Inside3DPrintingSantaClara_TylerReid
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Transcript of Inside3DPrintingSantaClara_TylerReid
I n d u s t r i a l 3 D PDigital Manufacturing
Agenda
IntroductionUnique Benefits of 3DPApplications
ToolingEnd Use Parts
What’s Next?
Growing market: hardware sales estimated to reach $6.6B in 2017, up from $2.2B in 201285% of that figure will be from industrial machinesDriving Markets:• Aerospace• Defense• Automotive
3DP Market Outlook
Copyright Taylor-Deal Aviation
3DP Adoption
Small and large firms are adopting additive manufacturingUses range from prototyping to end use parts
Why 3D Printing?
Iterative, purpose-driven, and adaptive designImproved design validationLow cost, on-demand toolingIncreased part complexityDistributed Manufacturing
Iterative Design
“Free” design changes• Cost of iteration reduced• Changes to production parts with less impact
Adaptive Design
3DP allows for design adaptability, mass customization, and reconfigurability
Purpose-Driven Design
Parts are designed from end-goal backwardsComplex, ergonomic shapes are created without increased difficulty
Design Validation
Prototypes for physical and/or destructive testing can supplement FEA and CFD analysisPrototypes tested for:
FunctionForm, Fit, & AssemblyErgonomics
Part Complexity
3DP simplifies BOM by combining partsParts are optimized for “needs” rather than “creation”
Distributed Manufacturing
Shift in supply chain from traditional modelManufactured -> Inventoried -> Distributed from different locations
3DP enables parts to be created on location
Rapid Tooling
Tooling applications often overlooked points of ROIJigs/fixturesCasting patterns (investment, sand, urethane)Thermoforming patternsComposite tooling (positive molds, clam shell, soluble core)Sheet metal forming toolsInjection molding tools
Jigs & Fixtures
Assembly Inspection Transportation• Trim templates• Drill guides• Masking• Positioning• Assembly aids
• Testing• Measuring• Go/No-Go
• Carrier trays• End of arm tooling• Cooling
Assembly Fixtures
Drill Guides• Drill accurately positioned and
oriented holes without CNC machinery
• High conformity to workpiece contours
• Bushings increase longevity• Popular in mechanical &
medical fields
Inspection Fixtures
Measuring• Primary concerns are accuracy &
repeatability• Consolidation of parts eliminates
fasteners• Design around CMM contact
points• Easily include text for part
numbers, SKUs, or QA instructions
Casting Patterns
Investment CastingMetal parts from printed parts
Silicone MoldingCastable plastics (urethane, silicone)
Sand CastingTraditional green sand mold or directly printed molds
Thermoforming
Forming tools for creating thin, plastic parts.FDM tools can be built with internal structure
Designed with internal porosity and stiffness in mind
Ideal for complex shapesPerform as-well or better than traditional tooling
¼” Kydex® (acrylic/PVC alloy)
Composite Tooling
Used in lay up, cored, and hybrid processesProven processes:• Carbon, glass, kevlar fiber• Epoxy, polyester resins• <350˚F (177˚C) cure temp• <100 psi cure pressure
Composite Tooling – Lay Up
Boeing FDM stiffenerOut of Autoclave (OoA) applicationPrinted in Ultem 9085Large, complex shape is printed in piecesProduction time and cost reduced
Composite Tooling – Soluble Cores
Wash-out cores made from support material:• Temps up to 180˚F (SR-30)
or 250˚F (SR-100) and 80psi
Ideal for trapped-core applications
Injection Molding
Directly print mold toolingDigital ABS material available on Connex series
Short run productionLow quantity runsMid-sized parts Mid-sized press
Create parts in non-printable materials (PP, PE, PS, TPE, POM, PA)
End-Use Parts
Final products used or sold in their printed form.• Post-processing is acceptable• Excludes manufacturing tools
(jigs, fixtures, molds, etc)
Source: Sebastian Errazuriz Studio
Joint Replacements
Models generated from CT scans are used to design bespoke joint replacement partsSurgeries are faster and less error-prone, while recovery is quickerJigs are also printed and used during surgery Cost is comparable due to low inventory
UNYQ Prosthetic Fairing
Fashionable protective covers for prosthetic limbsCustomized to each individual to restore symmetry and reflect personal style
normal Headphones
“One size fits none”Personalized 3D printed headphonesABS with soft-touch coatingShape developed from user-submitted photos, delivery within 48 hours
Photo credit: The Verge
Production Components
Kelly Manufacturing Company (KMC) created the M3500 “turn and bank” indicator from Ultem 9085• Replaced urethane casting• 500 part batches• 3 day lead time• Per-piece savings of 5%• Held 0.003” tolerance
What’s Next?
Companies investing in 3DP hardware and talent are benefiting from better R&D, quicker launchesEarly adopters are crossing threshold from tinkerer and prototyper to final product producersCompanies are anticipating saves from reduced material usage and transportation costs ($B)
What’s Next?
Increases in speed and volume will enable further applicationsHeavy R&D in materials by all top hardware manufacturers
What’s Next?
Top barriers to 3DP:Material concernsLack of expertisePrinter expenseSee no applicationPrinter speed
Education and R&D needed in coming years
GoEngineer provides design and manufacturing tools with Expertise that enables Customers to reduce the
cost, risk and time required to go live with new technologies and ultimately new product
introductions.More Information:Tyler [email protected]