manufacturing the future - how 3d printers are used for design and manufacturing
DESCRIPTION
How to Utilize Additive Fabrication Machines for Direct Digital Manufacturing, 3D Printing and Rapid Prototyping.TRANSCRIPT
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How 3D Printers and Rapid Prototyping Systems are Changing the Future of Product Development and Manufacturing
MANUFACTURING THE FUTURE
Stratasys, Inc.www.Stratasys.com/Future
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Additive Manufacturing
Objectives Clear understanding of additive manufacturing market
Content Terminology Types of additive manufacturing approaches Application areas and benefits
Importance Foundation for identifying opportunities
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Additive Manufacturing
Known by many names: 3D Printing
Rapid Prototyping
Rapid Tooling
Rapid Technologies
Rapid Manufacturing
Additive Fabrication
Advanced Manufacturing
Additive Layer Manufacturing
Direct Digital Manufacturing
Direct Manufacturing
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Terminology
Additive Manufacturing Preferred term covering all 3D printing technologies/ applications Preferred replacement for rapid prototyping
Definition: Collection of technologies, directly driven by CAD data, to
produce 3-Dimensional physical models and parts through an additive process.
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Primary Applications for Additive Manufacturing
Established / Traditional (Design)
Direct Digital Manufacturing(Manufacturing)
Additive ManufacturingAdditive Manufacturing
ConceptualModeling
ConceptualModeling
Functional PrototypingFunctional Prototyping
ManufacturingTools
ManufacturingTools
End-UseParts
End-UseParts
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Technology Assessment
ConceptModelingConceptModeling
Functional Prototyping
ManufacturingTools
ManufacturingTools
End-UseParts
End-UseParts
3D Printers 3D Production Systems
Performance Requirements Increase
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Conceptual Models & Functional Prototypes
Primary Benefits• Reduce time to market
Solidify design earlier Reduce late design changes
• Lower product development cost Make design changes earlier in process Make mistakes early and often
Secondary Benefits• Facilitate communication between teams and
vendors• Improve product design
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Jay Leno’s Garage: Concept Models
1907 White Steam Car D-Valve replacement needed Not available at local automotive center
Utilized multiple technologies 3D Scanning Materialise - software 3D Printing
From broken to fixed part - quickly1. 3D scan broken D-Valve2. Concept model produced3. Validated design
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Concept Models at Ducati
Design of Desmosedici Engine Saved over $1.5M in outsourcing costs
Concept to final engine design in 8 months vs. 28 months (71% time savings)
Eliminated 83 design problems
Major piston design change Started with twin oval piston Final design a four round side-by-side
“To keep Ducati at the forefront of engine design, we sought a technology that could make accurate, durable prototypes quickly.”
Piero Giusti, Ducati
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Functional Prototyping at Toro
Commercial & Residential SprinklersPrototyped in few hours for testing
Validated form, fit and function Pressure testing at +100 psi
Working prototype made for each new design
Over a 2 year period & many projects Reduced product development by 283 weeks Reduced tooling costs by $500,000
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Functional Prototypes at Logitech
Bluetooth Headset• Headset failure
Many iterations of functional prototypes Gave to focus groups for evaluation
• Found new, counterintuitive design fix 273% stronger
• Faster response, lower cost More functional prototypes Better products, satisfied customers
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Direct Digital Manufacturing Applications
Primary benefits Lowering costs Increasing profits Decreasing time-to-market Decreasing cycle time
• Secondary advantages Design freedom Product redesign frequency Rapid response
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Direct Digital Manufacturing Applications
Best fit when:• Relative low volumes
Short run production and bridge to tooling• High part complexity
Eliminate expensive tooling Reduce long lead times
• Part acceptable Aesthetics not critical Finishing processes feasible Physical properties acceptable
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Manufacturing Tools
Examples: Jigs Fixtures Check gauges Drill / rivet guides Go / no-go gauges Alignment tools & guides Tooling masters & patterns
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Manufacturing Tools at BMW
Emblem Headlight Alignment
Cubing Device Gage Checker
Bumper Reach
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Jigs & Fixtures at BMW
Manufacturing Jigs and Fixtures with FDM• Automobile assembly & testing tools
Over 400 jigs & fixtures / vehicle Many produced on Fortus system
• Benefits to workers and processes: Improved productivity Design optimized for worker comfort Increased process ease-of-use Greater process repeatability
AUTOMOTIVE
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Manufacturing Tools at Oreck
Repeatable & accurate assembly • Custom vacuum assembly pallets
• Requirements 40 – 50 / model 5 – 10 models in production
• Benefits 65% reduction in fixture costs $100,000 / fixture savings (up to) 58% reduction in manufacturing defects Replacement fixtures in hours vs. weeks Nearly eliminated worker fatigue & injuries
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End-Use Parts
• Primary Benefits Lower cost Shorter lead time
• Secondary Design freedom
• Few design for manufacturing constraints Change freedom Mass customization Supports lean initiatives True JIT (just-in-time) manufacturing Reduced warehouse space/inventory cost
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End Use Parts at DST Control
• Gimbal eye or camera For unmanned aerial and ground vehicles Stable images from unstable carriers
• Fortus machine produces 20 different parts Meet accuracy and quality standards Reduce delivery time for custom products
• FDM parts perform better Lower weight Better electrical insulation
• Time and cost savings Part cost reduced 66% Custom part production time reduced 63%
FDM reduces cost 66% & time 77%
Method Cost Time
Traditional Manufacturing
€2,441
11 weeks
Direct DigitalManufacturing
€830 4 weeks
Savings €1,611
(66%)
7 weeks(63%)
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• Custom bezels manufactured Accept only one vial size Easy customization
• Saving $25,000 on Engineering time Tooling / bezel
• Design flexibility New product design without tooling Able to support new vile sizes Unique competitive edge
Automated Pill Dispensing System
End Use Parts at ScriptPro
Method Cost Time
Traditional $31,650 60 Days
Fortus $ 6,750 2 Days
Savings $24,900(78%)
58 Days (97%)
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Summary
• Terminology AF DDM 3D Printer 3D Production system
• Business segments On Demand 3D Printers 3D Production Systems
• Applications Product design
• Concept models• Functional prototype
Manufacturing• Manufacturing tools• End-use parts
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More Information
Test it, Prove it. Send 3D cad file and have Stratasys build it for you Application Engineer consultation
www.Stratasys.com/Future Download Application Guides and White Papers Fill out form to get benchmark built Get FDM sample part Request Consultation