Smart 3D Printing DCMME Fall Conference Managing Smart Manufacturing October 20, 2015
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1 Smart 3D Printing DCMME Fall Conference Managing Smart Manufacturing October 20, 2015 Stacey M. DelVecchio Additive Manufacturing Product Manager Caterpillar Inc.
2 Smart 3D Printing Agenda Who We Are Building Engagement & Knowledge Use Cases
3 Agenda Who We Are Smart 3D Printing
4 Caterpillar is the world s leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives.
5 Additive Manufacturing at Caterpillar Inc Rapid Prototyping Lab SLA, LOM, SLS, FDM, Metal 2009 Design Groups FDM 2013 Innovation Group 2014 to present Additive Manufacturing Group Additive Manufacturing Factory Nomadic Printer Program SLA, SLS, FDM, DMLS, ink jet
6 Smart 3D Printing Agenda Who We Are Building Engagement & Knowledge
7 Building Engagement & Knowledge Deployment Acceleration Additive Manufacturing Factory Nomadic Printers
8 Deployment Acceleration Technical Expertise Nomadic Printers Catalyst Group bring in expertise RCWT Additive Manufacturing Summit Mentor and coach engineers Nomadic Printer Program Expose employees to 3D printing with a printer at their facility Technical Expertise Additive Factory Accelerate adoption of additive in product groups Product Group ownership A&I Additive Manufacturing Group enablers Additive Manufacturing Factory Source of supply First parts delivered
9 Machines available to produce production intent parts A tool to help with technical expertise and be a production source Status Additive Manufacturing Estimated completion: October 2015 Factory Additive Factory
10 Nomadic Printers Expose employees to the potential of 3DP by having a printer at their facility to use and experiment with Different Duration Processes Suppliers Materials Software 6 months 6 locations Printers named after inventors Nomadic Printers
11 Nomad Program Feedback Much innovation spurred by having a system Ink jet printers too much for our beginners Initial glee until sticker shock when re-ordering material Lessons Learned Internal website for sharing, i.e. ask questions, share failures Start small; move up the technology ladder Dispel the notion that it s nice, but we need metal Culture change: Cost of 3DP vs. realization of benefits Nomadic Printers
12 Smart 3D Printing Agenda Who We Are Building Engagement & Knowledge Use Cases
13 Use Cases Design Verification / Display Gauging Manufacturing Aids Casting Aids Production
14 1/12 TH Scale Dragline Bucket DESIGN VERIFICATION
15 Undercarriage Roller Comparison DESIGN VERIFICATION 3D Printed Assemblies to show design differences
16 Half Scale Hammer DESIGN VERIFICATION Saved $10K to $15K tooling cost
17 Tip/Adapter Assembly - Trade Show DISPLAY Tip/ Adapter Assembly Adapter truncated to make a base
18 Field Gauges GAUGING $50 vs. $600/ 1 Week Stacked assembly of four field gages Compactor Tip gage - Slider bar is lowered to meet tip surface, indicating worn percentage
19 CMM Plastic Link and Fixture MANUFACTURING AIDS 36 Track Links of various sizes Machine Setup Safety Improvement CMM Programming Savings = $160,000
20 Molds Silicone Masking MANUFACTURING AIDS Molds made from scrap steel: Heavy Sharp edges Not reliable Savings in repair = $27,000/yr
21 Snap Gauge Handles MANUFACTURING AIDS
22 Piston Ring Removal Tool MANUFACTURING AIDS
23 Rocker Arm Assembly Fixtures MANUFACTURING AIDS Savings: $10,000 design and fabrication cost 8 weeks lead time
24 Low Volume Bowl Gauge MANUFACTURING AIDS On returned cores the part numbers are usually worn away, so a profiling tool is required for identification.
25 Tool Holders & Covers MANUFACTURING AIDS Repair cost = $100s to $1000s Repair Cost = $100s
26 Patterns for Molded Parts CASTING AIDS Full size 3D printed pattern Urethane part made using silicon mold Pattern was used in mold box to make silicon mold
27 Pattern to Cast Compactor Wheel Tip CASTING AIDS
28 Pattern to Cast Compactor Wheel Tip CASTING AIDS
29 Hose Clamps PRODUCTION Optimization opportunities?
30 Additive Manufacturing Parts In Process PRODUCTION Dealer O Ring Installation Tools Printed by: A&I Additive Mfg Ready for parts orders now Shade Brackets Printed by: A&I Additive Mfg 1 st parts sold to fulfill backorder Southern Germany Hose Clamps Printed by: A&I Additive Mfg Ready for parts orders now Backup Rings Printed by: A&I Additive Mfg Ready for parts orders now Yokes Printed by: PD> Ready for parts orders: TBD
31 Smart 3D Printing Agenda Who We Are Building Engagement & Knowledge Use Cases
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GCSE 4111/01 DESIGN AND TECHNOLOGY UNIT 1 FOCUS AREA: Resistant Materials Technology
Surname Centre Number Candidate Number Other Names 0 GCSE 4111/01 DESIGN AND TECHNOLOGY UNIT 1 FOCUS AREA: Resistant Materials Technology A.M. TUESDAY, 19 May 2015 2 hours S15-4111-01 For s use Question
REQUIRED EQUIPMENT SETUP
#003-598 raverhone VS OPERATION AND MAINTENANCE MANUAL 24V IMPORTANT NOTICE FOR OPERATORS No user serviceable parts inside. Do not remove any outer surfaces. Do not modify this equipment or remove warning
Number Wheeler P/N Description Set Rex P/N Notes Base 1 J Support, Right 1 J Support, Left 1 J Nut (M8)
1 603500 Base 1 J001 2 603501 Support, Right 1 J002 3 603502 Support, Left 1 J003 4 600328 Nut (M8) 4 5 600130 Spring Washer (8mm) 4 6 600344 Roll Pin (M6x30) 4 7 600129 Socket Hd Cap Screw (M8x25) 4 8