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Dr Philip Reeves Rapid Manufacturing Eco-innovation in the context of recession TITLE Innov_ex09

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Dr Philip Reeves Rapid Manufacturing Innovation in the outdoor industries in the context of recession and the environment ALTERNATIVE & TRUTHFUL TITLE Innov_ex09

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Dr Philip Reeves Rapid Manufacturing Innovation & sustainability in the outdoor industries irrespective of recession ALTERNATIVE & TRUTHFUL TITLE Innov_ex09

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment – how can RM contribute </li></ul><ul><li>Innovation – how does RM enable </li></ul><ul><li>Outdoor Industries – where does RM fit </li></ul><ul><li>Outdoor Industries – where could RM fit </li></ul><ul><li>Questions </li></ul>Agenda

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment– how can it help </li></ul><ul><li>Innovation – how does it support it </li></ul><ul><li>Outdoor Industries – where does it fit </li></ul><ul><li>Outdoor Industries – where could it fit </li></ul><ul><li>Questions </li></ul>Agenda

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<ul><ul><li>Rapid Manufacturing is the manufacture of ‘ end-use ’ component parts using Additive Layer Manufacturing processes </li></ul></ul>WHAT IS RAPID MANUFACTURING? AGREEING TERMS

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<ul><li>There are Four fundamental manufacturing principles: </li></ul><ul><li>Subtractive </li></ul><ul><ul><li>Material is successively removed from a solid block until the desired shape is reached (2.5M BC – Hominids) </li></ul></ul><ul><li>Fabricative </li></ul><ul><ul><li>Elements or physical material are combined and joined (6,000 BC – Western Asia) </li></ul></ul><ul><li>Formative </li></ul><ul><ul><li>Mechanical forces and, or heat are applied to material to form it into the desired shape such as bending, casting and molding (3,000 BC – Egyptians) </li></ul></ul><ul><li>Additive </li></ul><ul><ul><li>Material is manipulated so that successive pieces of it combine to make the desired object (1985 – Californians) </li></ul></ul>How does ALM differ from traditional manufacturing

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<ul><ul><li>ALM processes are automated systems that take 2-dimensional layers of computer data and rebuild them into 3D solid objects </li></ul></ul>WHAT IS AN ALM PROCESS AGREEING TERMS

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ALM MATERIAL OPTIONS MATERIALS Waxes Polyamide (nylon) Organic materials Polymeric materials Metallic materials Ceramic materials ABS Glass filed Polyamide Composite loaded PA Thermosetting epoxies Ceramic (nano) loaded epoxies PMMA Polycarbonate Polyphenylsulfone Tool Steel Aluminium Titanium Inconel Cobalt Chrome Copper Stainless steel Mullite Alumina Zirconia Gold / platinum Silicon Carbide Hastelloy Aluminium loaded polyamide Beta-Tri calcium Phosphate Silica (sand) Plaster Graphite ULTEM

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<ul><ul><li>Prototypes (Rapid Prototyping) </li></ul></ul><ul><ul><li>Casting Patterns (Rapid Casting) </li></ul></ul><ul><ul><li>Tool cavities (Rapid Tooling) </li></ul></ul><ul><ul><li>Direct Parts (Rapid Manufacturing) </li></ul></ul>ALM IS THE ENABLER – RM IS THE APPLICATION AGREEING TERMS

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment– how can it help </li></ul><ul><li>Innovation – how does it support it </li></ul><ul><li>Outdoor Industries – where does it fit </li></ul><ul><li>Outdoor Industries – where could it fit </li></ul><ul><li>Questions </li></ul>Agenda

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THE PRIMARY BUSINESS DRIVERS <ul><li>RM reduced the need for tooling (moulds / jigs) </li></ul><ul><li>Risk mitigation </li></ul><ul><li>Enables the manufacture of low volume production (no fixed asset amortizations) </li></ul><ul><li>Simplifies the supply chain & reduces capital investment </li></ul><ul><li>Enables complicated assemblies to be built in one piece </li></ul>

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Enabling low volume complex part manufacture? CASE STUDIES

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment (sustainability) – how can RM help </li></ul><ul><li>Innovation – how does it support it </li></ul><ul><li>Outdoor Industries – where does it fit </li></ul><ul><li>Outdoor Industries – where could it fit </li></ul><ul><li>Questions </li></ul>Agenda

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<ul><li>Increased process & supply chain efficiencies </li></ul><ul><li>Less raw material usage </li></ul><ul><li>Less waste production & recycling </li></ul><ul><li>Less energy used in processing </li></ul><ul><li>Less transportation in the supply chain </li></ul><ul><li>Lighter weight more efficient products </li></ul>SUSTAINABILITY DRIVERS?

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A holistic approach SOLUTION

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TITANIUM ICE SCREWS SUSTAINABILITY 15,000 KWh per ton to extract 160 KWh per ton to CNC machine 8:1 – waste ratio Don’t machine from solid – sinter from powder!

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment– how can it help </li></ul><ul><li>Innovation – how does RM enable it </li></ul><ul><li>Outdoor Industries – where does it fit </li></ul><ul><li>Outdoor Industries – where could it fit </li></ul><ul><li>Questions </li></ul>Agenda

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THE PRIMARY BUSINESS BENEFITS OF RM <ul><li>RM enables complex geometries manufacture </li></ul><ul><li>RM enabled added functionality </li></ul><ul><li>RM enables optimised geometries </li></ul><ul><li>RM enables personalised products </li></ul><ul><li>RM enables distributed manufacture </li></ul><ul><li>Enables true just-in-time </li></ul><ul><li>Lean & agile = Legile </li></ul>

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(1) Images courtesy of Phonak www.phonak.com Design freedoms & personalized part manufacture? CASE STUDIES 1 2 3 4 5 6

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OBSERVATION “ Most current successful RM applications and business models are people-centric and driven by societal wants and needs ”

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment– how can it help </li></ul><ul><li>Innovation – how does it support it </li></ul><ul><li>Outdoor Industries – where does RM fit </li></ul><ul><li>Outdoor Industries – where could it fit </li></ul><ul><li>Questions </li></ul>Agenda

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<ul><li>Low volume </li></ul><ul><li>High value </li></ul><ul><li>Customised </li></ul><ul><li>Personalised </li></ul><ul><li>Niche </li></ul>OUTDOORS

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PETZL TECHNICAL ICE AXE EXAMPLE

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ECONOMICS & SUSTAINABILITY EXAMPLE PETZL TECHNICAL ICE AXE

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ERGONOMICS & PERSONALISATION EXAMPLE PETZL TECHNICAL ICE AXE

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BURTON SNOWBOARD BINDING EXAMPLE

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BURTON SNOWBOARD BINDING EXAMPLE ERGONOMICS, PERSONALISATION & MARKET DIFFERENCIATION

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PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE

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PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE ERGONOMICS, PERSONALISATION & PERFORMANCE

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PERSONAL PROTECTIVE EQUIPMENT (PPE) EXAMPLE

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<ul><li>Images courtesy of Liverpool University www.liv.ac.uk </li></ul>IMPACT ABSORBANCY EXAMPLE

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CUSTOM FOOTWARE EXAMPLE

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CUSTOM FOOTWARE EXAMPLE ORTHOTICS & PERFORMANCE

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CUSTOM ORTHESIS EXAMPLE

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CUSTOM ORTHESIS EXAMPLE PERFORMANCE, COMFORT & INCLUSIVITY

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<ul><li>Rapid Manufacturing – what is it </li></ul><ul><li>Recession – what are the business driver </li></ul><ul><li>Environment– how can it help </li></ul><ul><li>Innovation – how does it support it </li></ul><ul><li>Outdoor Industries – where does it fit </li></ul><ul><li>Outdoor Industries – where could RM fit </li></ul><ul><li>Questions </li></ul>Agenda

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Agenda OPPORTUNITIES + =

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Agenda OPPORTUNITIES + =

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Agenda OPPORTUNITIES + =

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<ul><li>Many successful applications of RM exist today </li></ul><ul><li>The best applications are people centric </li></ul><ul><li>Supporting consumers wants and needs </li></ul><ul><li>High value, low volume, Niche </li></ul><ul><li>Customize & Personalise </li></ul><ul><li>Product differentiation & competitive advantage </li></ul><ul><li>Sustainability & resource efficiency </li></ul><ul><li>Not so many current applications in the Outdoor Industries </li></ul><ul><li>I am sure the opportunities exist – talk to me if you have ideas! </li></ul>SUMMARY

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<ul><ul><li>QUESTIONS, OBSERVATIONS, DISCUSSION </li></ul></ul>END Dr Philip Reeves Econolyst Ltd The Silversmiths Crown Yard Wirksworth Derbyshire, UK DE4 4ET +44 (0) 1629 824447 [email_address] www.econolyst.co.uk www.rm-masterclass.com