This document summarizes key developments in industrial additive manufacturing (AM) based on a presentation given in 2015. It discusses the growth of the AM industry from $4.1 billion in 2014 to an estimated $21.2 billion by 2020. Emerging trends include new metal AM technologies using refractory metals and ceramics, as well as multi-material systems. Applications highlighted include fuel nozzles for jet engines and certified aerospace components. The document also outlines the maturing AM supply chain for metals and polymers.

1. Inside 3D Printing – Santa Clara ©2015 Wohlers Associates, Inc.
Important EmergingImportant Emerging
Developments inDevelopments in
Industrial AMIndustrial AM
October 22, 2015 • Santa Clara
Tim Caffrey
Note:Note:
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IndustryIndustry growthgrowth
EmergingEmerging trendstrends
NewNew technologiestechnologies
MetalMetal processes and applicationsprocesses and applications
ChallengesChallenges in metal AMin metal AM
Estimates and forecastsEstimates and forecasts
based onbased on 2020 yearsyears
of hard dataof hard data
Views fromViews from 7878 handhand--pickedpicked
coco--authors inauthors in 3131 countriescountries
Cooperation fromCooperation from 4040
system manufacturerssystem manufacturers
andand 8787 service providersservice providers
$4.1B$4.1B in 2014in 2014
CAGR: 35.2%CAGR: 35.2%
Source: Wohlers Report 2015Source: Wohlers Report 2015
HistoryHistory
Quadrupled inQuadrupled in
pastpast 55 yearsyears
productsproducts
servicesservicesStockStock pricesprices
2015:2015: ~$5.5B~$5.5B
Industrial system unit salesIndustrial system unit sales
Source: Wohlers Report 2015Source: Wohlers Report 2015
12,85012,85030.1%30.1% growth in 2014growth in 2014

2. Inside 3D Printing – Santa Clara ©2015 Wohlers Associates, Inc.
Companies that build and sellCompanies that build and sell
industrial (>$5,000) systemsindustrial (>$5,000) systems
NanoscribeNanoscribe
RPM InnovationsRPM Innovations
3DCeram3DCeram
SismaSisma
BigRepBigRep
2014:2014: 4949
2013:2013: 3434
XiXi’’an Brightan Bright
Laser TechnologiesLaser Technologies
XeryXery
MatsuuraMatsuura
OPM LabOPM Lab
Roland DGRoland DG
KeyenceKeyence
ExpiredExpired
Foundation patents on FDM, SL,Foundation patents on FDM, SL,
SLS, and 3DP from MITSLS, and 3DP from MIT
SLMSLM patentpatent by Meiners,by Meiners, WissenbachWissenbach,,
and Gasser (DE19649865C1)and Gasser (DE19649865C1)
expires 2 Dec 2016expires 2 Dec 2016
Desktop (<$5K) 3D printersDesktop (<$5K) 3D printers
Source: Wohlers Report 2015Source: Wohlers Report 2015
92.5%92.5% growth in 2014growth in 2014 139,584139,584
Vat photopolymerizationVat photopolymerization
AsigaAsiga
AutodeskAutodesk
Carbon3DCarbon3D
CarimaCarima
FormlabsFormlabs
LightforgeLightforge
Old World LabsOld World Labs
ProdwaysProdways
OthersOthers
HP Multi Jet FusionHP Multi Jet Fusion
BAAMBAAM
Carbon3DCarbon3D
Technologies to watchTechnologies to watch Hybrid material systemsHybrid material systems
Voxel8Voxel8: material extrusion head and conductive ink: material extrusion head and conductive ink
deposited with pneumatic directdeposited with pneumatic direct--write dispenserwrite dispenser
MarkForgedMarkForged: material extrusion head and second: material extrusion head and second
head that deposits a continuous strand ofhead that deposits a continuous strand of
carbon fiber, fiberglass, or Kevlarcarbon fiber, fiberglass, or Kevlar

3. Inside 3D Printing – Santa Clara ©2015 Wohlers Associates, Inc.
Refractory metalsRefractory metals
Ceramic materials and systemsCeramic materials and systems
ThermoplasticsThermoplastics
New material familiesNew material families
GrapheneGraphene and graphiteand graphite
Individuals with aIndividuals with a networkednetworked 3D printer3D printer
BrickBrick--andand--mortarmortar 3D print shops3D print shops
OnlineOnline marketplacesmarketplaces and communitiesand communities
New types of service providersNew types of service providers
““TraditionalTraditional”” service providersservice providers
SystemSystem manufacturersmanufacturers
Metal AM system salesMetal AM system sales
Source: Wohlers Report 2015Source: Wohlers Report 2015
543543
351351
199199
54.7%54.7% growth in 2014growth in 2014
ASTM International Committee F42 onASTM International Committee F42 on
Additive Manufacturing TechnologiesAdditive Manufacturing Technologies
material extrusionmaterial extrusion
material jettingmaterial jetting
binder jettingbinder jetting
powder bed fusionpowder bed fusion
directed energy depositiondirected energy deposition
vat photopolymerizationvat photopolymerization
sheet laminationsheet lamination
ProcessesProcesses
Metal options with AMMetal options with AM
Metal AMMetal AM
systemsystem
Digital dataDigital data Metal partMetal part
Pattern AMPattern AM
systemsystem
MetalMetal
castingcasting
Digital dataDigital data Metal partMetal part
Source: Wohlers Associates, Inc.Source: Wohlers Associates, Inc.
Investment patterns vs. direct metalInvestment patterns vs. direct metal
Jewelry and dental industries use bothJewelry and dental industries use both
Sand patterns vs. direct metalSand patterns vs. direct metal
Application: prototype engine blockApplication: prototype engine block
Application: final productApplication: final product

4. Inside 3D Printing – Santa Clara ©2015 Wohlers Associates, Inc.
ExOne: steelExOne: steel--bronze metal partsbronze metal parts
Binder jettingBinder jetting
Fabrisonic: ultrasonic AMFabrisonic: ultrasonic AM
Sheet laminationSheet lamination
““Blown powderBlown powder””: Optomec, Trumpf: Optomec, Trumpf
Directed energy depositionDirected energy deposition
WireWire--fed: Sciakyfed: Sciaky
Hybrid metal systemsHybrid metal systems
Powder bed fusionPowder bed fusion
MatsuuraMatsuura
OPM LabOPM Lab
Directed energy depositionDirected energy deposition
Hybrid Manufacturing TechnologiesHybrid Manufacturing Technologies
Flexible Robotic EnvironmentFlexible Robotic Environment
DMG Mori SeikiDMG Mori Seiki
MazakMazak
HurcoHurco
HermleHermle
FononFonon
Fuel nozzleFuel nozzle
19 per engine, 1,700 engines per year19 per engine, 1,700 engines per year
ConsolidatesConsolidates 2020 detail parts into onedetail parts into one
25% lighter, 5x more durable, reduces coking25% lighter, 5x more durable, reduces coking
T25 housingT25 housing
FAAFAA--certified temp/pressure housing spare partcertified temp/pressure housing spare part
Space vehiclesSpace vehicles
Combustion chamber and nozzle componentsCombustion chamber and nozzle components
Space X,Space X, AerojetAerojet Rocketdyne,Rocketdyne,
NASA, United Launch AllianceNASA, United Launch Alliance
Source:Source: Dr.Dr.--Ing. Michele Pressacco, Lima CorporateIng. Michele Pressacco, Lima CorporateSource:Source: Dr.Dr.--Ing.Ing. MicheleMichele PressaccoPressacco, Lima Corporate, Lima Corporate
50,00050,000 acetabularacetabular
cups in 6 yearscups in 6 years
100,000100,000 producedproduced
by all companiesby all companies
50,00050,000 implantedimplanted
Source: EOSSource: EOS
Dental copings 3D printedDental copings 3D printed every dayevery day

5. Inside 3D Printing – Santa Clara ©2015 Wohlers Associates, Inc.
Industrial AM supply chainIndustrial AM supply chain
MetalsMetals ~11 years~11 years
Additive Metal AlloysAdditive Metal Alloys
AP&CAP&C
ATIATI
CarpenterCarpenter
ErasteelErasteel
H.C. StarckH.C. Starck
LPWLPW
NanoSteelNanoSteel
NorskNorsk TitaniumTitanium
PraxairPraxair
SandvikSandvik
VDM AlloysVDM Alloys
ALMALM
ArkemaArkema
CRP TechnologyCRP Technology
DSM SomosDSM Somos
EvonikEvonik
ExceltecExceltec
Oxford Performance MaterialsOxford Performance Materials
SABICSABIC
PolymersPolymers ~27 years~27 years
CAD modeling, modifications, setupCAD modeling, modifications, setup
AddingAdding of machining stockof machining stock
(must know all post steps)(must know all post steps)
BuildBuild packingpacking
PartPart orientationorientation
GE Aviation: 2GE Aviation: 2 practicepractice
builds prior to a production runbuilds prior to a production run
Support structureSupport structure optimizationoptimization
Source: Wohlers Report 2015Source: Wohlers Report 2015
Growth forecastGrowth forecast
$7.3B$7.3B
$12.7B$12.7B
$21.2B$21.2BQuadrupling inQuadrupling in 55 years:years:
StrongStrong industryindustry--wide growthwide growth
SummarySummary
Metal applicationsMetal applications growinggrowing
Metal AM isMetal AM is complexcomplex
Powder bedPowder bed metal systemsmetal systems
NewNew technologies, materials, companiestechnologies, materials, companies
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