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by Oliver Zechlin
3D-Printing
Summary
Industrial 3D-printing is at a tipping point and about to go mainstream. The technology
has moved well beyond prototyping, rapid tooling and toys.
“Additive Manufacturing” is creating products for customers in moderate to large
quantities, already.
Contents1 | Technical Conditions ................................................... 2
2 | Applications ................................................................ 8
3 | Concerns & Misuse .................................................... 20
4 | Benefits ..................................................................... 23
5 | Business Opportunities .............................................. 30
6 | Outlook ..................................................................... 32
3D-Printing - Technical Conditions2
1Two different processes but imagine the possibilities that could result from having the best of both worlds.
Additive Manufacturing
In additive processes an object is created by
laying down successive layers of material.
Subtractive Manufacturing
Subtractive manufacturing is like carving a figure from a
solid block. Remove material, layer by layer, until you end
up with your finished model.
Subtractive vs. Additive Manufacturing
3D-Printing - Technical Conditions3
1
Laser
Laser technology is used to sinter
powdered materials.
Powdered metal
With recent advances in additive manufacturing
technology, metal and ceramic based printed
materials are becoming ever more common.
Layer by Layer
Highly efficient by using almost 100% of the printing
material, leading to minimal or zero waste.
How Additive Manufacturing works
3D-Printing - Technical Conditions4
1
CLIP
CLIP (continuous liquid interface production technology) operates through photo polymerization.
CLIP “grows” objects, rather than building them in layers.
Traditional 3D-Printing requires a number of mechanical steps, repeated over and over again in a
layer-by-layer approach. CLIP is a chemical process that balances light and oxygen to eliminate the
mechanical steps and the layers.
It works by projecting light through an oxygen-permeable window into a reservoir of UV curable
resin. The build platform lifts continuously as the object is grown. It is 25-100 times faster than
traditional 3D-printing technologies.
UV printing is different from conventional printing in many ways.
UV-Printing
3D-Printing - Technical Conditions5
1Required CAD data to print a product can easily be provided around the clock around the world.
worldwide
local printing
Wherever - whenever
Branded market places and platforms will provide customers licensed print files in
standardized formats:
Data structures
.stl.wrl
.vrlm2
BIMPhotographs
CAD Data
Scans
Different and multiple data sources may be used to facilitate 3D-Printing and manufacturing.
3D-Printing - Technical Conditions6
1 Construction size
LargeNano Small What comes next ?Medium
Print anything. From the very small to large sized products – 3D manufacturing covers it all.
35m
Super size your project
There are nearly no limits for construc-
tion sizes like printing buildings with a
suitable concrete and technology.
3D-Printing - Technical Conditions7
1 Materials
Metal
Carbon
Cement / concrete
Wood fibre composites
What is next?
Organic substances
Silicon
Plastic
Depending on the printing method - additive, substractive or UV based processes - many different materials may be used. 2015 already approximately 1250 printing materials are available. By 2020 you will be able to choose between 2000 materials.
8
2 Manufacturing End Products
3D-Printing - Applications
Customize unique items
Siemens uses AM to create In-
the-Ear hearing aids, for example.
Such hearing aids are individually
adapted to the wearer‘s auditory
canal.
Small batches
It is very costly to create molds and
production lines for small batches.
Such items can be produced cost-
efficiently with AM.
Very complex workpieces
AM can be used to produce very
complex workpieces, which would be
almost impossible to create with previ-
ously available techniques. One possible
area of application is that of gas turbine
blades, in which ventilation ducts could
be integrated for cooling.
Additive manufacturing will supplement conventional mass production methods, not replace them (for the time being). AM already offers unique advantages over traditional manufacturing, though.
9
Kidney
Artificial kidney
Stents
Artificial teeth
Hearing instruments
2 Biomedical engineering
3D-Printing - Applications
Artificial constructions of biomedical materials are becoming a reality. Medicines, artificial prosthetics, and even human tissue will be a part of everyday life in the hospital of the future.
10
2 Bridge construction
3D-Printing - Applications
3D-Printing allows the manufacturing of bridge parts like pavements or even the construction work of an entire site.
Bridge the gap
Think and print „outside the box“. Robots can draw steel structures in 3D with beautiful,
functional objects in almost any form.
11
Roof printing
Printing all parts including subsections
printed in one go
3D data can be visualized, customized and simulated until the result is as desired and the building is ready for manufacturing.
House construction / complex items
3D-Printing - Applications
2
12
2 Aeronautics / Astronautics
Printing complex items
Printing replacements parts leads to an effective implementation of enhancements without raising the development costs.
Conventionally manufactured nozzles had to be assembled from 20 separately cast parts. Cuts cost of manufacturing by
75%. It is 25% lighter, five times stronger and more efficient.
NASA had a 3D printer sent up to the space station.
NEW
NEWBroken
3D-Printing - Applications
The possibility of 3D manufacturing reduces time, and costs for individual parts of this industry.
13
2 Vehicles
Drive global - print local
Vehicles may be manufactured decentralized at
local manufacturing hubs.
Cars get still build in the same way there were in 1915 -
on assembly lines with thousands of individual parts.
In comparison, a locally printed car only needs about 50 parts.
3D-Printing - Applications
Printing cars with the 3D technology will revolutionize the entire automotive industry and their suppliers.
Local printing
today in few years
14 3D-Printing - Applications
2 Construction of industrial spare parts
On-site printing
Fast on-site production of mission critical spare parts
reducing expensive downtime.
NEWBroken
Data for local printing
15
2 Construction of models (architectural)
3D-Printing - Applications
Print small-scaled items of the desired interior design. Visualize space, dimensions and physical appearance hands-on in 3D.
Even if this room looks very good it would be perfect if this sofa will
be about 20cm larger.
2
16
NEW
Print required spare parts at home or in your neighborhood 3D print shop.
Replacement Parts
3D-Printing - Applications
17
2 Printing electronics
3D-Printing - Applications
PCB is the abbreviation for „printed circuit board“ - in the truest sense of the word.
Benefits
Print the carrier with the required
imprint for the electrical routing
and connections with individual
materials.
• Eco-friendly (laser engraving = no need for harmful chemicals)
• Resistant (Elastomers are water-, solvent, UV-, and ozone-resistant)
• Cost-effective (reduces material cost)
• Resolution (ultrafine structures are possible)
Print the components, such as
semiconductors, resistors… Get your finished PCB -
ready for operation.
18
2 Batteries
3D-Printing - Applications
Manufacturing of chargeable batteries in different shapes or sizes for multiple applications and requirements.
Print required size or capacity of a battery - even directly into or onto the
surface of a product.
19
2 Nano-Printing
3D-Printing - Applications
Remarkable facts
Nano Offset Printing can print structures more than
1000 times thinner than a human hair. It will operate at
up to 100th of today’s electronics nanofabrication cost.
Manufacturing on the micrometer scale will be supported by a suitable technology.
20
3
3D-Printing - Concerns & Misuse
1 : 1 Duplicate
Create easily a duplicate of unique items.
Be aware of misuse
By simply taking a picture of your door key anyone could build a functional copy.
Data for local printing
Duplicate
21
3 Plagiarism
3D-Printing - Concerns & Misuse
Almost everything can be copied.
Original or Duplicate?
There will be a new big market for counterfeiters (and lawyers), as well as difficult situations
for manufacturers of original rights-protected product.
3D printers shift IP considerations by making infringement happen not only faster but much
harder to find. 3D printing may increase the number of potential infringers and accelerates
their time-to-market.§
Original Duplicate
22
3 Approvals / warranty
3D-Printing - Concerns & Misuse
3D printed products like spare parts must fulfill the condition of all legal requirements.
NormsProduct approvals
§In the case of printing a spare
part on your own using a licensed
file - who is the manufacturer?
Warranty
23
4 Production of spare parts
reduction of labor costs
faster repairs
40%
90%
Local manufacturing
Get required data to print parts from anywhere - locally and global. Reduce
environmental impact due to improved shipping and delivery processes.
Local manufacturing can reduce effort and cost for transportation, warehousing and process.
3D-Printing - Benefits
24
2003
0
5
10
15
20
25
30
2004 2005 2006 2007 2008 2009 2010 2011 2012
Income from AM end products %
End products share of the total income from AM products and services.
Trend: From Rapid Prototyping to Series Productionyear 2012 28.3%
3.9
6.6
8.3 9.611.7
14
17.2
19.6
24
28.3
Rapid prototyping is the process of quickly mocking up the future state of a single item or an entire system.
Rapid Prototyping
Rapid prototyping helps teams experiment with multiple
approaches and ideas. It facilitates discussion through a
hands-on approach instead of just words and pictures.
It can ensure that everyone shares a common under-
standing and reduces the risk of missing customer
requirements. Rapid prototyping leads to a faster and
better design.
Rapid ‘real time’ Prototyping
3D-Printing - Benefits
4
25
400%fastercheaper
In the next five years*
50%
Forecast:Production costs for AM with metal (€/cm3)
Forecast:Production speed (cm3/h)
* Assuming manufacturers of AM systems improve process stability and achieve a fourhold increase in the production rate.
10cm3/h40cm3/h
80cm3/h
2013 2018 2023
73% Indirect27% Direct
59% Indirect41% Direct
2013 2018 2023
75% Indirect25% Direct
Effort / Cost Manpower Stock keeping / Material
Declining costs
3D-Printing - Benefits
4
26
CO2 Traffic congestion Logistics industry
3D-printing reduces manufacturing-
related CO2 emission.
Regional 3D-printing reduces traffic
congestion, motor vehicle emissions
and pavement wear.
Downscale warehousing and
convert third-party logistics into
mini-factories.
Reduce environmental impact
3D-Printing - Benefits
4
27
4 Local manufacturing
3D-Printing - Benefits
Cloud data for local printing
fire detector is broken
Enforce your maintenance support with local manufacturing options and reduce service time and missing spare parts.
Faulty products ?
Take a photo - use image recognition
technology - get data - manufacture a
spare part - service completed.
28
4 Rapid market growth
1.00.90.80.50.40.40.30.2<0.1<0.1
0.5
1.7
2.2
4.5
year 2023 €7.7 billion
3D-Printing - Benefits
Additive manufacturing market
worldwide, development and forecast (in billions of euros)
1990 2000 2010 2013 2018 2023
29
4 Further Benefits…
3D-Printing - Benefits
• You can build things that are impossible
• You can take more (design) risks: you just stop
producing w/out having filled warehouse.
• Improve the design-to-manufacturing process, making
low-volume production-based jigs, castings and molds.
• Small companies can compete (analogy to YouTube vs.
traditional video production). Less upfront investment
required (machines, equipment, tooling).
• Saving resources
• Flexibility
• No assembly required - production in single run using
different material properties, instead of having to use
different molds
30
5 Ready for Additive Manufacturing?
Production readiness level
Dentistry and dental technology Capable of full-scale production
Initial systems already manufactured
Concept phase and lab tests
Machine tool manufacturing
Aerospace
3D-Printing - Business Opportunities
Additive manufacturing
Sector overview
31
5
3D-Printing - Business Opportunities
Ready for Industry 4.0?
Industry 4.0 will address and solve some of the
challenges facing the world today such as resource
and energy efficiency, urban production and demo-
graphic change.
Industry 4.0 holds huge potential. Smart factories allow individual customer requirements to be met and mean that even one-off items can be manufactured profitably.
It is reality and it becomes a daily business.
A high flexibility enables – on one hand - an easy customization of goods and on the other
hand also eliminates assembly and inventories. The flexibility of 3D printing systems and
fragmentation in many product categories will then take off.
Additive manufacturing will reduce conventional mass production’s market share.
Already in the year 2020 fully automated, high-speed and economical AM systems will be
available to manufacture standardized parts.
6 Outlook
3D-Printing
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