Lowering the entry barrier to metal 3D printing

Marc Saunders

Director – Global Solutions Centres

Lowering the entry barrier to metal 3D printing

Getting the most from

additive manufacturing (AM)

Applying AM in series

production

Why everyone is interested in 3D printing…

Cast aluminium bike seat post bracket

and optimised titanium bracket.

A weight reduction of 44% was achieved

by optimising the design for AM.

Additive manufacturing (AM) benefits

Innovative product designs

Complex internal details

Lightweight, optimised forms

Efficient material usage with minimal waste

Improved cooling & heat transfer

Customisation for specific applications

Short lead times

Build from CAD with no special tooling

Low volume parts

made direct from CAD

Getting the most from AM

Rapid prototypes & tooling

Why use AM for prototype & tooling development?

• Prototypes help to de-risk system designs at low cost

• No intention to use AM to make production parts

• AM avoids tooling costs whilst the design is still in flux

• AM enables cost-effective manufacture of complex tooling

Ben

efi

t

Examples: Rapid prototypes & tooling

Complex bar

locators for part

handling

Prototype

exhaust

nozzle

Conformal

mould tooling for

rapid cooling

Re-production parts, that avoid

complex manufacturing

Low volume parts

made direct from CAD

Getting the most from AM

Rapid prototypes & tooling

Direct part replacement

Why use AM for direct part replacement?

• Gain experience with AM in low risk applications

• Develop a supply chain for AM parts

Ben

efi

t

Example: Direct part replacement

Significant

waste

reduction

with AM

process

Note: some finish

machining still

required on AM

part

Example courtesy of GKN Aerospace

Complex parts that simplify

assembly & enhance reliability

Re-production parts, that avoid

complex manufacturing

Low volume parts

made direct from CAD

Getting the most from AM

Rapid prototypes & tooling

Direct part replacement

Part consolidation

Why combine parts using AM?

• Simpler assembly & fewer joints / bonds

Hig

her

be

nefi

t

Example: Part consolidation

Single piece microwave guide reduces

weight and improves performance

New product designs that

1. Deliver lifetime benefits in use

2. Provide mass customisation

Complex parts that simplify

assembly & enhance reliability

Re-production parts, that avoid

complex manufacturing

Low volume parts

made direct from CAD

Getting the most from AM

Rapid prototypes & tooling

Direct part replacement

Part consolidation

DfAM

optimised

Hig

he

st

ben

efi

t

Examples: DfAM optimised

Customised

cranio-facial

implant

Increased

efficiency heat

exchanger

Light-weight,

efficient hydraulic

manifold

Lowering the entry barrier to metal 3D printing

Getting the most from additive

manufacturing (AM)

Applying AM in series

production

Few companies are using AM in series production – why?

Lowering the entry barrier for AM

Metal additive manufacturing

technology for industrial applications

Global network of Renishaw Solutions

Centres

Applications expertise in a wide range

of industries

Integrated manufacturing solutions

Global network of Solutions Centres

Stone

Pune

Shanghai

TorontoStuttgart

Dallas

Breda

Miskin

Chicago

Wotton

A mutually supporting

network of centres,

each with applications

specialisms to suit

local industrial

demand

Opening during 2015

and 2016

Renishaw location

UK

Europe

Solutions Centre services

Benchmark part:

benefits tangible

Concept embodies

AM benefits

Optimise process

& verify part

Demonstrate

process stability

AM & finishing processes

to make saleable product

Renishaw Solutions Centre

for Additive Manufacturing

Incubator cells to nurture your idea

Your private development facility,

including…

Secure, access-controlled process incubator cell

Dedicated AM250 additive manufacturing machine

Materials choice & option to use your own powder

Dedicated powder handling accessories

No overheads & predictable costs

Access to Renishaw engineers and technicians

Optional access to finishing processes, metrology

and materials analysis

Incubator cell services

Partially supported

• Secure incubator cell & office

• AM operator support

• Initial consultancy on build

orientation & support design

• Assisted build removal

• Systematic build data capture

• Reserved access to:

– De-build

– Filter management

Fully supported

Partially supported plus…

• Application engineering

• DfAM knowledge transfer

• Reserved access to:

– Heat treatment

– Part removal (EDM, saw)

– Support removal

– Surface-treatment

Additional services

Fully supported process

development & operation of:

• 5-axis CNC machining

• CMMs

• Equator gauges

• Standard or AM-built custom

fixtures

Pre-production capacity to prove your process

Ramp up towards production

volumes…

Access to multiple AM machines

Metrology and finishing processes

as required

Contracted price per part

Support for process capability

studies

Business case preparation

Integrated manufacturing capabilities

Support removal

Build plate removal

Heat treatment

Surface treatment

Machining CMM inspection

Polishing Gauging

Oil & gas Consumer

Aerospace AutomotiveHealthcare

Mould & die

Industrial applications expertise

Why choose Renishaw as your AM partner ?

• FTSE 250 plc, c £500m revenue and >4,000 staff

• Develops all aspects of AM technology in-house

(machines, software, metallurgy, services)

• World-class metrology, process control,

machining, electronics and assembly expertise

• Optimised solutions for your application, not just

standard product that you have to adapt

Thank you

Your product

design

Renishaw

expertise

Your AM

process

Global

support