Thinking ahead the Future. of Additive Manufacturing: Research Landscape, Opportunities and Barriers

Transcription

1 Thinking ahead the Future of Additive Manufacturing: Research Landscape, Opportunities and Barriers Analysing Future Commercial Opportunities For 3D Printing And Examining Trends In Additive Manufacturing Research to determine Areas of Future Investment Speaker: Dipl.-Wirt.-Ing Christian Lindemann Computeraplication and integration in Design and Planning 1

2 Thinking ahead the Future of Additive Manufacturing: Research Landscape, Opportunities and Barriers 1 Introduction 2 The business of Additive Manufacturing 3 Strategic planning of future AM-applications 4 Additive Manufacturing research landscape 5 Development of research strategies 2

3 Direct Manufacturing Research Center (DMRC) The DMRC is a proactive collaboration of key technology stakeholders who have a common interest in advancing Rapid Prototyping technology into dependable, production rugged Direct Manufacturing technology (DM). Partners of the DMRC: DMRC at the University of Paderborn 3

4 Research Projects Technology specific Projects Polymer Laser Fused Deposition Metal Laser Overarching Projects Sintering Modeling Melting Cross cutting topics Costs, Quality, Design Rules, Strategy, Future 4

5 The Heinz Nixdorf Institute Interdisciplinary Research Centre for Computer Science and Technology Established from the Heinz Nixdorf Foundation, the federal state North Rhine-Westphalia and the University of Paderborn in 1989 Heinz Nixdorf, 1986 The Heinz Nixdorf Institute 5

6 Applications faster and cheaper 1 Faster and cheaper 2 3 Individualized parts Complex parts Rubber boot sole (EOS & Tecnologia & Design) Injection molding: Tool costs T (Werksbild Hella KGaA 2009) Cable clips (EOS) Prototype of a fuel tank (EOS, FKM Sintertechnik) 6

7 Individual Applications 1 Faster and cheaper 2 3 Individualized parts Complex parts Artificial hip joint (SLM Solutions) Artificial leg (EOS & Fraunhofer) Tooth crowns (SLM Solutions) Designer sun glasses (small series) (EOS, Tecnologia & Design - Treviso Tecnologia) 7

8 Complex Applications 1 Faster and cheaper 2 3 Individualized parts Complex parts Pre-series tool for VW Golf control panel (EOS, Moldes Royas) Casting core for gear boxes (EOS, Poggipolini) Aerospace parts (EOS, Morris Technologies) 8

9 Proceeding for the development of research strategies Business of Additive Manufacturing Additive Manufacturing Research Landscape Business of Today Aerospace industry Automotive industry etc. Business of Tomorrow Aircraft production Automotive production Chapter 2 Analysis of Additive Manufacturing institutes Segmentation of research landscape into research fields Determination of research activity and intensity Chapter 4 Electronics industry manufacturing equipment Global environment Strategic Planning Product Discovery Future applications Future requirements Strategic Technology Planning Assessment of DM-technologies Innovation-Roadmaps Chapter 3 Research White Spots Allocation of future requirements Chapter 5 to sub-topics Relevance of sub-topics Degree of activity in sub-topics Deduction of promising White Spots Research Strategies Deduction of success factors on research strategies Development of research strategies 9

10 Research Strategies for Additive Manufacturing Technologies 1 Introduction 2 The business of Additive Manufacturing 3 Strategic planning of future DM-applications 4 Additive Manufacturing research landscape 5 Development of research strategies 10

11 The business of Additive Manufacturing Overview of relevant industries Sources: See study Thinking ahead the Future of Additive Manufacturing Innovation Roadmapping 11

12 The business of Additive Manufacturing Development of future scenarios 7 workshops took place at Boeing in St. Louis, USA and at the Heinz Nixdorf Institute in Paderborn. 12 scenarios were developed: global environment, automotive and aircraft production, electronics manufacturing equipment. 12

13 The business of Additive Manufacturing Reference scenario for the aircraft production Individual Customisation Fosters AM-Technologies Europe sets the pace in a globalized world. Many manufacturers jumped on board and improved the ratio of functionality and costs by increasing investments into AM-technologies. Functional-driven design is the key to success. AM-parts start to be associated with high performance and high quality. Strategic Direction Increasing individualisation of aircrafts fosters the application of AM-technologies. Build Up General Ground Rules for Design of Secondary Aircraft Structures, Systems etc. and Flow them down to Suppliers (Integration of Supply Chain) Sources: See study Thinking ahead the Future of Additive Manufacturing Innovation Roadmapping 13

14 Research Strategies for Additive Manufacturing Technologies 1 Introduction 2 The business of Additive Manufacturing 3 Strategic planning of future DM-applications 4 Additive Manufacturing research landscape 5 Development of research strategies 14

15 Priority of Innovation Fields Exemplary: Aerospace 15

16 Strategic planning of future DM-applications Exemplary product idea: Morphing Wing 120 idea characteristics in 28 innovation fields within the automotive, aerospace and electronics industry were developed. 16

17 Strategic planning of future DM-applications Exemplary product idea: Multi-Material 17

18 Strategic planning of future DM-applications Exemplary product idea: Embedded Sensors 18

19 Strategic planning of future DM-applications Exemplary product idea: Tailored Structures 19

20 Strategic planning of future DM-applications Exemplary product idea: Steering Wheel 20

21 Strategic planning of future DM-applications Exemplary product idea: Conformal Tooling 21

22 Strategic planning of future DM-applications Exemplary product idea: HVAC 22

23 Inner Tailored Structures 23

24 Intelligent Material Design 24

25 Air Duct 25

26 Design Application: Robot System Multiple in use Movable platform Measurement of load-turning Position of load (photoelectric sensor) All electronic parts are included Single application (low volume) Flexibility 26

27 Significance-performance portfolio powder bed fusion metal technologies (excerpt) Today, most requirements are In the future, the significance will balanced: the significance and increase. technology s performance largely Fundamental, technological advancements are required to meet future correlate. requirements. Most critical requirements are: high process stability, a database containing properties of AM-material, provision of design rules. 27

28 Example for Design rules Source: Adam, Zimmer; Project Direct Manufacturing Design Rules ; DMRC Yearly Report

29 Innovation Roadmap for powder bed fusion metal technologies (excerpt) Results from two expert surveys are used to develop innovation roadmaps. Innovation roadmaps indicate when developed applications can be realized (columns), as technological requirements will be fulfilled (rows). 29

30 Studies: Thinking ahead the Future of Additive Manufacturing Study 2 Future Applications (March 2012) Study 1 Analysis of Promising Industries (May 2011) Study 3 Innovation Roadmapping of Required Advancements (March 2013) 30

31 Research Strategies for Additive Manufacturing Technologies 1 Introduction 2 The business of Additive Manufacturing 3 Strategic planning of future DM-applications 4 Additive Manufacturing research landscape 5 Development of research strategies 31

32 Technology-specific strengths/weaknesses profiles Example for SLM 32

33 Additive Manufacturing Research Landscape The institutes were asked to indicate the research fields, applied technologies and the research intensity Annual budget Number of staff Number of projects Number of publications. The institutes were assisted in personal and telephone interviews. 33

34 Additive Manufacturing Research Landscape Key findings General Research focus is on PBF-plastic and PBF-metal technology; only a few institutes deal with FLM and Polymerization Most institutes focus technology across a number of research fields / sub-topics Research intensity is balanced in most research fields (overall research intensity correlates with number of institutes) High research activity / few institutes: Temperature Resistance, Material / Powder Generating Processes, Simulation of Parts and Materials Many institutes / low research activity: Part Tolerances, Development of Standards for Testing Procedures Design Rules and Part Tolerances are crosstechnological research fields / sub-topics High research activity Mechanical Properties (PBF-plastic & -metal) New Materials Material Quality Microstructure Manipulation Material / Powder Generation Low research activity Supply Chain Optimization Machine Costs Process Automatization Material Costs Recycling Costs 34

35 Research Strategies for Additive Manufacturing Technologies 1 Introduction 2 The business of Additive Manufacturing 3 Strategic planning of future DM-applications 4 Additive Manufacturing research landscape 5 Development of research strategies 35

36 Identification of White Spots Relevance and research intensity for powder bed fusion metal technologies (excerpt) White Spots: Design Rules Standards Development Multi-Material Manufacturing Process Automatization Certification etc. Success Factors for Research Strategies Interconnection within the research landscape Integration of industry along the value chain (material supplier, machine manufacturer, OEMs etc.) and long-term research partnerships Participation in Standardization Committees etc. 36

37 Strategy Map Position of strategy variants, and competitors using Multidimensional Scaling 37

38 Publication of study Additive Manufacturing Research Map Public Study: Analysis of the Additive Manufacturing Research Landscape Print run:

39 Conclusion How far can you imagine? 39

40 Don t be afraid of the future it does not begin until tomorrow. ZARKO PETAN Thank you for your attention Heinz Nixdorf Institute University of Paderborn Product Engineering Fuerstenallee Paderborn Find the Annual Report and Future Studies of the DMRC: Phone: Fax.: Juergen.Gausemeier@hni.upb.de 40