Lowering the barriers to additive manufacturing

Marc Saunders

Director – Global Solutions Centres

AM Solutions Centres

05/03/2023 Slide 2

Why everyone is interested in AM…

Disruptive additive manufacturing (AM) benefitsInnovative product designsComplex internal detailsLightweight, optimised formsEfficient material usage with minimal

wasteImproved cooling & heat transferCustomisation for specific

applicationsShort lead timesBuild from CAD with no special

tooling

05/03/2023 Slide 3

How AM is being deployed

Low volume parts made direct from CAD

New product designs that 1. Deliver lifetime benefits in use2. Provide mass customisation

Complex parts that simplify assembly & enhance reliability

Re-production parts, that avoid complex manufacturing

Rapid prototypes & tooling

Direct part replacement

Part consolidation

DfAMoptimised

Volume production applications will come from the higher levels

05/03/2023 Slide 4

Examples – rapid prototypes & tooling

Complex bar locators for part handling

Prototype exhaust

nozzle

Conformal mould tooling for rapid cooling

05/03/2023 Slide 5

Example – direct part replacement

Significant waste reduction with AM process

Note: some finish machining still required on AM part

Example courtesy of GKN Aerospace

05/03/2023 Slide 6

Example – part consolidation

Single piece microwave guide reduces weight and improves performance

05/03/2023 Slide 7

Examples – DfAM optimized

Customised cranio-facial implant

Increased efficiency heat

exchanger

Light-weight, efficient hydraulic manifold

05/03/2023 Slide 8

Financial benefits of AM

Production benefits

£ Less materials£ Lower tooling costs£ Shorter process time£ Shorter lead time£ Simpler assembly£ Automation

Lifetime benefits

£ Less weight£ Faster product launch£ Product reliability£ Higher performance£ Better adaptation£ Product attraction£ Reduced stocking£ Higher responsiveness

Financial benefit

05/03/2023 Slide 9

Few companies are using AM in series production – why?

05/03/2023 Slide 10

Lowering the entry barrier for AM

Metal additive manufacturing technology for industrial applications

Global network of Renishaw Solutions Centres

Applications expertise in a wide range of industries

Integrated manufacturing solutions

05/03/2023 Slide 11

Solutions Centre principles

• Help manufacturers to learn to think with an AM mind-set• Apply AM thinking to process and part design• A supported learning centre for all things AM• A secure environment for prototyping, re-manufacturing,

part consolidation and design optimisation• Customers supported by dedicated engineers and

technicians• On-site finishing methods for support removal, heat

treatment, machining, metrology etc.• Assisting customers to make an educated AM investment

05/03/2023 Slide 12

Global network of Solutions CentresUK - Stone

India – Pune

China – Shanghai

Canada - TorontoGermany - Stuttgart

USA –Texas

Holland – Breda

UK - Miskin

USA – Chicago

A mutually supporting network of 9 centres, each with applications specialisms to suit local industrial demand

Opening during 2016

05/03/2023 Slide 13

Solutions Centres services

Benchmark part: benefits tangible

Concept embodies AM benefits

Optimise process & verify part

Demonstrate process stability

AM & finishing processes to make saleable product

Accelerated learning curve

05/03/2023 Slide 14

Solutions Centres facilities

05/03/2023 Slide 15

Incubator cells to nurture your idea

Your private development facility, including…Secure, access-controlled process

incubator cellDedicated additive manufacturing machineMaterials choice & option to use your own

powderDedicated powder handling accessoriesNo overheads & predictable costsAccess to Renishaw engineers and

techniciansOptional access to finishing processes,

metrology and materials analysis

05/03/2023 Slide 16

Pre-production capacity to prove your process

Ramp up towards production volumes…Access to multiple AM machines

Metrology and finishing processes as required

Contracted price per part

Support for process capability studies

Business case preparation

Integrated solutions

Design for AM AM build Gauging Machining Inspection

Proc

esse

sTo

ols

05/03/2023 Slide 18

Dallas

• 20,000 ft²

• 3 Incubator Cells

• 3 pre-production machines

• Re-modelling during H1’16

• All post processing on-site

• Full or partial applications engineering support

• 3 CMM training rooms

• DfAM training courses

05/03/2023 Slide 19

Dallas

05/03/2023 Slide 20

Chicago

• 133,000 sqft

• 4,000 sqft dedicated AM development area

• 2 incubator cells

• Dedicated Class 2 Division II material handling

• Full post-processing facilities

05/03/2023 Slide 21

AM manufacturing & medical solutions: Miskin, UK

Why choose Renishaw as your AM partner ?

• FTSE 250 plc, c $750m revenue and >4,000 staff

• Develops all aspects of AM technology in-house (machines, software, metallurgy, services)

• World-class metrology, process control, machining, electronics and assembly expertise

• Optimised solutions for your application, not just standard product that you have to adapt

05/03/2023 Slide 23

• From research lab onto the factory floor

• From prototypes & tooling to series production

• From time compression to higher product performance

• From shapes to consistent, qualified parts

• From plastics to high performance alloys

• From 3D printing to an integrated production process

Your product design

Renishaw expertise

Your AM process

Global support

Thank you