tecnologie additive, un’opportunitÀ da cogliere
TRANSCRIPT
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Additive manufacturing of polymers – overview and case studies
20 MARZO 2019 TECNOLOGIE ADDITIVE, UN’OPPORTUNITÀ DA COGLIERE
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EOS: A Growing Company
Source: EOS. Installed base (includes purchased and rented systems) and staff figures as per 10/2017.
Some 1,200 employees worldwide (70% Germany, 30% International)
Strong patent portfolio: more than 750 active and pending patents in more than 175 patent families
EOS global footprint
3,000 systems EOS worldwide installed base
37 44 49 55 62
73 63 67
99 113
130
178
265
318
345
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2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17
Gross sales in m€ (left-hand scale)
Accumulated no. installed base
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Production capacity >1,000 systems per year
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EOS Polymer Systems
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Polymer push – image film
Source: https://www.youtube.com/watch?v=bqABiRV8ckA
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Metal and Polymer processing are different
Polymer Metal
warm process cold process
CO2 Laser Fiber Laser
low laserpower high laserpower
powder partly reusable all powder reusable
… …
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EOS Polymer Portfolio Fa
cto
ry L
ine
EOS P 800
EOS P 500
EOS P 770 EOS P 396 FORMIGA P 110 Velocis EOS P 810
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High temperature composite laser sintering. By EOS.
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Lowest cost-
per-part
Industrial Additive
Manufacturing
Best & desired
part quality
Enabling new materials & applications
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Polymer high quality materials
15 materials: the largest OEM-portfolio of Laser Sintering materials
Family Material name
PA 12 unfilled
PA 2200
PA 2201
PrimePart® PLUS (PA 2221)
PA 12 colored PA 2202 black
PA 2105 (gum colored)
PA 12-GB PA 3200 GF
PA 12-AL Alumide®
PA 12-CF CarbonMide®
PA 12-FR PA 2210 FR
PrimePart® FR (PA 2241 FR)
PA 11 unfilled PA 1101
PA 11 black PA 1102 black
Elastomer (TPE) PrimePart® ST
Polystyrene (PS) PrimeCast® 101
Polyaryletherketone (PAEK) EOS PEEK HP3
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EOS Additive Manufacturing is an established and efficient way of industrial production – today
Automotive: Exciting announcements in 2018!
Images: Courtesy of Under Armour, Wittmann/ABB/Kuhnstoff, Boeing/OPM, MINI, BMW, Daimler, Audi
Footwear
Automation
Aerospace
12 Source: EOS; Logos: Respective companies
We have a unique ecosystem to further accelerate innovation
Start Ups powered by
EOS GROUP
External Partners
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More than 80% of all OEMs use Additive Manufacturing. EOS is #1 in Automotive
Source: Official OEM press material
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How can we improve this gripping device to leverage the full potential of AM technology?
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A conventional handling device was redesigned leveraging the possibilities of AM
Source: Kuhnstoff, EOS, https://www.youtube.com/watch?v=Coo-bE7q1fg
Example for functional integration and lightweight design
Gripper solution
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KuhnStoff Lightweight Gripper Solution
Source: https://www.youtube.com/watch?v=Coo-bE7q1fg
EOS_Company-Presentation.pptx | EOS | 17
Patient Specific Instrument Cut and drill guides
Source: https://www.materialise.com/
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Various orthopedic companies produce patient matched surgery guides for their implant systems
Example Smith & Nephew
Source: Smith & Nephew, EOS
Cut and drill guide
Application
Patient specific knee surgery guides
Based on data generation by CT
Single-use instrument
Biocompatible polyamide material
FDA 510(k) approval
Advantages
OEM: less inventory, additional offer to surgeons
Surgeon: facilitates precision
Patient: less stressful (shorter anesthesia, less replacements)
Hospital: faster surgery (1min ~ 600$), no re-sterilization costs
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Disposable medical instruments are a perfect fit to polymer laser-sintering
SLS Focus Area for Instrumentation
Source: Smith & Nephew (picture)
Additive Manufacturing Advantages
Productivity advantage
Cost advantage
Freedom of design
Customization
$ Patient-specific disposable instruments
Reduced instrument inventory
Less cleaning and sterilization effort
Faster surgery
More precise surgery
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From DICOM acquisition to custom guide
Instrument design and optimization
CT/MRI based design (e.g. Materialise Software)
Design rules
Define part orientation in the building volume
DESIGN
Instrument building process
Different system solutions according to part dimension and production batch
Biocompatibility tests available
Quality assurance of the process
BUILD
Instrument post-processing
Cleaning
Dimensional and quality control
Packaging and Sterilization
FINISH Source: EOS
e.g.
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The disposable instruments can be produced using the integrated EOS portfolio
1)Including system list price with standard configuration, 5 years machine depreciation, 3% interest, maintenance contract, medium user (3500 h/year) and standard list price PA2200 .
2)Full job would be 112 sets/job in 29 hours , BUT due to workflow and processing time it is recommended to build max 5 layers (= 80 sets) per job! Source: EOS
BUILD Layer thickness can be adjusted to find the
right balance of detail resolution and cost per part
EOS application team can consult to optimize work flow
Sample calculation for knee guide set:
P110, 120µm:
24 sets/job
18 h/job
23 €/set1)
P396, 120µm:
80 sets/job2)
21h/job
18 €/set1)
EOS economic production
Sample geometry set consisting of Disposable guide and corresponding bone
section
24 guide sets packed into one P110 job
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New customers and markets can be addressed by manufacturing with 3D technology
Source: Mykita, https://www.youtube.com/watch?v=9u_Dm4NvTd0
Mykita Mylon – 3D printed glasses
“Additive Fashion”
Challenge
Address another customer group by offering a similar product manufactured with 3D technology
Solution
“Additive Fashion”
The “MYKITA MYLON” is produced using 3D technology
A whole new customer group is addressed with this product
Key benefits
Win new customers and gain new markets
Differentiate from competitors
Light weight and robust
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Mykita Mylon Image Film
Source: https://www.youtube.com/watch?v=9u_Dm4NvTd0
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MINI - British premium automobile manufacturer lifts individualization, digitalization and 3D printing to a new level
MINI Yours Customised
Source: https://www.press.bmwgroup.com
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Strong cooperation with DyeMansion on the post-processing of polymer parts
+ =
Print-to-Product Workflow From 3D-printed raw-part to high-value product in three hours cycle time
Polymer Portfolio Systems, Material, Software, Services
Step 1 Cleaning
Step 2 Surfacing
Step 3 Coloring
Entry level
.
.
.
Factory line
High-value product with unlimited coloring options
Source: EOS; DyeMansion; BMW; Daimler EvoBus
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Case Study: MINI - British premium automobile manufacturer lifts individualization, digitalization and 3D printing to a new level
Video Link: https://www.youtube.com/watch?v=r-p6f9Jfdu0