Additive Manufacturing
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Transcript of Additive Manufacturing
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Additive Manufacturing
The Automotive Industry
Alejandro | Gianmarco | Julia | Keyang | Quentin | Stefan | Verena
Team C Digital Solutions
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Agenda
Introduction
Advantages
Drawbacks
Expenses
AM in 2020
Recommendation
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What is Additive Manufacturing?
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Introduction
• Briefly: 3D Printing
• Definition: It is a process of adding ultrathin layers of material(metal, plastic, etc.) one by one to create a raw material or a product
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Introduction
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Advantages
“For the automotive industry, these advances have opened doors for newer designs; cleaner, lighter and safer products;
shorter lead times; and lower costs”.Deloitte University Press
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Advantages: New Design
The ability of producing different type of items for specific customers and market demands.
Example: Customized Dashboard
Competitor: Bentley
Possibility of customizing items
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Advantages: New Design
The ability to create lighter, safer, cleaner and more efficient products.
Example: Hand tools used in testing and assembly
Competitor: BMW
BMW: ”The new tools reduced project time by 92 %”
1st stage: Creating better quality items
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Advantages: New Design
2nd Stage: Creating better quality items
Example: Reducing the weight of a car without changing the
main structure
Competitor: None
The ability to create better quality items, that will change the industry.
Industry is not enough developed for this stage.
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Advantages: Shorter Lead times
The time between the initiation and completion of a production process.
Example: Prototyping process
Competitor: Ford
Ford: ”Prototyping usually took 4 years.
Now with AM it takes 4 days”
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Advantages: Lower costs
Capital vs. Scale
Reduction of capital required to achieve the same amount of products.
Example: Lowering the costs of production
Competitor: Ford & BMW
Ford: ”Prototyping cost decreased from 500,000 $ to
3000 $”
BMW: ”The new tools reduced the cost by 58 %”
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Advantages: Lower costs
Capital vs. Scope
Increase in scope of products with the same amount of capital.
Example: Increase in the variety of products portfolio
Competitor: None
Industry is not enough developed for this stage.
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Drawbacks
“The automotive industry still has challenges ahead
related to manufacturing of large parts; talent shortage;
intellectual property and materials variety.”Deloitte University Press
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Drawbacks: Manufacturing large parts
Printed products size is limited
Oak Ridge National Laboratory: No size restriction
Research
Materialise: Has build a machine to produce big components
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Drawbacks: Talent Shortage
Not enough AM specialist
Trainings
AM service providers and end-user industries areconcentrated to create a stable program for a capableworkforce.
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Drawbacks: Intellectual Property Concerns
Expansion of AM will lead to expansion of copying
Patents
• Patenting of produced products through AM can solvethis problem.
• Patent protection qualification should be clear
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Drawbacks: Limited materials
Materials for production are either limited or expensive
Example: Titanium powder (200-400 $ for 1 kg)
Competitor: Jaguar with Metalysis
Jaguar: Buying powder from Metalysis
with 75% lower price for AM
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2020 (5 years later)
Current
Fluid handlingApplications: Pumps, valves
Exterior TrimApplications: Bumpers, wind breakers
Manufacturing ProcessApplications: Prototyping, customizing Exhaust emissions
Applications: Cooling vents
Future
Interior & SeatingApplications: Dashboards, seat frames
Wheels, Tires & SuspensionApplications: Hubcaps, tires, suspension springs
ElectronicsApplications: Sensors, panels, etc.
Frame, body, doorsApplications: Body panels
Powertrain, drivetrainApplications: Engine components
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Expenses
Cost can be cut by 50% within 5 years
Investment EUR Direct Cost EUR
Machine Cost 500,000 Steel Powder price per kg 89
Technical Rate Energy per kWh 11
Utilization rate 86% Hourly labour 25
Monitoring 5% Yearly rent for 28 3,640
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What should Porsche do?
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Important Factors
•Technology is not fully developed yet
•The Industry is very interested in development
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Recommendation
Implement AM in prototyping
Be always aware about the innovation in AM
Try to use this technology with the current technology
Invest right now in order not to be outsider in the future
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Questions?