Digital Manufacturing: An Overview
Transcript of Digital Manufacturing: An Overview
-
8/9/2019 Digital Manufacturing: An Overview
1/63
Digital Design and
ManufacturingDavid W. Rosen
Professor and Associate Chair for Graduate Studies
Rapid Prototyping & Manufacturing Institute
Woodruff School of Mechanical Engineering
Georgia Institute of TechnologyAtlanta, Georgia 30332-0405
404-894-9668 [email protected]
http://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photos -
8/9/2019 Digital Manufacturing: An Overview
2/63
2
OverviewTechnologies
Direct Digital Manufacturing (DDM) 3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing Custom Manufacturing
Local/Distributed Manufacturing Low Volume Manufacturing
Issues and Prognosis
-
8/9/2019 Digital Manufacturing: An Overview
3/63
3
Takeaways
DDM, CAD, reverse engineering are
changing manufacturing industries:Customized, Personalized
manufacturingHigh value added products
Local vs. distributed manufacturing; on-
shoring vs. off-shoring
Enable innovative ideas
-
8/9/2019 Digital Manufacturing: An Overview
4/63
4
Direct Digital Manufacturing
Layer-based additive manufacturing
Parts, tools, patterns, prototypesWide range of polymers and metals
Ex: Stereolithography (SL)
-
8/9/2019 Digital Manufacturing: An Overview
5/63
StereoLithography (SL)
Process Characteristics
+ 3D Systems - inventor
+ UV laser solidifies liquidphotopolymer in layers using
a scanning system
+ Liquid is replenished and
leveled between layers+ Parts require support
structures
+ Completed parts require
cleaning and UV or Thermal
post curing
Related Technologies
+ DMEC/Sony, CMET, Denken,Meiko, EnvisionTec
-
8/9/2019 Digital Manufacturing: An Overview
6/63
Process Characteristics+ C02 laser fuses thermoplastics
powders in layers using a
computer controller scanning
system
+ Powder is replenished and the
next layer is scanned
+ Powder temperature is
maintained near melting point to
aid fusion and minimize
distortions
+ Supports may be used
Related Technologies+ EOS GmbH
3D Systems purchased
DTM Corp. in late 2001.
Selective Laser Sintering (SLS)
-
8/9/2019 Digital Manufacturing: An Overview
7/63
Process Characteristics+ A heated thermoplastic filament
is extruded from a capillary die
+ Thin layers are formed betweenthe die face and previous
layer(s)
+ Parts chamber is heated to
minimize stresses anddeformation
+ Required support structures
+ Cleanup required No post
processing Stratasys Corp.
Fused Deposition Modeling (FDM)
FDM 900mc
-
8/9/2019 Digital Manufacturing: An Overview
8/63
8
Selective Laser Melting
MCP Realizer
0 5 10 1505
10
0
2
4
6
8
10
12
X
Z
Y
University of Liverpool
-
8/9/2019 Digital Manufacturing: An Overview
9/63
9
Parts Gallery
-
8/9/2019 Digital Manufacturing: An Overview
10/63
10
Overview of Commercially
Available RP Systems Stereolithography (SLA) - 3D Systems
Selective Laser Sintering (SLS) - 3D Systems, EOS
Fused Deposition Modeling (FDM) - Stratasys
3D Printing Technology (3DP) - Z Corp., Ex One
3D Printing & Deposition Mill ing (MM) - Solidscape Multi-Jet Modeling (TJM) - 3D Systems, Objet
Laser Engineered Net Shaping (LENS) Optomec
Direct Metal Deposition (DMD) POM Group
Solid Ground Curing (SGC) Cubital (out of business 2000)
Laminated Object Manufacturing (LOM) Helisys(out
of business 1999)
-
8/9/2019 Digital Manufacturing: An Overview
11/63
-
8/9/2019 Digital Manufacturing: An Overview
12/63
12
3D Computer-Aided Design
3D solid modeling
Parametrics adjustable geometry
Assembly modeling
Interfaces to PDM,
PLM systemsKnowledge modeling and
capture
Computer-Aided Engineering
Computer-Aided Manufacturing
-
8/9/2019 Digital Manufacturing: An Overview
13/63
13
Capabilities
Solids
Assembly Modeling
Surfaces
Parametrics
Knowledge-Based
Engineering
-
8/9/2019 Digital Manufacturing: An Overview
14/63
14
CAD Systems
PTC: ProEngineer
Siemens Unigraphics: NX
SolidEdge
Dassault Systemes: CATIA
SolidWorks
-
8/9/2019 Digital Manufacturing: An Overview
15/63
15
Crash Simulation
Roof crush during simulated roll-over.
Body-in-prime + doors# Elements = 127,000
20 design variables
-
8/9/2019 Digital Manufacturing: An Overview
16/63
16
Reverse Engineering
Physical model to Point
Cloud to CAD modelScanners
Software
-
8/9/2019 Digital Manufacturing: An Overview
17/63
17
Scanners
ATOS White Light scanners
Canon Laser scannersFaro hand-held/robot laser scanners
-
8/9/2019 Digital Manufacturing: An Overview
18/63
18
Geomagic Software
Geomagic, Inc. www.geomagic.com
-
8/9/2019 Digital Manufacturing: An Overview
19/63
19
Clothing
Body Scanner, Cyberware
Virtual Fitting:http://www.explore.cornell.edu/scene.cfm?scene=Th
e%203d%20body%20scanner
-
8/9/2019 Digital Manufacturing: An Overview
20/63
20
OverviewTechnologies
Direct Digital Manufacturing (DDM) 3D Computer-Aided Design (CAD)
Reverse Engineering
ManufacturingCustom Manufacturing
Local/Distributed Manufacturing Low Volume Manufacturing
Issues and Prognosis
-
8/9/2019 Digital Manufacturing: An Overview
21/63
21
The Key Elements
SCANObtain the Digital Model
CADDesign the Part Based on the Digital Model
CAM/RPAutomated Manufacture
-
8/9/2019 Digital Manufacturing: An Overview
22/63
22
CynovadDental supply company.
Fabricate dental restorations (crowns,
bridges, etc.).Also markets systems for fabricating dental
restorations.
ThermoJet machines to fabricate patterns for
investment casting of
restorations.www.cynovad.com
-
8/9/2019 Digital Manufacturing: An Overview
23/63
-
8/9/2019 Digital Manufacturing: An Overview
24/63
24
Align Technology
Introduction to Align Technology:
650 employees world wide 2 facilities outside of US
> 200,000 cases treated.
> 5 million aligners.
www.aligntech.com or
www.invisalign.com
Most of this content from Long Pham
at Align (Aug. 2002)
-
8/9/2019 Digital Manufacturing: An Overview
25/63
25
Invisalign Manufacturing Process
Timeline
Receiving & Dent al Data Treat Align er Order Ent ry Laboratory Acquisition Operations Fabrication
SL A Mold
Fabrication
Prepare & Slice
SLA Build
Qu ali ty Control
Ship to Mexico
STL File Generat ion
Packing (orient & place)
Support Generat ion
Slice Data
Laser (Scanning)
Re-coat (dip in resin)
Sweep (remove excessresin)
Part Removal & Post-cure
Verify test parts
Conduct individual moldinspection
Kit in transportation box
-
8/9/2019 Digital Manufacturing: An Overview
26/63
26
Manufacturing Floor25+ SLA 7000 machines running 24/5
-
8/9/2019 Digital Manufacturing: An Overview
27/63
27
Automated UV Curing
2 minute UV post-cure
-
8/9/2019 Digital Manufacturing: An Overview
28/63
28
Personalized Golf Grips
-
8/9/2019 Digital Manufacturing: An Overview
29/63
29
Customized Radio Heads
-
8/9/2019 Digital Manufacturing: An Overview
30/63
30
OverviewTechnologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing Custom Manufacturing
Local/Distributed Manufacturing Low Volume Manufacturing
Issues and Prognosis
Align Technologies
-
8/9/2019 Digital Manufacturing: An Overview
31/63
31
g ec o og es
DistributionNovel supply chain and business model.
Orthodontist
Data Manipulation
(Pakistan before2002)Molding(Mexico)
Align Tech
Data Manipulation
(Costa Rica)
f
-
8/9/2019 Digital Manufacturing: An Overview
32/63
32
Distributed Manufacturing
Highly capable, integrated, inexpensive
manufacturing systems.
Put manufacturing capability where it is neededto best serve the customer:
Home Depot
Doctors or Dentists office
Home
Supply chains become very different
Manufacturing capability becomes a
commodity?
-
8/9/2019 Digital Manufacturing: An Overview
33/63
-
8/9/2019 Digital Manufacturing: An Overview
34/63
34
Siemens Hearing Instruments
Partnership with Phonak (Germany) to produce hear
aids.
Producing in-the-ear hearing aid shell using AM since2002.
Siemens using mostly stereolithography now; started
with SLS.More than 100,000 hearing aid shells yearly.
Courtesy: Martin Masters
Siemens Hearin Instruments, Inc
-
8/9/2019 Digital Manufacturing: An Overview
35/63
35
Digital Mechanical Processing
Create an impression of the ear.
Scan the impression
Modify the data through software
Fabricate the instrument shell
Create the desired surface finish
Close and ship the instrument
I i S i
-
8/9/2019 Digital Manufacturing: An Overview
36/63
36
Minolta Vivid 900
Dual Head Configuration
Impression Scanning
S ft M d li
-
8/9/2019 Digital Manufacturing: An Overview
37/63
37
Software Modeling
Create vent and wall
thickness from digital data.
H i Aid M f t i
-
8/9/2019 Digital Manufacturing: An Overview
38/63
38
Hearing Aid Manufacturing
Local office:
Scan impressions
Ship data to central
location
Design hearing aid
Ship data back to local
office
Fabricate shell
Assemble from kit
Local Laboratory:
Ship impression from local
office to local laboratory
Scan impressions
Ship data to central location
Design hearing aid
Ship data back to local lab
Fabricate shell
Assemble from kit
Ship to local off ice
Kit h R d ti
-
8/9/2019 Digital Manufacturing: An Overview
39/63
39
Kitchen Redecorating
Start with geometric layout of YOUR kitchen.
Select appliances, cabinets, sink, lighting
Configure (layout) items and appliances. Customize functionality of appliances (e.g., smart
refrigerator). Network appliances to ensure
everything interoperates. Customize appearance
of each item.
View in various lightingconditions.
.See: www.homedepot.com
S i B
-
8/9/2019 Digital Manufacturing: An Overview
40/63
40
Service Bureaus
Companies that own machining and
DDM equipment.Contract prototype fabricators.
Mold making, molding.
Short-run production.
Contract design and engineering work.
Ex: ARRK, Compression Engineering,
Morris Technologies, FineLine
Prototyping, RedEye RPM, etc.
RP Markets
-
8/9/2019 Digital Manufacturing: An Overview
41/63
41
RP Markets
Some companies act as market makers:
Xpress3D.com - central site for customers to
submit parts.
Solicits quotes from service bureaus.
QuickParts.com - Quotes directly oncustomers parts.
Finds service bureau.
Atlanta based.
Very nice web site.
Tough to make money.
Xpress3D com
-
8/9/2019 Digital Manufacturing: An Overview
42/63
42
Xpress3D.com
QuickParts com
-
8/9/2019 Digital Manufacturing: An Overview
43/63
43
QuickParts.com
QuickParts com (2)
-
8/9/2019 Digital Manufacturing: An Overview
44/63
44
QuickParts.com (2)
-
8/9/2019 Digital Manufacturing: An Overview
45/63
45
Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
Issues and Prognosis
Component Consolidation
-
8/9/2019 Digital Manufacturing: An Overview
46/63
46
Component Consolidation(A) Conventional Duct fabricated
from Vac Formed plastic
Part Count = 16 (plus glue)
(B) Component modified and
consolidated for fabrication via Additive
Rapid Direct Manufacture
Part Count = 1
Courtesy: Patrick Dunne, 3D Systems
Example for Production
-
8/9/2019 Digital Manufacturing: An Overview
47/63
47
ApplicationsPrevious (Kevlar/Rotomold)Configuration
New (SLS)
Configuration
Attach Straps
Eliminated
Part Count Reduct ion Quick & Easy Installation
Mult iple Ducts Combined to
Single-Piece Duct
Conformal Shapes Achieved and Internal Flow Features Added
Courtesy: Boeing PhantomWorks
Value of Direct Manufacturing
-
8/9/2019 Digital Manufacturing: An Overview
48/63
48
Value of Direct Manufacturing
Engineering Design:
Direct from 3-D Model Base Definition
Design and Build Flexibility
Production: Eliminate non-recurring tooling costs
Lower recurring unit part costs
Faster part delivery times
Supplier flexibility
Direct Fabrication:
50% Cost Reduction
67% Cycle Time Reduction at
Minimum
Product: Reduced part count and weight
Lower inventory and transportation
costs
Improved Life Cycle Product CostsCourtesy: Boeing PhantomWorks
Stratasys FDM 900mc
-
8/9/2019 Digital Manufacturing: An Overview
49/63
49
Stratasys FDM 900mc
32 parts for the FDM 900mc are built on
FDM machines.
RedEye RPM in-house rapid
manufacturing facility ~80 machines
FDM 900mc
-
8/9/2019 Digital Manufacturing: An Overview
50/63
O i
-
8/9/2019 Digital Manufacturing: An Overview
51/63
51
Overview
Technologies
Direct Digital Manufacturing (DDM) 3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
Issues and Prognosis
Unique Capabilities
-
8/9/2019 Digital Manufacturing: An Overview
52/63
52
Unique Capabilities
Shape Complexity
Material Complexity
Hierarchical Complexity
Functional Complexity
Customer-Driven Design
-
8/9/2019 Digital Manufacturing: An Overview
53/63
53
Customer Driven Design
Bottlenecks in product development:
capture specifications and design
delivery to customer
New design tools, userinterfaces needed.
Automated design/engineering
for customized products.
Levers enabling RM
-
8/9/2019 Digital Manufacturing: An Overview
54/63
54
Levers enabling RM
Unique Shapes: fabricate parts with customized
shapes.
Complex Shape: consolidate many parts into 1.
Lot Size of One: economical to fabricate
customized parts.
Fast Turnaround: save time, costs. Increase
customer satisfaction.
Digital Manufacturing: precisely duplicate CAD
model
correct shape.
Sustainability
-
8/9/2019 Digital Manufacturing: An Overview
55/63
55
Sustainability
+ 90-100% of feedstock ends up in parts.
+ Few processes require hazardouschemicals.
+ Designed structures can be much
lighter, stiffer, and stronger, reducing
need for energy.
+ Multifunctional structures.
- Processes can be slow, consume lots of
energy.
Issues
-
8/9/2019 Digital Manufacturing: An Overview
56/63
56
Issues
Rapid Prototyping industry
Prototyping is NOT productionMaterials need to be improved
Qualification of materials, processesCertification of users, suppliers, ...
Economics: costs, speeds, machinereliability, throughput
Supply Chains and Business Models
-
8/9/2019 Digital Manufacturing: An Overview
57/63
57
Dental restorations and custom medicaldevices role for labs, large
manufacturing facilities?
Home Depot: products manufactured
world-wide, shipped to each store.
Custom designed, fabricated in-house.Supply chain?
Custom enhancements to cars,motorcycles, bikes.
Childrens toys design your own...
Business ModelsO t iti b d B t d kill
-
8/9/2019 Digital Manufacturing: An Overview
58/63
58
Opportunities abound ... But need killer app
Custom manufactured World of Warcraft
figurines: www.figureprints.com (ZCorp
DDM machines).
What kinds of services and/or products canyou think of?
Prognosis
-
8/9/2019 Digital Manufacturing: An Overview
59/63
59
g
Opportunities abound: auto, aero,
industry, medical, consumer...
New products. Spares. Enhancements.
Materials.
Economics.
Qualification, certification, standards.
Machine configurations, open architecture
Design and CAD Methods
-
8/9/2019 Digital Manufacturing: An Overview
60/63
60
g
Medical Device Manufacturing
-
8/9/2019 Digital Manufacturing: An Overview
61/63
61
g
LASER
Source
BeamExpander Lens
Mirror
DMD Chip
Collimator
lenses
Diffuser
High Viscosity Ink-Jet Printing
-
8/9/2019 Digital Manufacturing: An Overview
62/63
62
g y g
Thank You!
-
8/9/2019 Digital Manufacturing: An Overview
63/63
63
RPMI Industry Members: 3D Systems, 3M,DSM, Ford, Huntsman, Lockheed-Martin,
Pratt & Whitney, Siemens
National Science Foundation
Georgia Tech, colleagues, students
Dr. David RosenRapid Prototyping & Manufacturing Institute
Woodruff School of Mechanical Engineering
Georgia Institute of Technology
Atlanta, Georgia 30332-0405
[email protected] 404-894-9668