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Metal 3D Printing - Trends & Emerging Technologies

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Metal 3D Printing - Trends & Emerging Technologies

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Descripción

Matt Sand, President of metal additive manufacturing company 3DEO, made this presentation at MD&M East, a leading conference in manufacturing medical devices and surgical instruments. His presentation covered the trends and emerging technology in metal 3D printing. This article summarizes the main trends he highlighted in the presentation.

Transcripción

  1. 1. 1 3DEO, Inc. © 2018 Metal 3D Printing Trends & Emerging Tech June 14, 2018
  2. 2. 2 3DEO, Inc. © 2018 Introduction
  3. 3. 3 3DEO, Inc. © 2018 Matt Sand ▪ President of 3DEO ▪ Serial entrepreneur with venture capital experience ▪ Officer in U.S. Air Force ▪ MBA from UCLA ▪ Email: matt.sand@3deo.co
  4. 4. 4 3DEO, Inc. © 2018 3DEO – Low-cost Production Metal AM www.3DEO.co
  5. 5. 5 3DEO, Inc. © 2018 Today’s Presentation ▪ Intro to Metal Additive Manufacturing (AM) ▪ Metal AM will change manufacturing ▪ Industry Trends ▪ AM vs. Traditional Manufacturing
  6. 6. 6 3DEO, Inc. © 2018 Intro to Metal Additive Manufacturing
  7. 7. 7 3DEO, Inc. © 2018 Setting the Stage… ▪ Forget everything you know about plastic 3D printing ▪ AM = Additive Manufacturing ▪ AM = 3D Printing ▪ Sintering ▪ Don’t hesitate to ask questions!
  8. 8. 8 3DEO, Inc. © 2018 Understanding Additive Manufacturing 3D model → Slicing → Printing → Post Processing
  9. 9. 9 3DEO, Inc. © 2018 Different metal AM Processes ▪ Powder Bed Fusion ▪ Binder Jetting ▪ Extrusion (FDM) ▪ Directed Energy Deposition ▪ Material Jetting ▪ Intelligent Layering® ▪ And more soon…
  10. 10. 10 3DEO, Inc. © 2018 Powder Bed Fusion Advantages ▪ Highly complex geometries ▪ Widest range of materials ▪ Large parts ▪ Good material properties Disadvantages ▪ High cost, degrading process ▪ Slow process ▪ Rough surface ▪ Weaker Z axis
  11. 11. 11 3DEO, Inc. © 2018 Binder Jetting Advantages ▪ Lower cost than PBF ▪ Faster than PBF Disadvantages ▪ Matrix composite materials ▪ Degrading inkjet process
  12. 12. 12 3DEO, Inc. © 2018 Extrusion (FDM) Advantages ▪ Lower cost ▪ Great for prototyping ▪ High precision, fine layers Disadvantages ▪ Limited production possibilities ▪ High binder content ▪ Shrinkage in sintering ▪ Supports required
  13. 13. 13 3DEO, Inc. © 2018 Directed Energy Deposition (DED) Advantages ▪ Fast builds with rapid material deposition ▪ Fully dense parts ▪ No need for supports Disadvantages ▪ Poor surface finish ▪ Wire less accurate ▪ Significant post processing
  14. 14. 14 3DEO, Inc. © 2018 Material Jetting Advantages ▪ Nanoscale = high resolution ▪ No loose powder, easier/safer to handle ▪ Very nice surface finish Disadvantages ▪ Expensive, slow process ▪ Small parts
  15. 15. 15 3DEO, Inc. © 2018 3DEO’s Intelligent Layering® Advantages ▪ Very low-cost process ▪ Nice surface finish ▪ Meets industry standard ▪ No degrading processes Disadvantages ▪ Shrinkage limits geometries ▪ Smaller parts
  16. 16. 16 3DEO, Inc. © 2018 It’s complicated…
  17. 17. 17 3DEO, Inc. © 2018 Metal AM will fundamentally Change manufacturing
  18. 18. 18 3DEO, Inc. © 2018 Gartner’s Technology Hype Cycle
  19. 19. 19 3DEO, Inc. © 2018 False start around 2012
  20. 20. 20 3DEO, Inc. © 2018 This time, the hype is (mostly) real
  21. 21. 21 3DEO, Inc. © 2018 Why AM will fundamentally change mfg. ▪ New, previously impossible designs ▪ Design for FUNCTION ▪ Mass customization ▪ Parts consolidation, light-weighting, internal channels ▪ On-demand manufacturing ▪ Eliminates inventory, supply chain becomes “demand chain” ▪ Low lead time, immediate turnaround ▪ FAST innovation / product development
  22. 22. 22 3DEO, Inc. © 2018 Light-weighting, honeycomb structure
  23. 23. 23 3DEO, Inc. © 2018 Part Consolidation Previously 20 pieces, now 1; 25% lighter, 5x stronger
  24. 24. 24 3DEO, Inc. © 2018 Extremely Complex Internal Channels
  25. 25. 25 3DEO, Inc. © 2018 Optimized Design for Function
  26. 26. 26 3DEO, Inc. © 2018 Combination of consolidation & function 20% less fuel, 5% lower weight, 855 parts → 12 parts
  27. 27. 27 3DEO, Inc. © 2018 Broad 3D Printing Industry Trends
  28. 28. 28 3DEO, Inc. © 2018 Explosion of different types of 3D printing ▪ Plastics & metals, of course ▪ Organs?!? ▪ Food: Chocolate & Pancakes ▪ Real estate – entire homes!
  29. 29. 29 3DEO, Inc. © 2018 Broad adoption is at an inflection point
  30. 30. 30 3DEO, Inc. © 2018 This is the year of metal ▪ 80% increase in sales of metal AM machine in ’17 (1,768 machines)
  31. 31. 31 3DEO, Inc. © 2018 Main Trend: Focus on Production ▪ Until now, 3D printing has been prototyping tech ▪ Every 3D printer wants to get into production ▪ What’s missing? ▪ Scalability of tech ▪ Consistent part quality ▪ Reduce the cost of parts
  32. 32. 32 3DEO, Inc. © 2018 Scalability of technology ▪ Different approaches ▪ Parallel manufacturing - 3D Systems Figure Four ▪ New technologies
  33. 33. 33 3DEO, Inc. © 2018 Consistent Part quality ▪ Verifying part quality can be 40-50% of part cost ▪ Terabytes of data generated in a build ▪ How can we be sure the build is good?
  34. 34. 34 3DEO, Inc. © 2018 reduce the cost of parts ▪ Part cost breaks down to four main components: ▪ Machine time ▪ Materials cost ▪ Labor cost ▪ Secondary operations
  35. 35. 35 3DEO, Inc. © 2018 Flood of New Entrants ▪ FDM & Binder Jetting patents expired ▪ MANY new METAL companies ▪ Stealth technologies – many innovations in the works
  36. 36. 36 3DEO, Inc. © 2018 Dose of Reality ▪ Previously – “3D Printing will take over manufacturing!” ▪ Now – “3D printing will be one of many tools in the toolkit!” ▪ We better understand where 3D printing fits, and applications that make real business sense
  37. 37. 37 3DEO, Inc. © 2018 Advances in Software ▪ Will become much easier to optimize a design for AM ▪ Streamlined workflows ▪ Integrated software
  38. 38. 38 3DEO, Inc. © 2018 Advances in Automation ▪ Factory of the Future ▪ Automation of processes ▪ Hybrid technologies ▪ Figure 4 ▪ 3DEO’s fully automated line
  39. 39. 39 3DEO, Inc. © 2018 Additive Vs. traditional manufacturing
  40. 40. 40 3DEO, Inc. © 2018 AM Vs. Traditional manufacturing Traditional AM Tooling Yes (can be costly) None MOQ Thousands One Lead Times Months to years Days to weeks Ease of Innovation Difficult & costly Easy & inexpensive Material Waste Medium to high Low Complexity Costly “Free” Quantities High Low to medium
  41. 41. 41 3DEO, Inc. © 2018 Cost vs. Complexity
  42. 42. 42 3DEO, Inc. © 2018 Cost vs. quantity Traditional Mfg. Additive Mfg.
  43. 43. 43 3DEO, Inc. © 2018 Low-volume Example cost calculations Tool/Setup Costs CPP 100 CPP 1,000 Lead Time Machining $500 $25.75 $22.00 8 Weeks AM $0 $11.44 $11.44 10 Days MIM $50,000 $503.23 $53.23 100 days
  44. 44. 44 3DEO, Inc. © 2018 Questions? Matt Sand President Matt.Sand@3DEO.co (310) 694-6847 Company Contact www.3DEO.co info@3DEO.co (844) 49-METAL

Descripción

Matt Sand, President of metal additive manufacturing company 3DEO, made this presentation at MD&M East, a leading conference in manufacturing medical devices and surgical instruments. His presentation covered the trends and emerging technology in metal 3D printing. This article summarizes the main trends he highlighted in the presentation.

Transcripción

  1. 1. 1 3DEO, Inc. © 2018 Metal 3D Printing Trends & Emerging Tech June 14, 2018
  2. 2. 2 3DEO, Inc. © 2018 Introduction
  3. 3. 3 3DEO, Inc. © 2018 Matt Sand ▪ President of 3DEO ▪ Serial entrepreneur with venture capital experience ▪ Officer in U.S. Air Force ▪ MBA from UCLA ▪ Email: matt.sand@3deo.co
  4. 4. 4 3DEO, Inc. © 2018 3DEO – Low-cost Production Metal AM www.3DEO.co
  5. 5. 5 3DEO, Inc. © 2018 Today’s Presentation ▪ Intro to Metal Additive Manufacturing (AM) ▪ Metal AM will change manufacturing ▪ Industry Trends ▪ AM vs. Traditional Manufacturing
  6. 6. 6 3DEO, Inc. © 2018 Intro to Metal Additive Manufacturing
  7. 7. 7 3DEO, Inc. © 2018 Setting the Stage… ▪ Forget everything you know about plastic 3D printing ▪ AM = Additive Manufacturing ▪ AM = 3D Printing ▪ Sintering ▪ Don’t hesitate to ask questions!
  8. 8. 8 3DEO, Inc. © 2018 Understanding Additive Manufacturing 3D model → Slicing → Printing → Post Processing
  9. 9. 9 3DEO, Inc. © 2018 Different metal AM Processes ▪ Powder Bed Fusion ▪ Binder Jetting ▪ Extrusion (FDM) ▪ Directed Energy Deposition ▪ Material Jetting ▪ Intelligent Layering® ▪ And more soon…
  10. 10. 10 3DEO, Inc. © 2018 Powder Bed Fusion Advantages ▪ Highly complex geometries ▪ Widest range of materials ▪ Large parts ▪ Good material properties Disadvantages ▪ High cost, degrading process ▪ Slow process ▪ Rough surface ▪ Weaker Z axis
  11. 11. 11 3DEO, Inc. © 2018 Binder Jetting Advantages ▪ Lower cost than PBF ▪ Faster than PBF Disadvantages ▪ Matrix composite materials ▪ Degrading inkjet process
  12. 12. 12 3DEO, Inc. © 2018 Extrusion (FDM) Advantages ▪ Lower cost ▪ Great for prototyping ▪ High precision, fine layers Disadvantages ▪ Limited production possibilities ▪ High binder content ▪ Shrinkage in sintering ▪ Supports required
  13. 13. 13 3DEO, Inc. © 2018 Directed Energy Deposition (DED) Advantages ▪ Fast builds with rapid material deposition ▪ Fully dense parts ▪ No need for supports Disadvantages ▪ Poor surface finish ▪ Wire less accurate ▪ Significant post processing
  14. 14. 14 3DEO, Inc. © 2018 Material Jetting Advantages ▪ Nanoscale = high resolution ▪ No loose powder, easier/safer to handle ▪ Very nice surface finish Disadvantages ▪ Expensive, slow process ▪ Small parts
  15. 15. 15 3DEO, Inc. © 2018 3DEO’s Intelligent Layering® Advantages ▪ Very low-cost process ▪ Nice surface finish ▪ Meets industry standard ▪ No degrading processes Disadvantages ▪ Shrinkage limits geometries ▪ Smaller parts
  16. 16. 16 3DEO, Inc. © 2018 It’s complicated…
  17. 17. 17 3DEO, Inc. © 2018 Metal AM will fundamentally Change manufacturing
  18. 18. 18 3DEO, Inc. © 2018 Gartner’s Technology Hype Cycle
  19. 19. 19 3DEO, Inc. © 2018 False start around 2012
  20. 20. 20 3DEO, Inc. © 2018 This time, the hype is (mostly) real
  21. 21. 21 3DEO, Inc. © 2018 Why AM will fundamentally change mfg. ▪ New, previously impossible designs ▪ Design for FUNCTION ▪ Mass customization ▪ Parts consolidation, light-weighting, internal channels ▪ On-demand manufacturing ▪ Eliminates inventory, supply chain becomes “demand chain” ▪ Low lead time, immediate turnaround ▪ FAST innovation / product development
  22. 22. 22 3DEO, Inc. © 2018 Light-weighting, honeycomb structure
  23. 23. 23 3DEO, Inc. © 2018 Part Consolidation Previously 20 pieces, now 1; 25% lighter, 5x stronger
  24. 24. 24 3DEO, Inc. © 2018 Extremely Complex Internal Channels
  25. 25. 25 3DEO, Inc. © 2018 Optimized Design for Function
  26. 26. 26 3DEO, Inc. © 2018 Combination of consolidation & function 20% less fuel, 5% lower weight, 855 parts → 12 parts
  27. 27. 27 3DEO, Inc. © 2018 Broad 3D Printing Industry Trends
  28. 28. 28 3DEO, Inc. © 2018 Explosion of different types of 3D printing ▪ Plastics & metals, of course ▪ Organs?!? ▪ Food: Chocolate & Pancakes ▪ Real estate – entire homes!
  29. 29. 29 3DEO, Inc. © 2018 Broad adoption is at an inflection point
  30. 30. 30 3DEO, Inc. © 2018 This is the year of metal ▪ 80% increase in sales of metal AM machine in ’17 (1,768 machines)
  31. 31. 31 3DEO, Inc. © 2018 Main Trend: Focus on Production ▪ Until now, 3D printing has been prototyping tech ▪ Every 3D printer wants to get into production ▪ What’s missing? ▪ Scalability of tech ▪ Consistent part quality ▪ Reduce the cost of parts
  32. 32. 32 3DEO, Inc. © 2018 Scalability of technology ▪ Different approaches ▪ Parallel manufacturing - 3D Systems Figure Four ▪ New technologies
  33. 33. 33 3DEO, Inc. © 2018 Consistent Part quality ▪ Verifying part quality can be 40-50% of part cost ▪ Terabytes of data generated in a build ▪ How can we be sure the build is good?
  34. 34. 34 3DEO, Inc. © 2018 reduce the cost of parts ▪ Part cost breaks down to four main components: ▪ Machine time ▪ Materials cost ▪ Labor cost ▪ Secondary operations
  35. 35. 35 3DEO, Inc. © 2018 Flood of New Entrants ▪ FDM & Binder Jetting patents expired ▪ MANY new METAL companies ▪ Stealth technologies – many innovations in the works
  36. 36. 36 3DEO, Inc. © 2018 Dose of Reality ▪ Previously – “3D Printing will take over manufacturing!” ▪ Now – “3D printing will be one of many tools in the toolkit!” ▪ We better understand where 3D printing fits, and applications that make real business sense
  37. 37. 37 3DEO, Inc. © 2018 Advances in Software ▪ Will become much easier to optimize a design for AM ▪ Streamlined workflows ▪ Integrated software
  38. 38. 38 3DEO, Inc. © 2018 Advances in Automation ▪ Factory of the Future ▪ Automation of processes ▪ Hybrid technologies ▪ Figure 4 ▪ 3DEO’s fully automated line
  39. 39. 39 3DEO, Inc. © 2018 Additive Vs. traditional manufacturing
  40. 40. 40 3DEO, Inc. © 2018 AM Vs. Traditional manufacturing Traditional AM Tooling Yes (can be costly) None MOQ Thousands One Lead Times Months to years Days to weeks Ease of Innovation Difficult & costly Easy & inexpensive Material Waste Medium to high Low Complexity Costly “Free” Quantities High Low to medium
  41. 41. 41 3DEO, Inc. © 2018 Cost vs. Complexity
  42. 42. 42 3DEO, Inc. © 2018 Cost vs. quantity Traditional Mfg. Additive Mfg.
  43. 43. 43 3DEO, Inc. © 2018 Low-volume Example cost calculations Tool/Setup Costs CPP 100 CPP 1,000 Lead Time Machining $500 $25.75 $22.00 8 Weeks AM $0 $11.44 $11.44 10 Days MIM $50,000 $503.23 $53.23 100 days
  44. 44. 44 3DEO, Inc. © 2018 Questions? Matt Sand President Matt.Sand@3DEO.co (310) 694-6847 Company Contact www.3DEO.co info@3DEO.co (844) 49-METAL

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