additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40...

Prototipazione virtuale

Additive ManufacturingAn opportunity for metal-working companies

Prof. Marco Taisch, Eng. Francesco Giovanni SiscaPolitecnico di MilanoDepartment of Management, Economics and Industrial Engineering

Copyright Politecnico di Milano2014

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Green products


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Green products in green plants104 gCO2/Km4,7L/100Km100 gCo2/Km6,2L/100Km

108 gCo2/Km4,0 L/100Km

Toyota PriusSeat Leon WV Polo 1400 cm3 Engines


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Mass Customisation


Product varietyProduct volumes18501913195519802000globalizationTime

Craft production


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MASS PRODUCTION1908

You can have any color for your car as long as it is black! (Henry Ford)


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Mass Customization

Copyright Politecnico di Milano2014Mass production processes led to the continuous improvement methods of production. The continuous improvement company is more participative, empowered, cross-functional team-based and focusing on total quality management (TQM) principles. Workers are given more participative and decision-making responsibilities and managers perform the facilitative and coaching function of motivating their employees toward continuous improvement efforts in the production facility. This type of a production system results in the manufacture of low-cost, high quality, standard goods and services.

The time period most typical of continuous improvement was in the 1980s when companies like Motorola began implementing TQM and other continuous improvement programs in their production operations management. The continuous improvement production methods led to the unique concept of mass customization, a process in which all aspects within the organization from people, processes, organizational structures, and technology are geared to provide customers specifically what they need and want. An efficient, well-integrated organizational system of production facilitates this process of mass customization. The result is low cost, high quality, customized goods and services produced on a large scale to a mass market. The time period most typical of mass customization was in the mid-1990s through the present time when companies like Dell began effectively implementing mass customization in their production operations facilities.

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Servitisation

ProductServizio per supportare il prodottoServizio per differenziare il prodottoServizio prodotto

Service for productService for customer

K.D. Thoben 2001


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ExampleCar Sharing: You dont buy no more a car but you rent it.

Golboo Pourabdollahian


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ExampleSale of flight hours instead of engines

Golboo Pourabdollahian


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Product becomes lighter

Strong special steelsAluminiumTitaniumAlloysCompositesBio-compositesCeramicsHybrid materials11Raw-material and energy efficiency improves

Pictures: Audi, UPMSlide courtesy of


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Product becomes smartInformation technology helps to improve energy efficiencyDigital steering and control systems enable improved ergonomicsMachines can be remotely controlled humans are freed from working in uncomfortable and dangerous surroundingsMachines can measure processes and output to optimise performanceMachines can send data on output, lapsed time, and their own condition over mobile internetImproved conditions for fleet managementNeed for repair and maintenance can be anticipated to minimise downtimePictures: Sandvik, Ponsse, Metos

Slide courtesy of


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Whats AM?Metal powder spread and fused time to time, on a working plan, layer by layer, in according with the sections which the net-shape to be formed consists of.

Courtesy of Avio Aero

Copyright Politecnico di Milano2014Peculiarities

Net shape directly from CAD fileNo tooling & No waste & lightweithingTime to market (Agile MFG operations)Geometry complexity & Design flexibility (Internal channels, blind holes, honeycomb)Immediate customizationPart consolidation14

Copyright Politecnico di Milano2014-Time to market means from the idea/design of the product to its commercialization into a market. Agile manufacturing means reactivity to change on product mix and product functionality becasue there is no tooling to prepare in other words there is no traditional Innovation process. No Tooling is better said as potential elimination of tooling in the sense that exeption made for the lattice supports AM does not need tools to be adopted. Therefore direct production is possible without implementation of dedicated tools. This leads companies into niche markets which with traditional manufacturing couldnt be reched due to the high break even. No waste for two characteristics occurring in adoption of AM: by definition additive manufacturing build layer by layer the product needed using the exact material needed while in subtractive manufacturing often happens that from a solid is obtained the final part using 10-40% of the material in input while the remaining is waste. Through Design Optimization (Topology Optimization) allowed by AM less material is used due to the lack of costraints of traditional manufacturing thus there will result a lighter end-use part. - The Geometry Complexity is for free in the sense that it is just marginally related to the increase of the related cost of production (Berenschot Report 2014).14

Applications Prototyping Tooling End-Use/Direct Parts Manufacturing Maintenance & Repair

Aims15

Copyright Politecnico di Milano2014These are applications for AM in respect of the aim it is used for. Tooling may be Direct tooling or Undirect. 15

Applications

Areospace

Fuel injectors , GE AviationBrackets for Airbus 320, Airbus16

Automotive

http://blogs.discovermagazine.com Dental

Defensehttp://d.ibtimes.co.uk/

Asda Supermarket in UK Consumer goods

Copyright Politecnico di Milano2014Borrowing the Technology Adoption Lifecycle curve terminology we may speak about:Innovators: Consumer goodsEarly Adopters: Aereospace, AutomotiveEarly Majority (1): Industrial/Business Machines, Medical, Dental, Defense (2): Fashion, Footwear, Jewelery, Toys, Industrial Design, Architecural, Oil &Gas, FoodLaggards (future applications in): Bioprinting, Metal AM in Space. The term Defense or Military may be interchangeable. Medical: models, surgical cutting, drill guides, orthopedic plants; Dental: dental plants, crown and bridges. While consumer products industry has been the first application for AM, (Innovators), the Aereospace sector has been the engine of AM pushing AM systems manufacturers and AM providers to improve AMTs , broadening the material range available and it is still urging AM Industry to cope with issues as A-Z process monitoring , closed loops controls, Topology Optimization sw, predictive sw which link the characteristics of the material in input to the mechanical specifics obtained in output; Optimal topology, flow needs given. There are several end-users ion Aereospace, among them Safran Avion, AVIO Aero, Airbus. Hinges for the Airbus A320 - conventional (background) and 3D printed (foreground) BBC articleThe Fuel nozzle here shown is the one which will be produced in 50.000 units by 2015 for LEAD engines. The Automotive Industry has been using 3D printers since 1980s Rakesh Sharma Here in this slide we see the famous case of Urbee, an urban electric vehicle whose body have been completely 3d printed, using CAD sw Autodesk and through a Stratasys machine. Its an electrical vehicle within the range 0-40 miles/hour and it goes through internatl combustion within the range 40-70 miles/hour. (Information sourced from korecologic.com/media/videos). Medtech products that ranges from jaw implants to dental implants, from skull to body-fitting implants. I preferred to use the term Defence rather than Military, because I wanted to make sound the concept that we can find AM applications in Army, Navy, Airforce, or in other words all the military forms of a Defense Department within whichever country. The respirator above in the current slide have been realised by Design Reality through a 3D printer Objet 260 Connex (Stratasys)https://www.youtube.com/watch?v=8vC8yoj61JY American AM pioneer Stratasys merged with Israeli-based Objet in December 2012. (The newly formed entity chose to register as a company of Israel Wohlers Report 2014). The weapon on the slide its from http://www.extremetech.com/extreme/133514-the-worlds-first-3d-printed-gun.Mass Market product has highly general utility and universal appeal.Jewels, home accessories, lamps, key-ring, glasses, bikes, mobile phone protection covers (in slide), memes, spore sculptures, etc. Mini-mes or Avatar are used as synonyms.

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What does AM change on the Product LC?17

++FoundryMachiningAssembly

Copyright Politecnico di Milano2014What does AM change on the Product LC?18

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AMPost Processing1. Collapse of foundry activities and assembling activities in the AM Process


What does AM change on the Product LC?

2. Ready turnkey kits needed to a final product in one batch. Set ups overcame. Minimum production lots disappear.


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What does AM change on the Product LC?20

3. Consolidation of several sub-parts in a unique net-shape. Part durability improves. Disappear stocks of many sub-components.http://www.rmbproducts.com/aerospace-aircraft-ducting/benefits

Copyright Politecnico di Milano2014What does AM change on the Product LC?4. Several iterations visual model - changes ... until reaching the optimum for the end customer. Customer more satisfied Decreases the time to market.

Copyright Politecnico di Milano2014What does AM change on the Product LC? 5. Conformal cooling Cooling channels conform to the exact shape of the mould. Injection molding 40&60 % more productive. http://www.mmsonline.com/cdn/cms/Image%206_Combo.jpg

Copyright Politecnico di Milano2014Manufacturing Trends

Volumi di produzioneVariet di prodotto

Tempo18501908195019802000GlobalizationAM

CRAFT PRODUCTIONMASS PRODUCTION

MASS CUSTOMIZATION(Henry Ford)

Copyright Politecnico di Milano2014Manufacturing Trends24Variet di prodotto

Volumi di produzione

Tempo18501908195019802000GlobalizationAM

CRAFT PRODUCTION(Henry Ford)MASS PRODUCTION

MASS CUSTOMIZATION20..

Se

Copyright Politecnico di Milano2014Game Changing tech.

Value Proposition Service Servitizzazione (Partnership strategiche) Cuncurrent Engineering Product New geometries not reachable by the subtractive MFG Lightweighting SustainabilityValue Creation Value Network Creation Mass Customization PersonalisationValue Delivery Distribution Channels MarketplacesTarget Market Segments Niche Market One-off products

Copyright Politecnico di Milano2014Existing company in existing market26

Backword integration

http://i.dailymail.co.uk/i/pix/2009/07/21/article-0-05C980A5000005DC-696_634x445.jpg Forward integrationProduct Service ProviderConsultant Service ProviderAM Powder Producer

Copyright Politecnico di Milano2014The New Markets27Main business categoriesInformation Provision & Knowledge sharingEnabling Service & DevelopmentProduction of Tooling & PartsBusinessesInformation CompaniesAM System ManufacturersPowder ManufacturersService ProvidersProduct Service ProvidersBerenschot Successful Business Models for 3D Printing 2014These technologies can enable fully adaptive and mobile (upstream/downstream, sideways, long or short) Business ModelsThe Impact of 3D Printing On Business Model Innovation, Thierry Rayna (2014)

Copyright Politecnico di Milano2014Organisational Implications1a. Market Customization1b. Client Customization2. Demand Manufacturing of the f.p.3. Demand Manufacturing of spare parts4. Time to market

Copyright Politecnico di Milano2014AM Industry SWOT analysisStrenghts

Opportunities

Reverse EngineeringIP IssuesWeaponsDangerous processesPowder Power***

Limited size of the buildDimensional AccuracyPost processing* neededMaterial LimitationCost of the AMT printerLow production volumesSuperficial roughnessSpeed of AMT printer

Net shape no toolingPart consolidationLightweighting partsComplex GeometryInner specificsElimination/Reduction of toolingImmediate CustomizationDesign Optimization and FlexibilityOne-off product

Weaknesses

Distributed MFGMFG on DemandMulti products batchesReduction in Inventories of of sub-components and end-use products

Threats

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Copyright Politecnico di Milano2014* speaking about metal AM parts.** MFG stands for Manufacturing*** Powder Power is a term used by Mauro Varetti in order to signal the ever growing strategical importance of the know-how above the material production. As in order to obtain certain technical/mechanical specifics it can be used a specific group of AMT thus a decision maker has to move within a certain range of materials. And moreover certain specifics for an end-use product may push towards the investigation of new materials which may give competition advantage. Another threat to be mentioned its what AM constituts for other well known sectors.. AM Its a threat for Tooling Companies.29

AM Industry PEST analysisSocialTechnological

Economic

Cost of materialCost of printers*Distributed Manufacturing Manufacturing on DemandService ProvidersPost processing dedicated companiesRecycling companies 4 plastic/4 metals

New structural design & Analysis toolsEnhanced range of material for AMFatigue properties & Reduced Surface roughnessTechnologies ConvergencyPredictive Process Models 4 microstructure & propertiesMtoM and PtoP variability and repeatibility

Qualification and certification for materialIndustry standards for AMIP issues

Politic

AM Perception IP issuesSelf-make issuesMass CustomizationEducation & Training for AM DesignersRecycling companies 4 plastic/4 metals

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Copyright Politecnico di Milano2014*Machines30

Sustainability31 is a math syllogism

Copyright Politecnico di Milano2014Susteinability with AMT is an aristotelian syllogism. (La sostenibilit dellAM, qui inteso come tecnologia, un sillogismo matematico). 1. Layer by layer manufacturing 2. No tooling needed3. Less use of material processed in the manufacturing process, (1,2) 4. Less waste in energy used during the manufacturing process, (1,2,3) 5. On demand manufacturing, (2) Distributed manufacturing, (2)TH1. Less pollution emitted during the m.p. (3,4) and released in the environment due to massive decrease of land transport means in logistics of multinationals, (5,6) TH2. Less inventory cost, (5)TH3. Saving weight and material leads to saving impact of the all AMed products and the all manufacturing process on the environment, (3)

1. And 2. are postulates by definiton of AM. Other sustainable implications of AM are 7. Retrofit through AM impacts on mainteinance and repair activities in the companes value chains. 8. People are eventually more satisfied and happy for hard customized products possible with AM technologies. 31

Sustainability is a Syllogism1. Layer by layer manufacturing, hp 2. No tooling needed, hphttp://www.mechanicalengineeringblog.com/wp-content/uploads/2011/03/01AdditiveManufacturingRapidPrototypinglayerbylayerflow.jpg

Copyright Politecnico di Milano2014Sustainability is a Syllogism3. Less use of material processed in the manufacturing process, (1,2) Less waste in energy used during the manufacturing process, (1,2,3) 5. On demand manufacturing, (2)

Copyright Politecnico di Milano2014Sustainability is a Syllogism


AM, The 6th wave?

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Copyright Politecnico di Milano2014This graphic is a continuation of the famous Kondratieff 5 waves. In according to Kondratieff within human history, better saying economic history, there are cicles which are signed by 4 stages Improvement (I), Prosperity (P), Recession (R) and Depression (D). In other words historically economies pass through Rising phases succeded by Decline phases. In Kondratieff opinion each waves aplitude is about 50 years and each of them is triggled by a disruptive innovation such as have been Steam engines, Railway steel, Electrical, Automobil and Petrolchemistry and Internet (wider term would be IT). Now it is interesting take this model in this contest of analysis of AM because there is pointed out that we are facing a Decline phase of our Economies and a Rising phase is at the dow triggled by several novelties of huge impact. The question in our presentation is whether AM it is just the new definitve disruptive Innovation which will triggle the down of new markets and paradigms. 35

Beyond the hype

Gartner Hype cycle http://www.michaeldiamond.com

Consumer 3D Printers

Industrial AM SystemsNot everything is possible or economically viable yet, but definitely more is possible right now than many people or managers know! Courtesy of Onno Ponfoort, Berenschot

Copyright Politecnico di Milano2014AM in details If

37If higher build ratesIf broader material range If lower Machine costs If lower material costsIf higher build volumesIf data base of certified materials for AMIf industrial standards for AM Industry If predictive algorithms If multi-products batching

Rudyard Kipling " If"Nobel Prize in Literature 1907


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References & SourcesThe Worldwide Guide to Rapid Prototyping www.additive3d.com/rm_c.htm EPMA (European Powder Metallurgy Association)www.epma.comAmerica Makes - National Additive Manufacturing Innovation Institute (NAMII)www.americamakes.us 3D Printing Industry www.3dprintingindustry.com AM Insight www.additivemanufacturinginsight.com Berenschot www.berenschot.com Wohlers Associatewww.wohlersassociates.com Forbes www.forbes.comBBCwww.bbc.co.uk

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Copyright Politecnico di Milano2014Conferences and events

Euro Mold, 25th to 28th November 2014, Frankfurt Metal AM 2014, 20th to 21st November 2014, Vien Inside 3D Printing, 13th to 14th November 2014, Milan39

Copyright Politecnico di Milano2014EuroMold is historically one of the most important event in AM industry; each time the main players of the market have announced their annual innovations within the scope of this fair. 39

Additive ManufacturingAn opportunity for metal-working companies

Thanks for your attentionProf. Marco Taisch, Eng. Francesco Giovanni SiscaPolitecnico di MilanoDepartment of Management, Economics and Industrial [email protected]@polimi.it


additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40...

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