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TRANSCRIPT
How 3D printing adds up for
Business Aviation
PRESENTED BY:
James Kulp, CAM
May 3, 2017| 10:45 – 12:00
2
Beam me up, Scotty
There’s no sign of intelligent life
Tea…
Earl Grey, Hot
3D printing
or
3
What is 3D printing
• 3 Dimensional printing is a process of making physical parts from a digital file
• 3D printing is some times called Additive Manufacturing, AM, which describes the
printing process
• Additive process is the joining of materials to objects in successive layers to form the
shape of parts
• Additive manufacturing is a synonym with metal 3D printing
• Enables rapid prototyping to make parts or molds for parts
• With new designs, allow freedom to innovate complex designs and geometries
4
Hype versus reality
Technology
breakthrough
Increasing
expectations
Technology shake out
2nd & 3rd gen
breakthroughs
MainstreamInnovation Trigger Peak of
Inflated
Expectations
Trough of
Disillusionment
Slope of
Enlightenment
Plateau of
Productivity
Gartner Hype Cycle: Emerging Technologies
4D Printing
Commercial
UAVs
Connected
homes
Brain computer interface
Autonomous Vehicles
Source: Gartner
Virtual reality
Augmented reality
Exp
ecta
tion
s
Time
5 – 10 Years
More than 10 Years
5Source: Gartner
6
Pace of change
Evolutionary versus revolutionary
2,000,000 bc
Stone tools
Bronze tools
3,300 bc
Iron tools
1,200 bc 1780 1848 1895 1940 1969 2017
Source M. Hilbert, University of California
Water
wheels
Steam engines
Electrical
engineering
Automobile
Aircraft
Cyber
Digital & Physical
convergence
4th3rd
7
Industrial revolution
The dawn of the 4th industrial revolution
Source: World Economic Forum
2nd1st
Mechanization: Railroads & steam
power
1784
Mass Production: Division of labor, mass
production & electrical power
1870
Computer & automation
1969
Cyber-physical systems
Now
Deg
ree
of
com
ple
xity
Industry 4.0
Industry 3.0
Industry 2.0
Industry 1.0
Combines
communication,
IT, data &
physical
elements
integrating a
number of
technologies
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3D printing
Architecture
Automotive
Consumer
HealthcareEntertainment
Apparel
Education
Industrial
Food
9
3D printing
Additive versus subtractive
Subtractive
Additive
Machined
Layer deposition
Pro
ce
ss
Volume Cost/Unit Time to Market Cost of Complexity
Attrib
ute
s
Material Scrap / Waste
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3D printing for product development
Prototyping
Cost reduction
Innovation
Efficiency
All new productNew sub-systemNew componentDesign verification
Category "Ink" Power Source
Thermoplastics
Ceramic slurries
Metal paste
SLS Selective Laser Sintering Polymer
DMLS Direct Metal Laser Sintering
DMLM
Electron Beam
Vat PhotopolymerizationSLA Sterolithography
Photopolymer
CeramicsUltraviolet Laser
MJ Metal Jetting Plastic
NPJ Nano Particle Jetting Metal
DOD Drop on Demand Wax
Polymer powder
Ceramic powerer
Metal powder
Gypsum
Sand
Plastic film
Metalic sheet
Ceramic tape
Composite
Paper
LENS Laser Engineering Net Shape
EBAM Electron Beam Additive Manf.Laser BeamMolten metal powderDirected Engergy Ddeposition
Thermal EnergyMaterial Jetting
Thermal EnergyIndirect Injet PrintingBinder Jetting BJ
Sheet Lamination LOM Laminated Object Manufacturing Laser Beam
Technology
FDM Fused Deposition ModelingMaterial Extrusion
High-powered laser BeamPowder Bed Fusion
Atomized metal powered
Stainless steel
Cobalt Chromium
Titatinium
Ceramic powder
Selective Laser Sintering
Direct Metal laser Melting
Electron Beam MeltingEBM
SLM
Thermal Energy
3D printing technology types
Source: 3Dhubs.com, Explainingthefuture.com
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Additive in aerospace
Source: 3D Printing industry.com, Investors Business Daily
manufacturing cost
DECREASES
design complexity
INCREASES
WITH
ADDITIVE
MANUFACTURING
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GE Additive
GE Additive
Power Aviation Transportation Oil & Gas Healthcare Medical Automotive
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GE Aviation Additive examples
All new productNew sub-systemNew componentDesign verification
Capabilities of full production35,000 – 40,000 per year
LEAP fuel nozzle
PARTS
DURABLEMORE
WEIGHT REDUCTION
LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines
20 1
525
17
Solution for traditional
engine shut-down fuel coking
19 additive fuel nozzles per engine
Advanced Turboprop engine (ATP)
PARTS
WEIGHT REDUCTION
Combustor test schedule reduced from 12 months to 6 months
LOWER MISSION
FUEL BURN
5
20
855 1218
19
GE Additive examplesHeat exchanger journey
All new productAdvanced traditionalTraditional
GE’s additive global network
20
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Competency and skills associated with 3D printing technologies
Function Importance Degree of skill change
required
New skills Evolution of existing skills
Engineering 3DP operations: ability to operate & perform task to run new printers
Maintenance repair & training: leverage current skill set to support 3DP
Education 3DP teaching: understand fundamentals & trends (tech & business)
3DP curriculum: create courses – concept to application
New product design
3DP design: convert 3D from 2D. 3DP fundamentals: process & capability
Design velocity: software support for customization
Sales & marketing
3DP market education: promote 3D products Activity velocity: rapid rate support new product launches
Human Resources
3DP high-level understanding: communicate capabilities
Employee retention: create strategies to maintain 3DP qualified employees
Procurement Sourcing strategy: understand market for materials, software, hardware
Supplier qualification: new criteria for 3DP
Aircraft Maintenance
Maintenance & support strategy: Understand3DP repairability, logistics, material, technology
Integration of 3DP into maintenance plan. Supplier & employee development
Workplace implication
Source: Adapted from Technology and Innovation for the Future of Production: Accelerating Value Creation: World Economic Forum
High Low
DO
M
22
Ready for the next revolution?
Source: Future of Jobs Report: World Economic Forum
35%Skills change
Thank You