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CHALLENGES AND OPPORTUNITIES FOR ADDITIVE MANUFACTURING IN THE AUTOMOTIVE INDUSTRY
Paul J. Wolcott Ph.D. – Body SMT Innovation
23-Feb-2017 | 2
Agenda
1. Additive Manufacturing in Industry
2. Opportunities in Automotive
3. Challenges and Needs Moving Forward
23-Feb-2017 | 3
Background: What is Additive Manufacturing (AM)?
A field of manufacturing processes that create three dimensional objects directly from digital data through
successive addition of layers of material
Additive Manufacturing, 3D printing, Rapid Prototyping, Freeform Fabrication, etc…..
23-Feb-2017 | 4
AM Technologies: Overview Standard Terminology for AM Processes (ASTM F2792-12a)
a. Binder jetting > Liquid bonding agent selectively deposited to join powder material > Powder bed and inkjet head (PBIH), plaster-based 3D printing (PP)
b. Directed energy deposition > Focused thermal energy fuses material by melting while depositing > Laser metal deposition (LMD)
c. Material extrusion > Material selectively dispensed through a [heated] nozzle/orifice > Fused deposition modelling (FDM)
d. Material jetting > Droplets of photopolymer + wax selectively deposited and UV cured > Multi-jet modeling (MJM)
e. Powder bed fusion > Thermal energy source selectively fuses regions of powder bed > Electron beam melting (EBM), selective laser sintering (SLS), and direct metal laser sintering (DMLS)
f. Sheet lamination > Thin sheets of material (plastic, metal) bonded together (glue, USW) > Laminated object manufacturing (LOM), ultrasonic consolidation (UC)
g. Vat polymerization > Liquid photopolymer selectively cured by light-active polymerization > Stereolithography (SLA), digital light processing (DLP)
23-Feb-2017 | 5
Past Commercial Uses of AM
• Stereolithography (SLA) prototypes ‒ Fit, form ‒ Limited functionality
• Plastics ‒ Limited metals capabilities
• Desktop printing ‒ Toys, trinkets
23-Feb-2017 | 6
Gartner Hype Cycle
23-Feb-2017 | 7
Additive Industry
• AM industry including all AM products and services is $5.2 bn ‒ Growth of 26% from 2015
• Patents issued on AM has more than tripled since 2010
23-Feb-2017 | 8
AM Acquisitions
23-Feb-2017 | 9
Applications of AM Technology in Production
23-Feb-2017 | 10
GE Fuel Nozzle • Part Consolidation
‒ Combined 20 individual pieces into one print ‒ Eliminates need to weld/braze multiple pieces
• Improved functionality ‒ Novel flow design not possible in conventional methods ‒ Improved durability over previous design ‒ 25% lighter
• 30% lower cost ‒ Improved cost due to part consolidation, many fewer steps
• Reportedly pursuing 100 k units annually by 2020 ‒ ~20 units / engine
23-Feb-2017 | 11
Airbus
• A350 XWB program with over 2,700 AM plastic parts
• Significant lightweighting advantages
• Less expensive over the lifetime of the program than conventional components
23-Feb-2017 | 12
Hearing Aids
• More than 15M 3D printed hearing aids in circulation worldwide
• Entire industry converted to 100% AM production within 500 days ‒ Those who did not, did not survive
“The U.S. hearing aid industry converted to 100% additive manufacturing in less than 500 days, and not one company that stuck to traditional manufacturing methods survived” - Harvard Business Review
23-Feb-2017 | 13
Automotive Components Rolls Royce • Approx. 10,000 parts on Phantom • Includes plastic holders, center lock buttons,
sockets, etc.
BMW • Over 500 water pumps used lifetime in racing
applications • Vehicle custom trim plates
23-Feb-2017 | 14
Additive Automobiles
Local Motors
EDAG
Divergent3D
ORNL
23-Feb-2017 | 15
New Technology Developments
• Carbon 3D ‒ CLIP technology up to 100x faster than stereolithography (SLA) ‒ Properties equal to or better than injection molding
• HP ‒ Multi-jet fusion technology
• Big Area Additive Manufacturing (Cincinnati Inc.) ‒ Large scale technology ‒ World record largest 3D printed part
23-Feb-2017 | 16
Opportunities in Automotive Industry
23-Feb-2017 | 17
Advantages of Additive Manufacturing
• Innovative design ‒ Complexity is free ‒ Creative freedom for innovation, customization ‒ Light weighting, lattice structures, internal fluid channels ‒ Limited design for manufacturing limitations ‒ Integration of structures and functionality
• Reduced development times ‒ Speed from design to part ‒ No tooling required, significantly improves lead times
• Decentralized manufacturing ‒ Reduction in supply chain costs, shipping ‒ Lower lead time risk
23-Feb-2017 | 18
Innovative Design
• Lightweighting ‒ Lattice structures ‒ Topological designs
• Tunable stiffness
• Fluid dynamics / conformal cooling
23-Feb-2017 | 19
Advantages in Tooling
• Conformal cooling tools for injection molding ‒ Improved cycle times
o Saving seconds/part in cooling can lead to significant $ savings
‒ Improved quality
• Lower lead times
• Ergonomic customization
Printed tools/inserts can lead to significant time/$ savings
23-Feb-2017 | 20
Design Iterations and Customization
• No Tooling
• Allows fast redesign
• Custom vehicles
23-Feb-2017 | 21
Reduced Development Times
• Design iterations without generating prototype tooling • Test functional parts without 6+ month lead time
• Recall mitigation
$$
Time
Costs of Change
23-Feb-2017 | 22
Decentralized Manufacturing
• Manufacturing directly at assembly plant
• Service parts ‒ Dealers ‒ After-market sales
• Reduce inventory costs
• Eliminate shipping costs
23-Feb-2017 | 23
Challenges and Needs
23-Feb-2017 | 24
Machine and Material Costs
• Both remain high, though the trajectory is improving rapidly, especially for metal components Decreases driven by: ‒ Increased volumes ‒ Improved competition
• Material costs a major driver for high piece costs
• Capital investment for machines remains high
0 0.5
1 1.5
2 2.5
3 3.5
2013 2018 2023
$/cm
3
Material Labor, Overhead, etc.
23-Feb-2017 | 25
Machine Development
• Current machines developed for aerospace and biomedical applications ‒ Build volumes and process times too small for many automotive applications
• Machine speeds continue to increase but require further developments for high volume applications
• Speed leads to fewer machines required for volumes and lower costs
• Key improvements: ‒ Faster, high number of lasers ‒ Less post-processing
10
40
80
0 10 20 30 40 50 60 70 80 90
2013 2018 2023
CM
3/H
R
Speed of SLM
23-Feb-2017 | 26
Material Development
• Limited available materials • Generally focused on higher cost materials – Titanium, Nickel, etc.
• Need ‘automotive’ grade materials – aluminum, steels
• Technologies specifically tailored to these materials ‒ Processing parameters
• Material characterization for automotive conditions ‒ Tensile, fatigue, corrosion, durability, etc. ‒ Current materials qualified for flight by FAA
0
20
40
60
80
100
120
Traditional AM Carbon CLIP
Rel
ativ
e S
treng
th %
X Y Z
23-Feb-2017 | 27
AM Understanding / Training
• Plenty of knowledge designing for more conventional processes: injection molding, stamping, casting, etc. ‒ Need to fully understanding the technology
to leverage it
• On-site training
• University and developmental school programs
23-Feb-2017 | 28
Summary
• Recent developments exhibit the benefits of Additive Manufacturing
• Moving from hype to reality
• Continued work required to fully realize automotive benefits
Paul J. Wolcott Ph.D paul.wolcott@gm.com
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