I n d u s t r i a l 3 D PDigital Manufacturing

Agenda

IntroductionUnique Benefits of 3DPApplications

ToolingEnd Use Parts

What’s Next?

Growing market: hardware sales estimated to reach $6.6B in 2017, up from $2.2B in 201285% of that figure will be from industrial machinesDriving Markets:• Aerospace• Defense• Automotive

3DP Market Outlook

Copyright Taylor-Deal Aviation

3DP Adoption

Small and large firms are adopting additive manufacturingUses range from prototyping to end use parts

Why 3D Printing?

Iterative, purpose-driven, and adaptive designImproved design validationLow cost, on-demand toolingIncreased part complexityDistributed Manufacturing

Iterative Design

“Free” design changes• Cost of iteration reduced• Changes to production parts with less impact

Adaptive Design

3DP allows for design adaptability, mass customization, and reconfigurability

Purpose-Driven Design

Parts are designed from end-goal backwardsComplex, ergonomic shapes are created without increased difficulty

Design Validation

Prototypes for physical and/or destructive testing can supplement FEA and CFD analysisPrototypes tested for:

FunctionForm, Fit, & AssemblyErgonomics

Part Complexity

3DP simplifies BOM by combining partsParts are optimized for “needs” rather than “creation”

Distributed Manufacturing

Shift in supply chain from traditional modelManufactured -> Inventoried -> Distributed from different locations

3DP enables parts to be created on location

Rapid Tooling

Tooling applications often overlooked points of ROIJigs/fixturesCasting patterns (investment, sand, urethane)Thermoforming patternsComposite tooling (positive molds, clam shell, soluble core)Sheet metal forming toolsInjection molding tools

Jigs & Fixtures

Assembly Inspection Transportation• Trim templates• Drill guides• Masking• Positioning• Assembly aids

• Testing• Measuring• Go/No-Go

• Carrier trays• End of arm tooling• Cooling

Assembly Fixtures

Drill Guides• Drill accurately positioned and

oriented holes without CNC machinery

• High conformity to workpiece contours

• Bushings increase longevity• Popular in mechanical &

medical fields

Inspection Fixtures

Measuring• Primary concerns are accuracy &

repeatability• Consolidation of parts eliminates

fasteners• Design around CMM contact

points• Easily include text for part

numbers, SKUs, or QA instructions

Casting Patterns

Investment CastingMetal parts from printed parts

Silicone MoldingCastable plastics (urethane, silicone)

Sand CastingTraditional green sand mold or directly printed molds

Thermoforming

Forming tools for creating thin, plastic parts.FDM tools can be built with internal structure

Designed with internal porosity and stiffness in mind

Ideal for complex shapesPerform as-well or better than traditional tooling

¼” Kydex® (acrylic/PVC alloy)

Composite Tooling

Used in lay up, cored, and hybrid processesProven processes:• Carbon, glass, kevlar fiber• Epoxy, polyester resins• <350˚F (177˚C) cure temp• <100 psi cure pressure

Composite Tooling – Lay Up

Boeing FDM stiffenerOut of Autoclave (OoA) applicationPrinted in Ultem 9085Large, complex shape is printed in piecesProduction time and cost reduced

Composite Tooling – Soluble Cores

Wash-out cores made from support material:• Temps up to 180˚F (SR-30)

or 250˚F (SR-100) and 80psi

Ideal for trapped-core applications

Injection Molding

Directly print mold toolingDigital ABS material available on Connex series

Short run productionLow quantity runsMid-sized parts Mid-sized press

Create parts in non-printable materials (PP, PE, PS, TPE, POM, PA)

End-Use Parts

Final products used or sold in their printed form.• Post-processing is acceptable• Excludes manufacturing tools

(jigs, fixtures, molds, etc)

Source: Sebastian Errazuriz Studio

Joint Replacements

Models generated from CT scans are used to design bespoke joint replacement partsSurgeries are faster and less error-prone, while recovery is quickerJigs are also printed and used during surgery Cost is comparable due to low inventory

UNYQ Prosthetic Fairing

Fashionable protective covers for prosthetic limbsCustomized to each individual to restore symmetry and reflect personal style

normal Headphones

“One size fits none”Personalized 3D printed headphonesABS with soft-touch coatingShape developed from user-submitted photos, delivery within 48 hours

Photo credit: The Verge

Production Components

Kelly Manufacturing Company (KMC) created the M3500 “turn and bank” indicator from Ultem 9085• Replaced urethane casting• 500 part batches• 3 day lead time• Per-piece savings of 5%• Held 0.003” tolerance

What’s Next?

Companies investing in 3DP hardware and talent are benefiting from better R&D, quicker launchesEarly adopters are crossing threshold from tinkerer and prototyper to final product producersCompanies are anticipating saves from reduced material usage and transportation costs ($B)

What’s Next?

Increases in speed and volume will enable further applicationsHeavy R&D in materials by all top hardware manufacturers

What’s Next?

Top barriers to 3DP:Material concernsLack of expertisePrinter expenseSee no applicationPrinter speed

Education and R&D needed in coming years

GoEngineer provides design and manufacturing tools with Expertise that enables Customers to reduce the

cost, risk and time required to go live with new technologies and ultimately new product

introductions.More Information:Tyler Reidtreid@goengineer.com