The Impact of 3D Printing on Industrial Manufacturing

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1 Powered By The Impact of 3D Printing on Industrial Manufacturing Moderator David Wagman Editorial Director, Engineering360 Producer, Jonathan Fuller

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3 Housekeeping 3 Using the Webinar console PowerPoint Box Speaker s Bio Q&A Icons Webinar Survey Please ask questions early and often webinar series Powered By 3

4 Powered By The Impact of 3D Printing on Industrial Manufacturing Alex Chausovsky Senior Principal Analyst, Industrial Automation IHS Technology 4

5 Information Analytics Expertise NOVEMBER 11, 2014 THE IMPACT OF 3D PRINTING ON INDUSTRIAL MANUFACTURING ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING ALEX CHAUSOVSKY MANAGER & SENIOR PRINCIPAL ANALYST INDUSTRIAL AUTOMATION +1 (512) / ALL RIGHTS RESERVED

6 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Contents About IHS 3 CapEx, Machinery Production and Automation Equipment Overview 6 3D Printing Technology and Capabilities Overview 11 The Threats and Opportunities for 3D Printing in Industrial Manufacturing 23

7 Shaping the Future with Super Efficient Electric Motors February 27 th, 2014 About IHS Introduction to IHS Introduction to Electric Motors and Industrial Energy Efficiency Industrial Motors Market Update Alex Chausovsky Manager & Principal Analyst IHS Technology Industrial Automation

8 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING IHS - Leading information, advanced analytics and deep expertise IHS Since 1959 Headquartered in Englewood, CO (traded on the NYSE) 8,000+ colleagues in 30+ countries speaking 50+ languages Serve businesses and governments in 165+ countries worldwide 70% of the US Fortune % of the Global Fortune 500 Small businesses & enterprises IHS is supported by 140+ offices around the world United States United Kingdom Canada India Singapore Malaysia China France Germany Switzerland Poland Japan Belarus Brazil South Korea Russian Federation United Arab Emirates Norway Australia Spain South Africa Mexico Hong Kong Netherlands Thailand Taiwan Italy Denmark Sweden

9 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING IHS Business Lines Aerospace & Defense Automotive Chemicals Technology Energy Financial Services Maritime Economics Country Risk Operational Excellence and Risk Management Product Design Supply Chain

10 Shaping the Future with Super Efficient Electric Motors February 27 th, 2014 Introduction to IHS CapEx, Machinery Production and Automation Equipment Updates Introduction to Electric Motors and Industrial Energy Efficiency Industrial Motors Market Update Alex Chausovsky Manager & Principal Analyst IHS Technology Industrial Automation

11 2013 CapEx Analysis Improved Macroeconomic Performance Capital Expenditure Spend ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Consumer and Business Spending $3.8 Trillion 5.7% Growth Government Investment Profits for End-Users Transport & Defence Budgets 43% Of Spend 5% Of Spend 52% Of Spend Machinery Production Automation Products substantial portion in MP Automation Products Direct to End-Users Building, Land, Services & Other

12 MACHINERY PRODUCTION 2013 SUMMARY $1.6 Trillion of Machinery produced in 2013 Americas Europe Asia Pacific World % of world total ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Trend Line ( ) CAGR ( ) Agricultural Machinery $170B 11.1% 7.4% $51.5bn $38.4bn $78.7bn Food, Beverage & Tobacco Machinery $50B 3.3% 4.4% $7.8bn $27.2bn $14.6bn Furnaces & Furnace Burners 1.3% 4.8% $4.4bn $6.6bn $9.4bn Machine Tools $95B 6.2% 2.0% $6.9bn $30.8bn $56.5bn Materials Handling $197B 12.9% 5.5% $21.6bn $81.6bn $93.4bn Packaging Machinery $40B 2.7% 5.5% $4.6bn $21.9bn $14.2bn Paper & Paperboard Machinery 1.3% 1.3% $3.0bn $10.1bn $6.0bn Printing Machinery 1.3% 1.9% $3.1bn $11.4bn $6.1bn Robotics 0.8% 2.4% $1.7bn $4.5bn $6.7bn Rubber & Plastics Machinery $38B 2.5% 2.3% $5.0bn $19.6bn $13.2bn Semiconductor Machinery $34B 2.2% 2.4% $10.6bn $5.9bn $17.6bn Textile Machinery $38B 2.5% 2.5% $1.0bn $13.9bn $23.4bn Woodworking Machinery 0.8% 2.4% $1.3bn $7.8bn $3.6bn

13 MACHINERY PRODUCTION BY REGION ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING 32.9% 21.7% 45.4% % of 2013 global machinery production $330bn $500bn $691bn Americas Europe Asia Pacific $400bn $599bn $988bn

14 2014 Key Point Summary Industrial Automation $185.3b 2014 Equipment Revenue $47.4 billion Motors ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING $31.8 billion $26.9 billion Discrete Controllers Motor Controls $36.5 billion Linear & Fluid Products 40.1% 31.1% 28.8% Motors & Motor Controls Automation Equipment Power Transmission Equipment 2014 Regional Sales Growth Americas 6.9% EMEA 4.3% Asia 7.7% Japan 5.4% 45% IAE Sales into Discrete Manufacturing 2014 Market Drivers 3.1% Global GDP Growth 41% IAE Sales into Process Manufacturing Machinery Production 6.3% Growth Capital Expenditure 5.4% Growth

15 3D Printing Technology and Capabilities Overview

16 The Impact of 3D Printing Technology A Transformative Manufacturing Process ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Although the technology has existed since the 1980s, 3D Printing has really gone mainstream in the last five years. Some industries that the technology has penetrated include: Consumer Products: Clothing, Shoes, Jewelry, Toys, Home Décor, Electronics Medical Products: Joint Replacements, Prosthetics, Crowns / Invisalign Braces Industrial Products: Tools, Molds, Fuel Injection Nozzles, Gas Turbine Parts, Pumps What benefits and drawbacks does 3D Printing technology have compared to traditional manufacturing techniques? 3D Printing, also called Additive Manufacturing, adds materials to create products, rather than subtracting them as is typical in traditional manufacturing processes. This presents significant potential cost savings to manufacturers that invest in the technology. Products are designed using complex computer software platforms and are then printed layer by layer, allowing for features that were not possible with traditional machine or human manufacturing techniques. Currently, the biggest drawbacks for 3D Printing are size and speed limitations, which prevent the technology from replacing many assembly line manufacturing processes.

17 Overview of 3D Printing/Additive Manufacturing Technologies Vat Photopolymerization: Stereolithography (SLA), Digital Light Processing (DLP) Liquid photopolymers, either plastics or wax, are selectively cured, normally using UV light. Powder Bed Fusion: Selective Laser Sintering (SLS), Direct Metal Laser Sintering (DMLS), Selective Heat Sintering (SHS) and Electron Beam Melting (EBM) Thermal energy (lasers) used to fuse materials, either metals or plastics, in a powder bed. Directed Energy Deposition: Laser Metal Deposition (LMD) ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Thermal energy (lasers) used to fuse materials, either metals or plastics, as they are deposited Binder Jetting: Powder Bed and Inkjet Head (PBIH), Plaster-based Printing (PP) Metal or plastic powders bound together using a specialized glue and then cured in an oven for post processing.

18 Overview of 3D Printing/Additive Manufacturing Technologies Material Extrusion: Fused Deposition Modeling (FDM), Fused Filament Fabrication (FFF) Two plastic cords (build & support material) extruded through a heated nozzle that melts the plastic and traces out a pattern. FDM is the basis for most home-use systems. Material Jetting: Multi-jet Modeling (MJM) ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Droplets of plastic build material are selectively deposited on a platform and cured by UV light. Sheet Lamination: Ultrasonic Consolidation (UC), Laminated Object Manufacturing (LOM) Older technology in which sheets of material - paper, plastic or metal - are bonded together to form an object.

19 The Impact of 3D Printing Technology ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Implementation of 3D printing technology into our everyday lives, both personal and business Biomaterials Moldable Polymers Human Cells and Tissues Synthetic Tissues Metals & other industrial materials Medical and Biotechnology Applications Integration of 3D printing technology with traditional manufacturing processes, materials and software Invention of technology and development of first hardware prototype Technology Capabilities Time Rapid Prototyping Plastics ABS, Nylon, PLA, HIPS Polycarbonates Glass-filled Polyamide Photopolymers and Wax Titanium, Stainless Steel Nickel and Cobalt Chrome Alloys Aluminum, Gold, Inconel Epoxy resins, Ceramics, Sand Carbon Fiber (new) Industrial Manufacturing Wide Adoption by Consumers & Businesses 1987 ~

20 The Impact of 3D Printing Technology ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Increases design innovation by creating new structures and shapes; engineers are able to take an idea, create a CAD model, and have a part in their hands by the next day. They are then able to see exactly how it fits into the piece of equipment they are building. It also improves the design process by allowing for new combinations of materials. Speeds up time to market by making the idea to prototype cycle much shorter. Necessary adjustments to prototypes are made quickly and new prototypes are printed within hours or days, which really speeds up the entire design process. Reduces development costs and waste by using less materials, and increases personalization of products for customers, without additional cost increases. Reverse-engineering of old, outdated parts is possible through digital scanning. The part might be 20 years old and there was never a CAD model for it. The engineers can scan it, turn it into a CAD model and then 3D print it and have complete repeatability.

21 Expiring Patents ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING In 2009, expiration of several early patent families enabled the emergence of lowercost desktop printers from companies like Makerbot, as well as consumer-facing 3D printer service providers such as Shapeways. Another major shift is coming as patents on other key 3D printing technologies start to expire over the next three years, lowering costs for those methods and widening the range of capabilities available to users. Patents on selective laser sintering (SLS) along with the process for removing support material on fused deposition modeling and photopolymer inkjet printing all expire this year. In 2015, the patent for SLS printing of filled composites also expires. This is bound to result in increased competition among SLS printer suppliers as new entrants come to market in the coming years.

22 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Market Data: 3D Printing Industry Growth Projections 40.0 Revenue Forecast for the 3D Printing Industry from 2014 to Revenues ($B) Y2014 Y2015 Y2016 Y2017 Y2018 Y2019 Y2020 Consumer Systems and Parts Industrial Systems and Parts Service Providers Materials Tooling Source: IHS Technology November 2014

23 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Market Data: Additive Manufacturing Value by Sector Source: IHS Technology November 2014

24 Suppliers Industrial Grade 3D Printers ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING 3D Systems* Arcam* Beijing Tiertime* Carima CMET Concept Laser DWS EOS* Envisiontec* ExOne* Mcor* Optomec Rapid Shape Shaanxi Hengtong SLM Solutions Stratasys* Voxeljet* Wuhan Binhu * Top printer manufacturers own over 40% of the 3D printer market, and nearly 100% of the Metal 3D printer market.

25 Big Names Getting Involved in the Industry ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Hewlett Packard Canon Epson Xerox 3M Google Microsoft Apple Samsung IBM Amazon Traditional 2D printer manufacturers that are planning on entering the market in the near future. These players have deep pockets and a lot of expertise in printing technology. They are focusing on addressing the current limitations of the technology, namely speed, size and cost issues.

26 3D Printing Challenges and Limitations Prohibitive Printer and Materials Costs Speed and Size limitations Intellectual Property Concerns Environmental Impact Effect on Traditional Manufacturing Jobs Required Certifications for Medical/Aerospace ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING

27 The Threats and Opportunities for 3D Printing in Industrial Manufacturing

28 Threat: Replacement of MT and Plastics Machinery ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Revenues ($M) Unit Volume Metal Cutting Machines Metal Forming Machines Plastic Machinery Metal Cutting Machines Metal Forming Machines Plastic Machinery Total

29 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING 3D Printing vs. Machine Tooling and Plastics Injection Molding

30 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Threat: Replacement of MT and Plastics Machinery

31 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Opportunity and Threat in One: Hybrid & Large Scale Image Source: DMG MORI Image Source: Sciaky Above: DMG MORI s LASERTEC 65 3D Right: Sciaky s EBAM AM System Others: ZMorph3D, Rokit s 3Dison Multi

32 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Opportunity: Increased Sales of Automation Components More than 70,000 personal 3D printers were sold in This number is expected to grow to over 100,000 this year, and rapidly over the next decade. Each printer contains one or more electric motors. There were nearly 10,000 industrial grade 3D printers sold in The potential for future growth in industrial applications exceeds that of the consumer space. Each machine has multiple servo motors.

33 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Opportunity: Production of Automation Equipment using Additive Manufacturing Systems Nearly 50 million low voltage motors were made in The leading motor manufacturers are experimenting with potentially using additive manufacturing techniques in the future. Industrial electronics, such as variable speed drives, represent a large and rapidly growing market. In 2013, nearly 20 million drives were sold worldwide. With the advent of 3D printed circuitry, will it be possible to print drive parts?

34 ENGINEERING360 WEBINAR ON ADDITIVE MANUFACTURING Thank you very much! Alex Chausovsky Senior Principal Analyst Industrial Automation IHS Technology