by Oliver Zechlin

3D-Printing

Summary

Industrial 3D-printing is at a tipping point and about to go mainstream. The technology

has moved well beyond prototyping, rapid tooling and toys.

“Additive Manufacturing” is creating products for customers in moderate to large

quantities, already.

Contents1 | Technical Conditions ................................................... 2

2 | Applications ................................................................ 8

3 | Concerns & Misuse .................................................... 20

4 | Benefits ..................................................................... 23

5 | Business Opportunities .............................................. 30

6 | Outlook ..................................................................... 32

3D-Printing - Technical Conditions2

1Two different processes but imagine the possibilities that could result from having the best of both worlds.

Additive Manufacturing

In additive processes an object is created by

laying down successive layers of material.

Subtractive Manufacturing

Subtractive manufacturing is like carving a figure from a

solid block. Remove material, layer by layer, until you end

up with your finished model.

Subtractive vs. Additive Manufacturing

3D-Printing - Technical Conditions3

1

Laser

Laser technology is used to sinter

powdered materials.

Powdered metal

With recent advances in additive manufacturing

technology, metal and ceramic based printed

materials are becoming ever more common.

Layer by Layer

Highly efficient by using almost 100% of the printing

material, leading to minimal or zero waste.

How Additive Manufacturing works

3D-Printing - Technical Conditions4

1

CLIP

CLIP (continuous liquid interface production technology) operates through photo polymerization.

CLIP “grows” objects, rather than building them in layers.

Traditional 3D-Printing requires a number of mechanical steps, repeated over and over again in a

layer-by-layer approach. CLIP is a chemical process that balances light and oxygen to eliminate the

mechanical steps and the layers.

It works by projecting light through an oxygen-permeable window into a reservoir of UV curable

resin. The build platform lifts continuously as the object is grown. It is 25-100 times faster than

traditional 3D-printing technologies.

UV printing is different from conventional printing in many ways.

UV-Printing

3D-Printing - Technical Conditions5

1Required CAD data to print a product can easily be provided around the clock around the world.

worldwide

local printing

Wherever - whenever

Branded market places and platforms will provide customers licensed print files in

standardized formats:

Data structures

.stl.wrl

.vrlm2

BIMPhotographs

CAD Data

Scans

Different and multiple data sources may be used to facilitate 3D-Printing and manufacturing.

3D-Printing - Technical Conditions6

1 Construction size

LargeNano Small What comes next ?Medium

Print anything. From the very small to large sized products – 3D manufacturing covers it all.

35m

Super size your project

There are nearly no limits for construc-

tion sizes like printing buildings with a

suitable concrete and technology.

3D-Printing - Technical Conditions7

1 Materials

Metal

Carbon

Cement / concrete

Wood fibre composites

What is next?

Organic substances

Silicon

Plastic

Depending on the printing method - additive, substractive or UV based processes - many different materials may be used. 2015 already approximately 1250 printing materials are available. By 2020 you will be able to choose between 2000 materials.

8

2 Manufacturing End Products

3D-Printing - Applications

Customize unique items

Siemens uses AM to create In-

the-Ear hearing aids, for example.

Such hearing aids are individually

adapted to the wearer‘s auditory

canal.

Small batches

It is very costly to create molds and

production lines for small batches.

Such items can be produced cost-

efficiently with AM.

Very complex workpieces

AM can be used to produce very

complex workpieces, which would be

almost impossible to create with previ-

ously available techniques. One possible

area of application is that of gas turbine

blades, in which ventilation ducts could

be integrated for cooling.

Additive manufacturing will supplement conventional mass production methods, not replace them (for the time being). AM already offers unique advantages over traditional manufacturing, though.

9

Kidney

Artificial kidney

Stents

Artificial teeth

Hearing instruments

2 Biomedical engineering

3D-Printing - Applications

Artificial constructions of biomedical materials are becoming a reality. Medicines, artificial prosthetics, and even human tissue will be a part of everyday life in the hospital of the future.

10

2 Bridge construction

3D-Printing - Applications

3D-Printing allows the manufacturing of bridge parts like pavements or even the construction work of an entire site.

Bridge the gap

Think and print „outside the box“. Robots can draw steel structures in 3D with beautiful,

functional objects in almost any form.

11

Roof printing

Printing all parts including subsections

printed in one go

3D data can be visualized, customized and simulated until the result is as desired and the building is ready for manufacturing.

House construction / complex items

3D-Printing - Applications

2

12

2 Aeronautics / Astronautics

Printing complex items

Printing replacements parts leads to an effective implementation of enhancements without raising the development costs.

Conventionally manufactured nozzles had to be assembled from 20 separately cast parts. Cuts cost of manufacturing by

75%. It is 25% lighter, five times stronger and more efficient.

NASA had a 3D printer sent up to the space station.

NEW

NEWBroken

3D-Printing - Applications

The possibility of 3D manufacturing reduces time, and costs for individual parts of this industry.

13

2 Vehicles

Drive global - print local

Vehicles may be manufactured decentralized at

local manufacturing hubs.

Cars get still build in the same way there were in 1915 -

on assembly lines with thousands of individual parts.

In comparison, a locally printed car only needs about 50 parts.

3D-Printing - Applications

Printing cars with the 3D technology will revolutionize the entire automotive industry and their suppliers.

Local printing

today in few years

14 3D-Printing - Applications

2 Construction of industrial spare parts

On-site printing

Fast on-site production of mission critical spare parts

reducing expensive downtime.

NEWBroken

Data for local printing

15

2 Construction of models (architectural)

3D-Printing - Applications

Print small-scaled items of the desired interior design. Visualize space, dimensions and physical appearance hands-on in 3D.

Even if this room looks very good it would be perfect if this sofa will

be about 20cm larger.

2

16

NEW

Print required spare parts at home or in your neighborhood 3D print shop.

Replacement Parts

3D-Printing - Applications

17

2 Printing electronics

3D-Printing - Applications

PCB is the abbreviation for „printed circuit board“ - in the truest sense of the word.

Benefits

Print the carrier with the required

imprint for the electrical routing

and connections with individual

materials.

• Eco-friendly (laser engraving = no need for harmful chemicals)

• Resistant (Elastomers are water-, solvent, UV-, and ozone-resistant)

• Cost-effective (reduces material cost)

• Resolution (ultrafine structures are possible)

Print the components, such as

semiconductors, resistors… Get your finished PCB -

ready for operation.

18

2 Batteries

3D-Printing - Applications

Manufacturing of chargeable batteries in different shapes or sizes for multiple applications and requirements.

Print required size or capacity of a battery - even directly into or onto the

surface of a product.

19

2 Nano-Printing

3D-Printing - Applications

Remarkable facts

Nano Offset Printing can print structures more than

1000 times thinner than a human hair. It will operate at

up to 100th of today’s electronics nanofabrication cost.

Manufacturing on the micrometer scale will be supported by a suitable technology.

20

3

3D-Printing - Concerns & Misuse

1 : 1 Duplicate

Create easily a duplicate of unique items.

Be aware of misuse

By simply taking a picture of your door key anyone could build a functional copy.

Data for local printing

Duplicate

21

3 Plagiarism

3D-Printing - Concerns & Misuse

Almost everything can be copied.

Original or Duplicate?

There will be a new big market for counterfeiters (and lawyers), as well as difficult situations

for manufacturers of original rights-protected product.

3D printers shift IP considerations by making infringement happen not only faster but much

harder to find. 3D printing may increase the number of potential infringers and accelerates

their time-to-market.§

Original Duplicate

22

3 Approvals / warranty

3D-Printing - Concerns & Misuse

3D printed products like spare parts must fulfill the condition of all legal requirements.

NormsProduct approvals

§In the case of printing a spare

part on your own using a licensed

file - who is the manufacturer?

Warranty

23

4 Production of spare parts

reduction of labor costs

faster repairs

40%

90%

Local manufacturing

Get required data to print parts from anywhere - locally and global. Reduce

environmental impact due to improved shipping and delivery processes.

Local manufacturing can reduce effort and cost for transportation, warehousing and process.

3D-Printing - Benefits

24

2003

0

5

10

15

20

25

30

2004 2005 2006 2007 2008 2009 2010 2011 2012

Income from AM end products %

End products share of the total income from AM products and services.

Trend: From Rapid Prototyping to Series Productionyear 2012 28.3%

3.9

6.6

8.3 9.611.7

14

17.2

19.6

24

28.3

Rapid prototyping is the process of quickly mocking up the future state of a single item or an entire system.

Rapid Prototyping

Rapid prototyping helps teams experiment with multiple

approaches and ideas. It facilitates discussion through a

hands-on approach instead of just words and pictures.

It can ensure that everyone shares a common under-

standing and reduces the risk of missing customer

requirements. Rapid prototyping leads to a faster and

better design.

Rapid ‘real time’ Prototyping

3D-Printing - Benefits

4

25

400%fastercheaper

In the next five years*

50%

Forecast:Production costs for AM with metal (€/cm3)

Forecast:Production speed (cm3/h)

* Assuming manufacturers of AM systems improve process stability and achieve a fourhold increase in the production rate.

10cm3/h40cm3/h

80cm3/h

2013 2018 2023

73% Indirect27% Direct

59% Indirect41% Direct

2013 2018 2023

75% Indirect25% Direct

Effort / Cost Manpower Stock keeping / Material

Declining costs

3D-Printing - Benefits

4

26

CO2 Traffic congestion Logistics industry

3D-printing reduces manufacturing-

related CO2 emission.

Regional 3D-printing reduces traffic

congestion, motor vehicle emissions

and pavement wear.

Downscale warehousing and

convert third-party logistics into

mini-factories.

Reduce environmental impact

3D-Printing - Benefits

4

27

4 Local manufacturing

3D-Printing - Benefits

Cloud data for local printing

fire detector is broken

Enforce your maintenance support with local manufacturing options and reduce service time and missing spare parts.

Faulty products ?

Take a photo - use image recognition

technology - get data - manufacture a

spare part - service completed.

28

4 Rapid market growth

1.00.90.80.50.40.40.30.2<0.1<0.1

0.5

1.7

2.2

4.5

year 2023 €7.7 billion

3D-Printing - Benefits

Additive manufacturing market

worldwide, development and forecast (in billions of euros)

1990 2000 2010 2013 2018 2023

29

4 Further Benefits…

3D-Printing - Benefits

• You can build things that are impossible

• You can take more (design) risks: you just stop

producing w/out having filled warehouse.

• Improve the design-to-manufacturing process, making

low-volume production-based jigs, castings and molds.

• Small companies can compete (analogy to YouTube vs.

traditional video production). Less upfront investment

required (machines, equipment, tooling).

• Saving resources

• Flexibility

• No assembly required - production in single run using

different material properties, instead of having to use

different molds

30

5 Ready for Additive Manufacturing?

Production readiness level

Dentistry and dental technology Capable of full-scale production

Initial systems already manufactured

Concept phase and lab tests

Machine tool manufacturing

Aerospace

3D-Printing - Business Opportunities

Additive manufacturing

Sector overview

31

5

3D-Printing - Business Opportunities

Ready for Industry 4.0?

Industry 4.0 will address and solve some of the

challenges facing the world today such as resource

and energy efficiency, urban production and demo-

graphic change.

Industry 4.0 holds huge potential. Smart factories allow individual customer requirements to be met and mean that even one-off items can be manufactured profitably.

It is reality and it becomes a daily business.

A high flexibility enables – on one hand - an easy customization of goods and on the other

hand also eliminates assembly and inventories. The flexibility of 3D printing systems and

fragmentation in many product categories will then take off.

Additive manufacturing will reduce conventional mass production’s market share.

Already in the year 2020 fully automated, high-speed and economical AM systems will be

available to manufacture standardized parts.

6 Outlook

3D-Printing