Emerging Trends in Additive Manufacturing

Transcription

1 Emerging Trends in Additive Manufacturing September 2016 Dhruv Bhate Senior Technologist, PADT Inc. 1

2 Outline Introduction PADT AM Trends Considerations Resources AZ AM landscape 2

3 INTRODUCTION TO ADDITIVE MANUFACTURING AT PADT 3

4 PADT: What We Do Simulation Product Development Manufacturing Sales Services R&D Training Consulting 4

5 PADT by the Numbers Founded in 1994, 22 years in business ~85 employees Over 1,700 Customers served R&D labs with $2M in equipment 13 Small Business Innovation & Research (SBIR) awards since 1999, America Makes award in Additive Manufacturing 2016 Tempe, AZ Torrance, CA Phoenix, AZ Littleton, CO Albuquerque, NM Murray, UT 5

6 PADT Additive Manufacturing (AM) Technology Timeline Stereo lithography SLA 250 Viper Si2 ProJet * FDM 2000 Prodigy Dimension Fortus 400 Fortus 450 Fused Deposition Modeling 1995* 2000* Selective Laser Sintering Sinterstation 2000 plus 1999 HiQThermal Sensing Upgrade 2005 Multi-zone Heating Upgrade 2012 Connex 500 Objet 500 Material Jetting (Polyjet) MLab Cusing R Laser Melting (Metal) *retired 6

7 Additive Concept Raw Material Process Technology Product 7

8 Classification of Additive Manufacturing Processes Raw Material Process Technology Laser Fusion/Sintering Electron Beam Melting Binder Jetting Powder + Laser Sheet Filament / Wire Liquid Powder Laser Polymerization Light Projection Polymerization Material Jetting Fused Deposition Wire + Electron Beam Ultrasonic bonding Laser Lamination 8

9 ADDITIVE MANUFACTURING TRENDS 9

10 Top 5 AM Drivers 1 Rapid Prototyping and Tooling Design Freedom Lead Time Reduction Manufacturing Cost Reduction 5 New Applications Rolls Royce Trent XWB 10

11 Additive Manufacturing Trends AM System Installations by Sector Worldwide AM Revenue (USD, Millions) Services Percentage of AM Revenue from Functional Parts Products 11

12 AM in Aerospace & Defense AM System Installations by Sector FAA Approvals Sensor Housing, GE(2015) first 3D printed jet engine part to be approved AM Aerospace Market Projection $M USD Custom Airduct, Flying Eye Hospital(2015) A few high volume parts in production can greatly impact the market C. Ozores (2015) 12

13 Typical AM Adoption Process in Aerospace Companies Fused Deposition Modeling (Polymers) Laser-based Powder Bed Fusion (Metals) Material & Part Size ABS only 10x10x12 in. ABS, Nylon, ULTEM, Polycarbonate, ABS-ESD 16x14x16 in. / 36x24x26 in. Steels, Inconel, Al alloys, Ti alloys, Bronze, CoCrW 3.5x3.5x3 in. 10x10x11 in. 31.5x16x20 in. Value Rapid Prototypes, Rapid Tooling High performance polymers for part production Large part production Small Part Production, R&D, Prototypes Large part production Continuous production Approx. Capital Expenditure $45 K $145 K $400 K $235 K $650K (single laser) $750 (dual laser) $2.1M 13

14 Future Growth: AM in Medicine 2015 AM Revenues by Industry 2015 Hype Cycle for 3D Printing Revenues in medical/dental are similar to aerospace 14

15 Manufacturing Institute Roadmaps 15

16 Classification of AM in Medical Applications

17 Summary of FDA Approvals for AM Devices (as of 2015) 70+ AM devices cleared through 510(k) pathway, some emergency use of AM devices 68% of cleared AM devices utilized a complex or porous structure Renovis(EBM) Device Type 58% Orthopedic Implants 35% Surgical Guides 7% Dental AM Technology 80% powder bed fusion 13% SLA 4% Extrusion 3% Jetting Materials 50% Polymers 37% Ti6Al4V 4% CoCrMo 4% Comm. Pure Titanium 17

18 PRACTICAL CONSIDERATIONS 18

19 Building Blocks for AM in Functional Part Production Scaling & Production Cost - Benefit Quality & Automation Safety & Training Qualification & Certification Standards Material Models Simulation Fundamental Understanding Materials R&D Process R&D Structure Property Relationship s Design for AM 19

20 Post-Processing for a Finished Part (Metal) Excavation Heat Treatment Inert gas furnace for stress relief Support Removal Finishing Micropeening Ti6Al4V Bandsaw Ultrasonic Cleaner Grinder Sander/Wire Additional requirements as determined (microstructure optimization) (or) Wire EDM Handtools chiv/transfer/ /pdf/ pdf 20

21 Ancillary Requirements for Operating Machines (Metal) Vacuuming & Disposal Build Plate Preparation Milling Bead Blasting Demagnitization Inert Gas (N 2 /Ar) Sieving PPE & Class D Fire Extinguisher Material Storage O 2 Sensor 21

22 Safety & Environmental Considerations Key Risks: 1. Fire & Explosion 2. Physiological Metal powder inhalation Inert gas asphyxiation 3. Laser exposure Four key levels of certification: 1. Equipment (NRTL) 2. Building Safety 3. Fire 4. Environmental Local regulations drive site-specific requirements Related Safety in Metal 3D Printing White Paper available on request 22

23 Design & Simulation for AM Basic Requirements Scanning & File Transfer Improving Performance Through Analysis Process R&D 1. Design Modeler 3. Geometry Repair 4. Topology Optimization 5. Lattice Generation 7. Process Simulation 2. Build Preparation 6. Part Analysis Note: Not a complete list Related AMUG 2016 Conference Presentation Available on Request 23

24 RESOURCES 24

25 Online Courses: Learn More 3D Opportunity: Additive Manufacturing for Business Leaders : Bioprinting: 3D Printing Body Parts : Reading: European Powder Metallurgy Association (EPMA) Brochure: Introduction to Additive Manufacturing : Wohlers Report (annual, fee): Metal Additive Manufacturing Magazine (free digital editions): Conferences: AMUG: RAPID: SFF Symposium: formnext: America Makes Membership: Online, Living Textbook expected by end-2017 (PADT leading effort) 25

26 Existing Arizona Additive Manufacturing Ecosystem Aerospace, Aviation & Defense Academia Companies with AM users in AZ Helicopter Several entities in AZ driving a wide range of AM efforts (estimated 250+ companies have users of AM technology, 25+ involved in functional part AM) ASU Polytechnic positioned as the Southwest s leading AM R&D institution with $2M in metal and polymer 3D printing equipment, in addition to materials processing and analysis World-class characterization and simulation facilities and expertise 26

27 Arizona Additive Manufacturing Committee (AZ Tech Council) Started June 2016, with goals: Promote AM and educatepotential users Act as a forum to influence local regulation Inform progress of national certification and standards organizations Serve as a rallying point for collaboration - 53 individuals representing 34 entities in AZ (and growing) - Monthly meeting at different sites (so far: LAI, ASU, PADT, Intel. October: UofA) - Contact dhruv.bhate@padtinc.comto learn more and/or join 27

28 Thank You! 28

29 1 Rapid Prototyping Low-cost, rapid manufacturing of one of a kind parts allows for faster product development cycles 50-90% cost reductions 80-95% lead time reductions Wind Tunnel Models (Lockheed Martin Corp.) Mock-Ups & Fit Tests (Lockheed Martin Corp.) Display Models (Lockheed Martin Corp.) 29

30 1 Rapid Tooling Organic Innovation, operators and engineers design and print tooling and improvements at low cost and fast turnaround time and see the results of their ideas C-130 MicrovaneTooling (Lockheed Martin Corp.) Drill Jigs (Lockheed Martin Corp.) Layup Tool (Lockheed Martin Corp.) 30

31 2 Design Freedom Internal Features Layer-by-layer manufacturing process allows for more complex geometries design with (almost) no constraints! Fuel Nozzle (GE Aviation) UAV Wing (Aurora Flight Sciences) Space Launch Fuel Nozzle (NASA Marshall) 31

32 2 Design Freedom Strength-Weight Optimization Topology optimization allows for reducing the material requirements for any desired objective (stiffness, strength, extension etc.) AM enables manufacturing of these designs! Topology Optimization (ANSYS) Bracket with 30% weight reduction (Airbus) Seat-belt buckle -55% weight reduction, estd. 72.5kg on Airbus 380 (EOS) Exhaust Sensor (RSC Engg.) Bracket (Honeywell) 32

33 2 Design Freedom Parts Consolidation Parts previously designed for manufacturing and subsequent assembly can now be printed in a consolidated manner to eliminate assembly costs (labor and parts) Satellite Waveguide, Renishaw (77 parts to 1) Sensor Housing, GE(20 parts to 1) Airbus Fuel Assembly(10 parts to 1) 133 g 53 g 33

34 3 Lead Time Reduction Eliminate Supplier Sourcing Deloitte University Press 2011 Committee on Examination of the U.S. Air Force's Aircraft Sustainment Needs Additive Manufacturing enables point-of-use manufacturing! US Navy Raytheon 34

35 3 Lead Time Reduction Accelerate Development, Replacement & Repair Super Draco Thruster: concept to hot firing in 100 days (Space X) Replacement parts for a 30-year old component within a week (Airbus) Turbine blade repair (DM3D, MT Additive) 35

36 4 Manufacturing Cost Reduction Mass Customization Low Volume, High Mix High Volume Manufacturing 36

37 5 3D Printed Electronics (PEN, Inc.) New Applications Space Construction (ESA) Armor & Exoskeleton On-Orbit Manufacturing (Tethers Unlimited) Bioprinting 37