS IN THIS PRESENTATION

Tools and Dies for Car Body Components Production

34

High‐strength steel

Extra‐high‐strength steel

Ultra‐high‐strengt h steelUltra‐high‐strengt h steel

Ultra‐High‐strengt h hot‐formed steel

Aluminium


Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &

ManufacturingTryout

Part

Production

1.95 mm thick uncoated Docol 600 DL

1.45 mm thick Rephos

Forming die ‐ B‐pillar, Volvo Cars

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Calmax + plasma nitriding + CrN (PVD)(Calmax + Duplex treatment)

Inserts in CalmaxCVD ‐coatedinsert

Product Development

Source:Nader Asnaf i: ”Tooling and Technologies for Processing of Ultra High Strength Sheet Steels”, Conf. Proc. of Tools and Technologies for Processing Ultra High Strength Materials, Sept 19 ‐21, 2011, Graz, Austria, At Graz, Austria


Concept/

Styling

Product

Design

Production

Planning

Process

Engineering

Tool Design &

ManufacturingTryout

Part

Production

A two‐out automotive side member progressive stamping die in the build process

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Product Development

Source: Tooling Systems Group, http://www.tooling syst emsg roup.com/compa nie s/a ts

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3D metal printing

(& metal related printing) ‐ current possibilities & limitations

The current maximum size of the metal piece to 3Dprint?

The metallic materials that can be printed?

Tool/die weight/design: Solid structure vs hollow honeycomb structure?

The strength of the printed metallic material?

Surface roughness of the printed metal piece?

Hardness of the printed metal piece?

Can the printed metal piece be machined, polished, hardened and surface‐coated?

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The current maximum size of

the metal piece to 3D‐print?

38

500

500

500

100

10080

140

140100

250

250

300

275

275

420

Current maximum build

volume

Source: 3D Systems, http://www.3dsystems.com/


500

500

500

100

10080

140

140100

250

250

300

275

275

420


volume

CoCrMo

1.2709

17‐4PH

Full

CoCrMo

1.2709

17‐4PH

AlSi12

CoCrMo

1.2709

17‐4PH

AlSi12 AlSi12

CoCrMo

1.2709

17‐4PH

AISI 316

Inconel 718

Ti Gr. 1

Ti Gr. 23

Ti Gr. 5

PdAg

Ti6Al4V/

Ti6Al4V ELITi6Al4V/Ti6Al4 V ELI Inconel 718 Hastelloy X AISI 316 CuSn6 AL2O3/AL2O3+Al

Au alloysTiO2

Partial

Misc. Steel Stainless st Aluminium Titanium alloy Precious alloy Nickle alloy Copper alloy Ceramic



2016-11-25

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500

500

500

100

10080

140

140100

250

250

300

275

275

420


volume

CoCrMo

1.2709

17‐4PH

Full

CoCrMo

1.2709

17‐4PH

AlSi12

CoCrMo

1.2709

17‐4PH

AlSi12 AlSi12

CoCrMo

1.2709

17‐4PH

AISI 316

Inconel 718

Ti Gr. 1

Ti Gr. 23

Ti Gr. 5

PdAg

Ti6Al4V/


Au alloysTiO2

Partial



Processing is understood but standard build

parameters and data sheet are not available. Powder could be stocked but is not today.



500

500

500

100

10080

140

140100

250

250

300

275

275

420


volume

CoCrMo

1.2709

17‐4PH

Full

CoCrMo

1.2709

17‐4PH

AlSi12

CoCrMo

1.2709

17‐4PH

AlSi12 AlSi12

CoCrMo

1.2709

17‐4PH

AISI 316

Inconel 718

Ti Gr. 1

Ti Gr. 23

Ti Gr. 5

PdAg

Ti6Al4V/


Au alloysTiO2

Partial



Standard build parameters &

data sheets. Powder stocked.



Comparison: AISI D2/DIN 1.2379 vs Maraging SteelAs delivered/built After post heat treatment

AISI D2/ Maraging AISI D2/ MaragingDIN 1.2379* steel (1.2709) DIN 1.2379* steel (1.2709)

Yield strength 350‐550 MPa 860 MPa 1900 MPa** 1930 MPa

Ultimate tensile strength 706‐870 MPa 1110 MPa 2000 MPa

Fracture elongation >11% & <20% 11% 1%

Hardness 210‐255 HB 37 HRC 55 HRC*** 55 HRC

(18‐26 HRC*)

* Sources: matweb.com, steelexpress.co.uk & saajsteel.com

** Compressive yield strength.*** AISI D2/DIN 1.2379 can be hardened to 62 HRC but maraging steel’s maximum attainable hardness is 55 HRC.

Adobe Acrobat Document

Maraging Steel (1.2709)

42

2016-11-25

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C‐Bow Lower Progressive Die

Punch

Puller

58

140

240


Punch and Puller Made in a Metallic Material

Punch Puller

64

123

140

24058

64.3


3D Printed Punch and Puller Made in a Metallic Material

2016-11-25

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3D Printed Punch and Puller Made in a Metallic Material



Conventional Procedure Compared to 3D Printing

1 € = 9.42 SEK

Lead Time (Working days)

Conventional 3D PrintedHoneycomb structure

Punch 8

Puller 6Total 8 3.7

Cost (SEK)Conventional 3D Printed

Honeycomb structure

Punch 10 500Puller 15 500

Total 26 000 31 000

Based on a depreciation period(for the 3D‐printing machine) of 5years (incl. a 5 years long warranty)



Conventional Procedure Compared to 3D Printing

1 € = 9.42 SEK

Lead Time (Working days)

Conventional 3D PrintedHoneycomb structure

Punch 8

Puller 6Total 8 3.7

Cost (SEK)Conventional 3D Printed

Honeycomb structure

Punch 10 500Puller 15 500

Total 26 000 29 000

Based on a depreciation period (forthe 3D‐printing machine) of 10 years(incl. a 10 years long warranty)

2016-11-25

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Conclusions

o 3D printing enables a significant lead time reduction at reasonable costs.

o The current possible applications need to be explored.

o Design of components and design for manufacturing have great unexplored possibilities.

o 3D printers need to be included in the current industrial structure at each

company.

o The current limitations (size, few relevant materials, quality assurance issues…)

need to be addressed.


final3dpnaderasnafi23nov2016 · 2016-11-25 5 nader asnafi 13 nader asnafi the new koenigsegg agera...

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