a guideline for quality assured 3d printed (spare) parts
TRANSCRIPT
A guideline for quality assured 3D printed (spare) parts
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Onno Ponfoort
Practice Leader 3D Printing, Berenschot
May 15, 2019 – The Hague,
A guideline for quality assured 3D printed (spare) parts
• 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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A guideline for quality assured 3D printed (spare) parts
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?
A guideline for quality assured 3D printed (spare) parts
A guideline for quality assured 3D Printed (spare) parts
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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
- Framework for assessment of quality assurance
- Experience gained in a number of projects
- A model for assessing the bottom line impact (sneak preview)
As input for possible
NRK strategy & services
A guideline for quality assured 3D printed (spare) parts
3D Printing Value chain
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A guideline for quality assured 3D printed (spare) parts
• A trinity: Design – material – process
➔ For NRK:
Knowledge of material development, only valuable when combined with process and design possibilities
(and impossibilities!!)
• Production: preparation and in-process monitoring
➔ For NRK:
Work environment Health & Safety, operator skills, simulations and monitoring
• Use and Maintenance
➔ For NRK:
Real-life cases, knowledge centre, including economic benefits
3D Printing Value chain – 1. The Workflow
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- 1 -
A guideline for quality assured 3D printed (spare) parts
• Applications: Rules and regulations
➔ For NRK:
Support the development of guidelines and standards to increase up-take of AM as valid technology
• Application arena’s: industry sectors
➔ For NRK:
Availability of sector specific information (working groups/champions for aero, automotive, medical, dental,
tooling, oil&gas, toys, etc.) linked to the knowledge centre
3D Printing Value chain - 2. The application
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- 2 -
A guideline for quality assured 3D printed (spare) parts
• Testing
➔ For NRK:
International scope, R&D, ensure ‘economic’ quality assurance
• Education
➔ For NRK:
Availability of skilled operators, but also ‘3D savvy’ general managers, marketeers/sales and purchasing
• Service bureaus
➔ For NRK:
awareness andn easy access to knowledge and service infrastructure (3D Print Atlas)
3D Printing Value chain - 3. Services
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- 3 -
A guideline for quality assured 3D printed (spare) parts
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
Example: JIP ProGRAM Oil & Gas
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JIP ProGRAM
A guideline for quality assured 3D printed (spare) parts
• 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
• Material: Titanium
• 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
A guideline for quality assured 3D printed (spare) parts
• 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, 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
A guideline for quality assured 3D printed (spare) parts
• 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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A guideline for quality assured 3D printed (spare) parts
Business Impact tool : sneak preview Typical benefits of AM
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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
A guideline for quality assured 3D printed (spare) parts
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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A guideline for quality assured 3D printed (spare) parts
3D Printing Quick Scan: Where to focus, what to expect
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Most promising
for this company
A guideline for quality assured 3D printed (spare) parts 16
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
July 2019
A guideline for quality assured 3D printed (spare) parts
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
A guideline for quality assured 3D printed (spare) parts
Overview of set up and proposed functionality (2)
Example: Selections & drop down menu’s from generic datasheets
A guideline for quality assured 3D printed (spare) parts
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
A guideline for quality assured 3D printed (spare) parts
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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A guideline for quality assured 3D printed (spare) parts
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
Find me as ‘onno ponfoort’ on