Towards a guideline for quality assured 3D printed spare parts

Towards a guideline for quality assured 3D printed spare parts

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Onno Ponfoort

Practice Leader 3D Printing, Berenschot

April 17, 2019 – Brightlands (Chemelot), Geleen, The Netherlands

Towards a guideline for quality assured 3D printed spare parts – Brightlands (Chemelot) - April 17, 2019

Towards a guideline for quality assured 3D Printed spare parts –Presented by Onno Ponfoort, Berenschot

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• Many industrial sectors require quality assurance and certification for parts to be used.

- Additive manufacturing holds the promise to allow customization of the design of parts, to meet case

specific demands.

- But certification of each individual part is a time consuming and costly operation.

- This is an entrance hurdle for many ‘standards controlled’ industries.

• In this presentation you will learn

- how to overcome these hurdles, and

- create a quality controlled and economic value chain set up.

• Joint Innovation Program in the Oil & Gas Industry, managed by DNV-GL and Berenschot.

- The guideline for that industry, for the use of PBF and WAAM technologies, will be issued early June 2019

by DNV-GL.

- A model for assessing the bottom line impact of using Additive Manufacturing versus conventional

manufacturing will accompany that guideline. ➔You will get a sneak preview.


• Introduction Berenschot

• Guideline

• Business impact model

• Conclusions, Q&A

Agenda

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• Oldest consulting firm in the Netherlands, founded in 1938

• Over 300 staff, active globally with offices in 6 countries

• General practice, 50/50 split Private / Public

• 15 years of experience in AM/3DP. We:

- Build strategies, investment plans, business cases and define

organizational set up for AM / 3D Printing

- Assist and create awareness for 3D Printing

• Onno Ponfoort

- Practice Leader 3D Printing, involved as of 2004

- Focus on the business side

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Berenschot: Building on Experience

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Education

Do you know how?

Qualification

Production ready?

Collaboration

Meeting requirements?

Ecosystem

Economic growth?

Distribution

Business model?Spare parts

Supply chain economics?

Technology

Can we print it?

Platform

Quality & online ordering?


3D Printing Value chain

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Looking for benefits

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MARKET

OPPORTUNITIES

PRODUCTION

EFFICIENCIES

SUPPLY CHAIN

BENEFITS

Product performance

& functionality

Time to

market

Customisation &

Personalisation

Design &

Engineering

Manufacturing, Assembly

& Post-processing

Tooling & Support

equipment

Transportation

& Distribution

Value chain

architecture

Stock &

Inventory

Co-creation

https://www.berenschot.nl/expertise/diensten/digitalisering/quick-scan-3d-printen/



• Guideline



Agenda

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JIP ProGRAM


Source: Jabil Engineering (Jan 2018); research amongst 300 US Clients)

Jabil is a manufacturing solutions provider that delivers comprehensive design, manufacturing,

supply chain and product management services, leveraging the power of more than 200,000

people across 100 facilities in 29 countries to simplify complexity and deliver value.

What is 3D Printing used for?

Berenschot interviews @ Formnext

• Issues indicated @ Formnext 2016

- Quality?

- Speed?

- Materials?

• Current Topics /Trends @ Formnext 20182018)

- Software & Integration with process / ERP

- Increased productivity

- Better & Cheaper metal printing

- Desktops go professional

- No more crowd-funded 3D start-ups

- No consumer 3D Printing, its all business

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Two seamlessly aligned Joint Innovation Projects:

The Guideline ProGRAM is managed by DNV GL.

• The objective of this Guideline ProGRAM is to develop

requirements necessary to introduce components made

by Additive Manufacturing (3D Printing) for the Oil, Gas

and Maritime industries and related applications

• Information from the part selection and production

will be used as case studies in the project guideline.

The Toolbox part is managed by Berenschot.

• This ProGRAM is dedicated to the part and material selection,

and the assessment of the impact on the bottom line.

Economic viability, including a reference database of 100 parts

JIP ProGRAM Oil & Gas

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JIP ProGRAM


• Name/owner: Propeller blade / Rolls Royce

• Size: 375*200*320

• Material: Titanium

• Process partner: SLM

• Process: PBF

• Redesign: Light weighted at SLM

• Status: Printing in SLM 800.

ProGRAM JIP: 1st round of parts

• Name/owner: Impeller / Equinor

• Size: 250ø * 70


• Process/partner: Add. Industries

• Process: PBF

• Redesign at Eureka & Ivaldi

• Status AI validated printing strategy, heat & hip

• Name/owner: section of Cross-over / BP

• Size: 190 ø * 300

• Material: nconel 718

• Process/partner:, Ramlab

• Process: WAAM

• Redesign at Strathclyde/ Dutch universities

• Status: produced at Ramlab, Strathclyde to finish, Valourec to test

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Roll Royce

Turbine Blade

Equinor

Pump impeller

Core teams Equino

r

BP Tech

nipF

MC

RollsRo

yce

Voes

talpine

SLM

Solut

ions

Additiv

e Ind

AFRC

HIPte

ch

Ivaldi

OCA

S

DNV-G

L

Bere

nsch

ot

Exte

rnal par

tner

Pump Impeller (I) Owner production design guideline Bus. Model Eureka

Pump Impeller (T) Owner expertise production design guideline Bus. Model Eureka

Thruster blade Owner material process expertise guideline Bus. Model

Cross-over Owner production expertise guideline Bus. Model RAMLab

• Name/owner: Impeller / Equinor

• Size: 250ø * 70

• Material: Inconel 625 (SLM)

• Process/partner: SLM

• Process: PBF

• Redesign at Eureka & Ivaldi

• Status: SLM validated printing strategy, heat treated, testing

Inconel

Titanium Section


• Name/owner: Propeller blade / Rolls Royce

• Size: 375*200*320


• Process partner: SLM

• Process: PBF

• Redesign: Light weighted at SLM

• Status: Printing in SLM 800, functional testing.

ProGRAM JIP: 2nd round of parts

• Name/owner: Crossover, combination, incl. FMC Threat

• Size: 300*300

• Material: Dual: F22 core, Inconel 625 coating

• Process/partner: RamLab

• Process: WAAM

• Design: Total, Redesign at TechnipFMC

• Status: Business case speed of delivery, overcoming obsolete.

• Name/owner: Crank Pin / Rolls Royce

• Size: 400ø * 120

• Material: Steel alloy, Low grade

• Process/partner: Voestalpine

• Process: WAAM

• Redesign at Voestalpine

• Status: Goal validate strengths & short production time

• Name/owner: Cross-over / BP, Full size, fully functional

• Size: 140ø * 1170

• Material: Inconel 718

• Process/partner:, AFRC, in combination with Cranfield Univ.

• Process: WAAM

• Redesign: at Strathclyde & Vallourec

• Status: part produced at Ramlab, Strathclyde will finish it

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Roll Royce Turbine

Blade

Rolls Royce

Crank Pin

Technip FMC/ Total

Combi Bonnet/X-over

Core teams Equino

r

Tota

l

BP Tech

nipF

MC

RollsRo

yce

Voestalpine

Siem

ens

Aidr

oVa

llour

ec

SLM

Solut

ions

Additiv

e Ind

AFRC

HIPtech

Quint

us

Ivaldi

OCA

S

DNV-G

L

Berens

chot

Thruster blade Owner support quality expertise production Heattreatm. guideline Bus. Model

Crank Pin Owner material quality support process expertise guideline Bus. Model

Bonnet/X-over Owner expertise Owner material testing Hip/Heat design expertise guideline Bus. Model

Cross-over support support Owner expertise testinmg production Heattreatm expertise guideline Bus. Model


• Quality control ‘every step of the way’

• Documentation to ensure up-to-standard hand-overs

when involving partners for specific tasks

Guideline is based on activities in the value cahin

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• Guideline



Agenda

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How to compare?

What to focus on?

• Many companies contemplate investments in 3D printing, but reaching a decision is hard:

• Improved functionality of products

• Extra speed in product design

• Better tooling

• Lower stock levels

• Etc.

• Each opportunity requires a specific kind of investment:

• A polymer printer, will not produce metal parts

• With printing comes adjustments in workflow and value chain

• Education of personnel.

How to assess and compare opportunities?

• Improved functionality of products

• Extra speed in product design

• Better tooling

• Lower stock levels

• Etc.

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3D Printing Quick Scan: Where to focus, what to expect

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Most promising

for this company

Towards a guideline for quality assured 3D printed spare parts – Brightlands (Chemelot) - April 17, 2019 17

Summary: set-up and utilization of the Business impact model

• The Business impact model helps to determine the economic impact op 3D Printing

• The model can be used on 4 different levels of detail

1. Quick cost assessment to determine the unit cost price of a 3D Printed part

2. Operational cost assessment, 1. + an estimation of revenue and organizational cost impact

3. Benefit assessment 2. + a variance analysis versus traditional manufacturing of the part

4. Full Business case 3. + simulation and investment assessment

• Depending on the maturity of the

company with regards to 3D printing,

we have standardised and limited

the input required

• The Business impact model delivers

realistic data, based on the amount

of input available

• The model ensures awareness of all

aspects regarding 3D printing

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3D MaturityLevel of detail

Testing/pilots/ experiments

Single part production Regular production(incl outsourcing)

1. Quick cost assessment

Indication production & postprocessing costs,Awareness full process

2. Operational cost assessment

Production, postpro-cess, revenues & switch cost estimate

Actual production, postprocess revenue & switch cost

3. Benefit assessment

Actual production, postprocess revenue & cost variances

Actual cost, variances vs traditional for multiple parts/groups

4. Full Business case

All costs, investments and variations versus traditional

June 2019


Overview of set up and functionality (1)

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Tab per Phase / group of activities

Traditional activities, cost

driver & cost base

Changes in # or € when AM

for traditional activities

Extra activities due to AM,

cost driver & cost baseVolume related costs

Total Traditional costs Total AM costsVariance


Overview of set up and proposed functionality (2)

Example: Selections & drop down menu’s from generic datasheets


Generic information tabs

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• Cost base with generic costs, based on cost related to our produced

parts (+ further available generic info)

• Separate information tabs to ease selection and collection of cost info

• Default values, can be overwritten

• Room to add own cost elements


2.

3.

4.

5.

• Limited info, part cost indication ➔

• Full info, business case for investment

Report based on the information level and needs of the user

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• Guideline



Agenda

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3D Printing: the future of make and supply

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From Lab

• Prototype

• R&D, makerspace

• Manual

• Slow

To Fab

• Validated end part

• Industrial setting

• Automated

• Quick

• Nowadays 3D Printing offers increased functionality, certified quality (spare) parts and tooling

• Large size metal printing is possible

• 3D printing is a means, not a goal:

➢Determine the benefits you want to achieve

➢Be your visionary self and create the future for your company


Any Questions?

Or touch base afterwards

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Onno Ponfoort Practice Leader 3D Printing

T +31 (0) 30 - 291 68 74

M + 31 (0) 6 - 150 14 751

F +31 (0) 30 – 294 70 70

e [email protected]

Find me as ‘onno ponfoort’ on

Towards a guideline for quality assured 3D printed spare parts

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