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Dr Philip Reeves

Rapid Manufacturing Eco-innovation in the context of recession

TITLEInnov_ex09

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Dr Philip Reeves

Rapid Manufacturing Innovation in the outdoor

industries in the context of recession and the

environment

ALTERNATIVE & TRUTHFUL TITLEInnov_ex09

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Dr Philip Reeves

Rapid Manufacturing Innovation & sustainability in the outdoor industries irrespective of recession

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

• Environment – how can RM contribute

• Innovation – how does RM enable

• Outdoor Industries – where does RM fit

• Outdoor Industries – where could RM fit

•Questions

Agenda

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

•Environment– how can it help

• Innovation – how does it support it

• Outdoor Industries – where does it fit

• Outdoor Industries – where could it fit

•Questions

Agenda

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Rapid Manufacturing is the manufacture of ‘end-use’ component

parts using Additive Layer Manufacturing processes

WHAT IS RAPID MANUFACTURING?AGREEING TERMS

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There are Four fundamental manufacturing principles:

• Subtractive

– Material is successively removed from a solid block until the desired shape is

reached (2.5M BC – Hominids)

• Fabricative

– Elements or physical material are combined and joined (6,000 BC – Western

Asia)

• Formative

– Mechanical forces and, or heat are applied to material to form it into the

desired shape such as bending, casting and molding (3,000 BC – Egyptians)

• Additive

– Material is manipulated so that successive pieces of it combine to make the

desired object (1985 – Californians)

How does ALM differ from traditional manufacturing

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ALM processes are automated

systems that take 2-dimensional

layers of computer data and rebuild

them into 3D solid objects

WHAT IS AN ALM PROCESSAGREEING TERMS

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ALM MATERIAL OPTIONSMATERIALS

Waxes

Polyamide (nylon)

Organic materials Polymeric materials Metallic materials Ceramic materials

ABS

Glass filed Polyamide

Composite loaded PA

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

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Prototypes (Rapid Prototyping)

Casting Patterns (Rapid Casting)

Tool cavities (Rapid Tooling)

Direct Parts (Rapid Manufacturing)

ALM IS THE ENABLER – RM IS THE APPLICATIONAGREEING TERMS

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

•Environment– how can it help

• Innovation – how does it support it

• Outdoor Industries – where does it fit

• Outdoor Industries – where could it fit

•Questions

Agenda

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THE PRIMARY BUSINESS DRIVERS

RM reduced the need for tooling (moulds / jigs)

Risk mitigation

Enables the manufacture of low volume production (no fixed asset amortizations)

Simplifies the supply chain & reduces capital investment

Enables complicated assemblies to be built in one piece

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Enabling low volume complex part manufacture?CASE STUDIES

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

• Environment (sustainability) – how can RM

help

• Innovation – how does it support it

• Outdoor Industries – where does it fit

• Outdoor Industries – where could it fit

•Questions

Agenda

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Increased process & supply chain efficienciesLess raw material usage

Less waste production & recycling

Less energy used in processing

Less transportation in the supply chain

Lighter weight more efficient products

SUSTAINABILITY DRIVERS?

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A holistic approachSOLUTION

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TITANIUM ICE SCREWSSUSTAINABILITY

15,000 KWh per ton to extract160 KWh per ton to CNC machine8:1 – waste ratio

Don’t machine from solid – sinter from powder!

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

•Environment– how can it help

• Innovation – how does RM enable it

• Outdoor Industries – where does it fit

• Outdoor Industries – where could it fit

•Questions

Agenda

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THE PRIMARY BUSINESS BENEFITS OF RM

RM enables complex geometries manufacture

RM enabled added functionality

RM enables optimised geometries

RM enables personalised products

RM enables distributed manufacture

Enables true just-in-time

Lean & agile = Legile

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(1) Images courtesy of Phonak www.phonak.com

Design freedoms & personalized part manufacture?CASE STUDIES

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OBSERVATION

“Most current successful RM applications and business models are people-centric

and driven by societal wants and needs ”

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

•Environment– how can it help

• Innovation – how does it support it

• Outdoor Industries – where does RM fit

• Outdoor Industries – where could it fit

•Questions

Agenda

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• Low volume

• High value

• Customised

• Personalised

• Niche

OUTDOORS

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PETZL TECHNICAL ICE AXEEXAMPLE

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ECONOMICS & SUSTAINABILITY

EXAMPLE PETZL TECHNICAL ICE AXE

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ERGONOMICS &PERSONALISATION

EXAMPLE PETZL TECHNICAL ICE AXE

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BURTON SNOWBOARD BINDINGEXAMPLE

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BURTON SNOWBOARD BINDINGEXAMPLE

ERGONOMICS,PERSONALISATION

& MARKET DIFFERENCIATION

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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE

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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE

ERGONOMICS,PERSONALISATION& PERFORMANCE

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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE

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(1) Images courtesy of Liverpool University www.liv.ac.uk

IMPACT ABSORBANCYEXAMPLE

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CUSTOM FOOTWAREEXAMPLE

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CUSTOM FOOTWAREEXAMPLE

ORTHOTICS& PERFORMANCE

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CUSTOM ORTHESISEXAMPLE

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CUSTOM ORTHESISEXAMPLE

PERFORMANCE, COMFORT& INCLUSIVITY

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• Rapid Manufacturing – what is it

• Recession – what are the business

driver

•Environment– how can it help

• Innovation – how does it support it

• Outdoor Industries – where does it fit

• Outdoor Industries – where could RM fit

•Questions

Agenda

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Agenda OPPORTUNITIES

+ =

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Agenda OPPORTUNITIES

+ =

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Agenda OPPORTUNITIES

+ =

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• Many successful applications of RM exist today• The best applications are people centric• Supporting consumers wants and needs• High value, low volume, Niche• Customize & Personalise • Product differentiation & competitive advantage• Sustainability & resource efficiency• Not so many current applications in the Outdoor Industries• I am sure the opportunities exist – talk to me if you have

ideas!

SUMMARY

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QUESTIONS, OBSERVATIONS, DISCUSSIONEND

Dr Philip ReevesEconolyst Ltd

The SilversmithsCrown YardWirksworth

Derbyshire, UKDE4 4ET

+44 (0) 1629 824447phil.reeves@econolyst.co.uk

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