Additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40 slides)
•Descargar como PPTX, PDF•
2 recomendaciones•656 vistas
Industrial Additive Manufacturing
Recomendados
Recomendados
Más contenido relacionado
La actualidad más candente
La actualidad más candente (20)
Similar a Additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40 slides)
Similar a Additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40 slides) (20)
Último
Último (20)
Additive manufacturing at bimu (01 10-2014) eng v.7 - an opportunity for metal-working companies (40 slides)
- 1. Copyright Politecnico di Milano 2014 Additive Manufacturing An opportunity for metal-working companies Prof. Marco Taisch, Eng. Francesco Giovanni Sisca Politecnico di Milano Department of Management, Economics and Industrial Engineering
- 2. Copyright Politecnico di Milano 2014 Green products
- 3. Copyright Politecnico di Milano 2014 Green products in green plants • 104 gCO2/Km • 4,7L/100Km • 100 gCo2/Km • 6,2L/100Km 108 gCo2/Km 4,0 L/100Km
- 4. Copyright Politecnico di Milano 2014 Mass Customisation
- 5. Copyright Politecnico di Milano 2014 Product variety Productvolumes 1850 1913 1955 1980 2000 Time Craft production
- 6. Copyright Politecnico di Milano 2014 Product variety Productvolumes 1850 1950 1980 2000 Time MASS PRODUCTION1908 “You can have any color for your car as long as it is black!” (Henry Ford)
- 7. Copyright Politecnico di Milano 2014 Product variety Productvolumes 1850 1908 1950 1980 2000 Time Mass Customization
- 8. Copyright Politecnico di Milano 2014 Servitisation Product Servizio per supportare il prodotto Servizio per differenziare il prodotto Servizio è prodotto Service for product Service for customer K.D. Thoben 2001
- 9. Copyright Politecnico di Milano 2014 Example • Car Sharing: You don’t buy no more a car but you rent it. Golboo Pourabdollahian
- 10. Copyright Politecnico di Milano 2014 Example • Sale of flight hours instead of engines Golboo Pourabdollahian
- 11. Copyright Politecnico di Milano 2014 Product becomes lighter • Strong special steels • Aluminium • Titanium • Alloys • Composites • Bio-composites • Ceramics • Hybrid materials 11 • Raw-material and energy efficiency improves Pictures: Audi, UPM Slide courtesy of
- 12. Copyright Politecnico di Milano 2014 Product becomes smart’ • Information technology helps to improve energy efficiency • Digital steering and control systems enable improved ergonomics • Machines can be remotely controlled – humans are freed from working in uncomfortable and dangerous surroundings • Machines can measure processes and output to optimise performance • Machines can send data on output, lapsed time, and their own condition over mobile internet • Improved conditions for fleet management • Need for repair and maintenance can be anticipated to minimise downtime Pictures: Sandvik, Ponsse, Metos Slide courtesy of
- 13. Copyright Politecnico di Milano 2014 What’s AM? Metal powder spread and fused time to time, on a working plan, layer by layer, in according with the sections which the net-shape to be formed consists of. Courtesy of Avio Aero
- 14. Copyright Politecnico di Milano 2014 Applications Areospace Fuel injectors , GE AviationBrackets for Airbus 320, Airbus 16 Automotive http://blogs.discovermagazine.com Dental Defense http://d.ibtimes.co.uk/ Asda Supermarket in UK Consumer goods
- 15. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 17 Foundry Machining Assembly
- 16. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 18 AM Post Processing 1. Collapse of foundry activities and assembling activities in the AM Process
- 17. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 2. Ready turnkey kits needed to a final product in one batch. Set ups overcame. Minimum production lots disappear.
- 18. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 20 3. Consolidation of several sub-parts in a unique net-shape. Part durability improves. Disappear stocks of many sub-components. http://www.rmbproducts.com/aerospace-aircraft-ducting/benefits
- 19. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 4. Several iterations visual model - changes ... until reaching the optimum for the end customer. Customer more satisfied Decreases the time to market.
- 20. Copyright Politecnico di Milano 2014 What does AM change on the Product LC? 5. Conformal cooling Cooling channels conform to the exact shape of the mould. Injection molding 40&60 % more productive. http://www.mmsonline.com/cdn/cms/Image%206_Combo.jpg
- 21. Copyright Politecnico di Milano 2014 Manufacturing Trends Volumidiproduzione Varietà di prodotto Tempo1850 1908 1950 1980 2000 CRAFT PRODUCTION MASS PRODUCTION MASS CUSTOMIZATION (Henry Ford)
- 22. Copyright Politecnico di Milano 2014 Manufacturing Trends 24 Varietà di prodotto Volumidiproduzione Tempo1850 1908 1950 1980 2000 CRAFT PRODUCTION (Henry Ford) MASS PRODUCTION MASS CUSTOMIZATION 20.. “Se –”
- 23. Copyright Politecnico di Milano 2014 Game Changing tech. Value Proposition Service Servitizzazione (Partnership strategiche) Cuncurrent Engineering Product New geometries not «reachable» by the subtractive MFG Lightweighting Sustainability Value Creation Value Network Creation Mass Customization Personalisation Value Delivery Distribution Channels Marketplaces Target Market Segments Niche Market One-off products
- 24. Copyright Politecnico di Milano 2014 Organisational Implications 1a. Market Customization 1b. Client Customization 2. Demand Manufacturing of the f.p. 3. Demand Manufacturing of spare parts 4. Time to market
- 25. Copyright Politecnico di Milano 2014 AM Industry – SWOT analysis Strenghts Opportunities Reverse Engineering IP Issues Weapons Dangerous processes Powder Power*** Limited size of the build Dimensional Accuracy Post processing* needed Material Limitation Cost of the AMT printer Low production volumes Superficial roughness Speed of AMT printer Net shape «no» tooling Part consolidation Lightweighting parts Complex Geometry Inner specifics Elimination/Reduction of tooling Immediate Customization Design Optimization and Flexibility One-off product Weaknesses Distributed MFG MFG on Demand Multi products batches Reduction in Inventories of of sub- components and end-use products Threats 29
- 26. Copyright Politecnico di Milano 2014 Sustainability… 31 … is a math syllogism
- 27. Copyright Politecnico di Milano 2014 Sustainability is a Syllogism 1. Layer by layer manufacturing, hp 2. No tooling needed, hp http://www.mechanicalengineeringblog.com/wp- content/uploads/2011/03/01AdditiveManufacturingRapidPrototypinglayerbylayerflow.jpg
- 28. Copyright Politecnico di Milano 2014 Sustainability is a Syllogism 3. Less use of material processed in the manufacturing process, (1,2) 4. Less waste in energy used during the manufacturing process, (1,2,3) 5. On demand manufacturing, (2)
- 29. Copyright Politecnico di Milano 2014 Sustainability is a Syllogism Th1. Less pollution emitted during the m.p. (3,4) Th2. Less pollution released in the environment due to massive decrease of the transport means in Logistics of multinationals, (5) TH3. Saving weight and material leads to saving impact on the environment of the all AMed products, all manufacturing process, and all final products using the Amed parts/components, (3)
- 30. Copyright Politecnico di Milano 2014 AM in details – ‘‘If…’’ 37 If… higher build rates If… broader material range If… lower Machine costs If… lower material costs If… higher build volumes If… data base of certified materials for AM If… industrial standards for AM Industry If… predictive algorithms If… multi-products batching Rudyard Kipling " If…" Nobel Prize in Literature 1907
- 31. Copyright Politecnico di Milano 2014 References & Sources The Worldwide Guide to Rapid Prototyping www.additive3d.com/rm_c.htm EPMA (European Powder Metallurgy Association) www.epma.com America Makes - National Additive Manufacturing Innovation Institute (NAMII) www.americamakes.us 3D Printing Industry www.3dprintingindustry.com AM Insight www.additivemanufacturinginsight.com Berenschot www.berenschot.com Wohlers Associate www.wohlersassociates.com Forbes www.forbes.com BBC www.bbc.co.uk 38
- 32. Copyright Politecnico di Milano 2014 Conferences and events Euro Mold, 25th to 28th November 2014, Frankfurt Metal AM 2014, 20th to 21st November 2014, Vien Inside 3D Printing, 13th to 14th November 2014, Milan 39
- 33. Copyright Politecnico di Milano 2014 Additive Manufacturing An opportunity for metal-working companies «Thanks for your attention» Prof. Marco Taisch, Eng. Francesco Giovanni Sisca Politecnico di Milano Department of Management, Economics and Industrial Engineering marco.taisch@polimi.it francescogiovanni.sisca@polimi.it
Notas del editor
- Mass production processes led to the continuous improvement methods of production. The continuous improvement company is more participative, empowered, cross-functional team-based and focusing on total quality management (TQM) principles. Workers are given more participative and decision-making responsibilities and managers perform the facilitative and coaching function of motivating their employees toward continuous improvement efforts in the production facility. This type of a production system results in the manufacture of low-cost, high quality, standard goods and services. The time period most typical of continuous improvement was in the 1980s when companies like Motorola began implementing TQM and other continuous improvement programs in their production operations management. The continuous improvement production methods led to the unique concept of mass customization, a process in which all aspects within the organization from people, processes, organizational structures, and technology are geared to provide customers specifically what they need and want. An efficient, well-integrated organizational system of production facilitates this process of mass customization. The result is low cost, high quality, customized goods and services produced on a large scale to a mass market. The time period most typical of mass customization was in the mid-1990s through the present time when companies like Dell began effectively implementing mass customization in their production operations facilities.
- -Time to market means from the idea/design of the product to its commercialization into a market. Agile manufacturing means reactivity to change on product mix and product functionality becasue there is no tooling to prepare in other words there is no traditional Innovation process. No Tooling is better said as potential elimination of tooling in the sense that exeption made for the lattice supports AM does not need tools to be adopted. Therefore direct production is possible without implementation of dedicated tools. This leads companies into niche markets which with traditional manufacturing couldn’t be reched due to the high break even. No waste for two characteristics occurring in adoption of AM: by definition additive manufacturing build layer by layer the product needed using the exact material needed while in subtractive manufacturing often happens that from a solid is obtained the final part using 10-40% of the material in input while the remaining is waste. Through Design Optimization (Topology Optimization) allowed by AM less material is used due to the lack of costraints of traditional manufacturing thus there will result a lighter end-use part. - The Geometry Complexity is for free in the sense that it is just marginally related to the increase of the related cost of production (Berenschot Report 2014).
- These are applications for AM in respect of the aim it is used for. Tooling may be Direct tooling or Undirect.
- Borrowing the Technology Adoption Lifecycle curve terminology we may speak about: Innovators: Consumer goods Early Adopters: Aereospace, Automotive Early Majority (1): Industrial/Business Machines, Medical, Dental, Defense (2): Fashion, Footwear, Jewelery, Toys, Industrial Design, Architecural, Oil &Gas, Food Laggards (future applications in): Bioprinting, Metal AM in Space. The term Defense or Military may be interchangeable. Medical: models, surgical cutting, drill guides, orthopedic plants; Dental: dental plants, crown and bridges. While consumer products industry has been the first application for AM, (Innovators), the Aereospace sector has been the engine of AM pushing AM systems manufacturers and AM providers to improve AMTs , broadening the material range available and it is still urging AM Industry to cope with issues as A-Z process monitoring , closed loops controls, Topology Optimization sw, predictive sw which link the characteristics of the material in input to the mechanical specifics obtained in output; Optimal topology, flow needs given. There are several end-users ion Aereospace, among them Safran Avion, AVIO Aero, Airbus. “Hinges for the Airbus A320 - conventional (background) and 3D printed (foreground)” BBC article The Fuel nozzle here shown is the one which will be produced in 50.000 units by 2015 for LEAD engines. «The Automotive Industry has been using 3D printers since 1980s» Rakesh Sharma Here in this slide we see the famous case of Urbee, an urban electric vehicle whose body have been completely 3d printed, using CAD sw Autodesk and through a Stratasys machine. It’s an electrical vehicle within the range 0-40 miles/hour and it goes through internatl combustion within the range 40-70 miles/hour. (Information sourced from korecologic.com/media/videos). Medtech products that ranges from jaw implants to dental implants, from skull to body-fitting implants. I preferred to use the term Defence rather than Military, because I wanted to make sound the concept that we can find AM applications in Army, Navy, Airforce, or in other words all the military forms of a Defense Department within whichever country. The respirator above in the current slide have been realised by Design Reality through a 3D printer Objet 260 Connex (Stratasys) https://www.youtube.com/watch?v=8vC8yoj61JY American AM pioneer Stratasys merged with Israeli-based Objet in December 2012. («The newly formed entity chose to register as a company of Israel» Wohlers Report 2014). The weapon on the slide it’s from http://www.extremetech.com/extreme/133514-the-worlds-first-3d-printed-gun. Mass Market product has highly general utility and universal appeal. Jewels, home accessories, lamps, key-ring, glasses, bikes, mobile phone protection covers (in slide), memes, spore sculptures, etc. Mini-mes or Avatar are used as synonyms.
- * speaking about metal AM parts. ** MFG stands for Manufacturing *** «Powder Power» is a term used by Mauro Varetti in order to signal the ever growing strategical importance of the know-how above the material production. As in order to obtain certain technical/mechanical specifics it can be used a specific group of AMT thus a decision maker has to move within a certain range of materials. And moreover certain specifics for an end-use product may push towards the investigation of new materials which may give competition advantage. Another threat to be mentioned it’s what AM constituts for other well known sectors.. AM It’s a threat for Tooling Companies.
- *Machines
- Susteinability with AMT is an aristotelian syllogism. (La sostenibilità dell’AM, qui inteso come tecnologia, è un sillogismo matematico). 1. Layer by layer manufacturing 2. No tooling needed 3. Less use of material processed in the manufacturing process, (1,2) 4. Less waste in energy used during the manufacturing process, (1,2,3) 5. On demand manufacturing, (2) Distributed manufacturing, (2) TH1. Less pollution emitted during the m.p. (3,4) and released in the environment due to massive decrease of land transport means in logistics of multinationals, (5,6) TH2. Less inventory cost, (5) TH3. Saving weight and material leads to saving impact of the all AMed products and the all manufacturing process on the environment, (3) 1. And 2. are postulates by definiton of AM. Other sustainable implications of AM are 7. Retrofit through AM impacts on mainteinance and repair activities in the companes’ value chains. 8. People are eventually more satisfied and happy for hard customized products possible with AM technologies.
- This graphic is a continuation of the famous Kondratieff 5 waves. In according to Kondratieff within human history, better saying economic history, there are cicles which are signed by 4 stages Improvement (I), Prosperity (P), Recession (R) and Depression (D). In other words historically economies pass through Rising phases succeded by Decline phases. In Kondratieff opinion each wave’s aplitude is about 50 years and each of them is triggled by a «disruptive» innovation such as have been Steam engines, Railway steel, Electrical, Automobil and Petrolchemistry and Internet (wider term would be IT). Now it is interesting take this model in this contest of analysis of AM because there is pointed out that we are facing a Decline phase of our Economies and a Rising phase is at the dow triggled by several novelties of huge impact. The question in our presentation is whether AM it is just the new definitve disruptive Innovation which will triggle the down of new markets and paradigms.
- EuroMold is historically one of the most important event in AM industry; each time the main players of the market have announced their annual innovations within the scope of this fair.