3D printing: hype or industrial revolution? · Ink-jet printing of 2D layers Laser scanning of 2D...

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Let Additive Manufacturing Inspire You

3D printing: hype or industrial revolution?

Peter Mercelis, PhD

2014/04/30

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Introduction to Layerwise

Technology basics – what’s in a name?

Applications of 3DP

New technology introduction process

Role of engineers within our organization

Contents

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LayerWise

Incorporated in 2008 as spin-off from university of Leuven K.U.Leuven prof. Jean-Pierre Kruth

Focus on metal AM only

Unique technological expertise in metal AM since 2001 Phd Jonas Van Vaerenbergh

Phd Peter Mercelis

12 years experience with AM titanium

Developing AM technology and applications together with our customers

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LayerWise markets

chemical pharma

pressure & gas precision mechanics

semicon tooling

food electronics

imaging

standard implants customized implants medical instruments

dental prostheses implant supported

and cemented

aviation space

ISO 9001 and ISO 13485 certified

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Technology basics

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Various technologies are today called “3D Printing”

In the past, many different names were used to refer to Additive Manufacturing technologies;

Rapid Prototyping

Rapid Manufacturing

Technology basics

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Basic principle; 3D object is manufactured as a stack of 2D layers that are interconnected

Technology basics

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Technology basics

Directly from 3D CAD Layer-wise production 3D components by successive

connection of thin 2D layers

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3D complexity is reduced to 2D complexity! Constructing 2D geometries is easier than constructing 3D

geometries! Various methods possible to generate 2D layers

Ink-jet printing of 2D layers Laser scanning of 2D layers Moving ejector nozzles ….

Various materials possible to generate 2D layers Plastics, polymers Metals and metal alloys Ceramic materials Organic materials Food …

Technology basics

3DP allows build ‘impossible shapes’ and assemblies

Technology basics

Applications of 3D printing

Consumer applications

Industrial applications

Medical applications

Applications of 3DP

Home use 3D printers

Available for low prices (< 1000 €)

Low entry barrier

Online 3D printing services

Shapeways, iMaterialise, etc.

Consumer applications of 3DP

Architectural models

Jewelry

Design

Fashion

Online 3D printing websites give everyone access to 3DP technology

Applications currently rather limited;

Action figures

Gadgets

Jewelry

But other things are also possible …

Prototyping applications

Extremely short lead times possible

Visual prototypes

Functional prototypes

Industrial applications of AM

As always, technology can be used for the good and for the bad

AM of function parts; industry drivers

Manufacturing Cost Total cost of ownership & performance

Mostly small parts

cost weight

all size of parts

Tool-less manufacturing

Single step production

• Monolithic construction

• Reduced # components

• Flow-optimized

• Miniaturization

• Customization

• Mass reduction

Short time to market Flexible production

Use of internal cooling channels in tooling applications

Mass production of ejector nozzles in food industry

Aerospace applications

Weight savings

Complex shaped

Integrated functionality

Digital manufacturing is perfectly adapted to patient-specific instruments and implants!

Medical imaging (CT scans, MRI, etc. ) already provides 3D digital input!

Bio-compatible materials (e.g. titanium) can be processed with AM technology

Medical applications of AM

Patient specific hearing aids

Patient specific imprint

3D scanning and digital design

Digital printing of hearing aid housing

Facial reconstructions; printing of soft tissue replacements

Facial reconstructions; printing of bone tissue replacements

First 3DP printed jawbone prosthesis

Patient specific and standard orthopedic implants

Illustration of series production; veterinarian implants for treatment of dogs

> 10,000 per year

Current media hype on 3DP created unrealistic expectations!

Organ printing possible in the near future …

Everyone should have a 3D Printer @ home …

Everything can be 3D printed …

3D printing is cheap …

Risks of the current 3DP hype

Importance of realistic expectations!

3DP is NOT a cheap manufacturing technology

Traditional manufacturing will not dissapear!

3DP often needs to be combined with traditional manufacturing methods

Traditional manufacturing techniques generally have higher accuracy than 3DP

Limited number of materials possible

Size limitations limit the application field

Printing of living tissue is still in its infancy!

Risks of the current 3DP hype

Essence: the new technology should add value to the product/service compared with the traditional technology

Added value: product/service definition Increased functionality = technical improvement Improved appearance = esthetic improvement Reduced drawbacks!

Ergonomics Safety Complexity Reliability Maintenance …

Your technology should increase added value

of your direct customer

of the end customer only = more difficult

of your direct customer and the end customer = easiest + synergetic

Regulation; Existing products or markets are often regulated by

government or by industry Examples:

Medical implants standards (ISO / ASTM / FDA …) E.g. ASTM F2068 - 09 Standard Specification for Femoral

Prostheses—Metallic Implants

Quality management systems (Medical / Aerospace …) E.g. AS 9000 or Aerospace Basic Quality System

Technology standards; E.g. ASTM F1472 - 08e1 Standard Specification for Wrought

Titanium-6Aluminum-4Vanadium Alloy for Surgical Implant Applications (UNS R56400)

Often no standards exist yet for a new technology in an existing market/ product category!

Innovative technology itself can be a trigger to convince innovators!

But; this is a short term effect, in the end the it is the added value that counts to convince the early adoptors and the majority

Strategy; try to become a chameleon after convincing the innovators Most customers are not

interested in technology, but simply want added value in their products or services

Risk aversion of most (large) companies demands full compliance to their existing technologies, habits, existing standards and personal opinions …

Illustration; dental prosthetics Traditional technology:

Analog imprints

Wax modelling

Casting technique

Labour intensive

Inaccurate

Recent technologies: Digital prosthesis design

Digital prosthesis manufacturing; CNC milling

3D printing / Additive Manufacturing

Dental prostheses @ DentWise

Digitalisation of the design and manufacturing process

Digital scanning at dentist practise is the logical next step

Knowledge and expertise needed @ LayerWise Hard skills:

Machine design (mechanics)

System and control theory

Laser and optics

Software development

Metallurgy

Process engineering

Soft skills: Project management

Technical writing

(Small team) management skills

Role of engineers @ LayerWise

Equally important but often neglected

Budget responsibility

Continuous improvement mindset

Commercial insight

‘multiple hat attitude’

IP basics; DO’s and DON’ts

Basic legal knowledge

Pragmatic approach

Boerenverstand (sorry, no englisch translation)

Role of engineers @ LayerWise

3D printing is currently in a hype

However, application domains are all over

Although some might look as science fiction

Future outlook

They are not that far from reality

Future outlook

Images by LayerWise, DentWise, Materialise, Freedom of Creation, Mobelife, EOS, Concept Laser, 3D Systems, Arcam, Dizingof and Stratasys

Source files

Let Additive Manufacturing Inspire You

Click to edit Master subtitle style

LayerWise NV Grauwmeer 14

3001 Leuven Belgium

Tel.: +32 16 94 64 00 www.layerwise.com

3D printing: hype or industrial revolution? · Ink-jet printing of 2D layers Laser scanning of 2D...

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