Additive

Studentská 1402/2 | 461 17 Liberec 1 | tel.: +420 485 353 342 | [email protected] |cxi.tul.cz | Personal website: http://bit.ly/eldessouki

Additive Manufacturing and SMEs:

Opportunities and Challenges

Dr. Mohamed EldessoukiInstitute for Nanomaterials, Advanced Technologies and Innovation

Technical University of Liberec (Liberec, Czech Republic)

www.excelr.com/industrial-revolution-4-0/


Alliance for Additive

Manufacturing in Central Europe

(AMiCE)


Additive Manufacturing

is part of the current

Industrial Revolution 4.0

➢What is “Additive Manufacturing”?

➢What is “Industrial Revolution 4.0”?

➢What is a “Revolution”?


What is a “Revolution”?

Revolution = Abrupt and Fundamental Change


Human MilestonesCognitive Revolution

Language, writing, social formulations

sites.google.com/a/hope.ac.uk/cognitive-development-jennifer-sullivan/the-cognitive-revolution


Human MilestonesAgricultural Revolution

Settlement, domestication of animals and their use in human service,

…etc

www.ancient-origins.net/history-important-events/neolithic-revolution-0010298


Human MilestonesScientific Revolution

From muscle to mechanical power, digital…etc

/www.worldatlas.com/articles/what-was-the-scientific-revolution-of-the-16th-through-18th-centuries.html


Scientific RevolutionEmbrace our IGNORANCE

https://learnodo-newtonic.com/industrial-revolution-facts /www.businessbecause.com/online-mba/2897/digital-revolution-in-business-education-poised-to-take-off

www.zmescience.com/science/news-science/who-discovered-america-21102017/

Geographical RevolutionChristopher Columbus

Amerigo Vespucci

Industrial Revolution Digital Revolution


4. Industrial revolutionBased on cyber-physical-systems

3. Industrial revolution Through the use of electronicsand IT further progression inautonomous production

2. Industrial revolution Introducing mass production lines powered by electric energy

1. Industrial revolutionIntroducing mechanical production machines poweredby water and steam

End of the 18th century

Beginning of the 20th century

Beginning of the 70th

Industry 1.0 Industry 3.0Industry 2.0 Industry 4.0

Leve

l of

com

ple

xity

Source: DFKI/Bauer IAOToday

Industrial Revolutions


Cyber-Physical Systems (CPS)• Definition: A system of collaborating

computational elements controlling physical

entities.

• CPS allows adding more capabilities to physical

systems, such as:

– Monitoring physical processes,

– Creating a virtual copy of the physical world,

– Making decentralized decisions,

– Communicating of objects with each other and with

humans in real time.


• Communications infrastructure

• Sensors

• Artificial Intelligence

• Autonomous robots

• Augmented Reality

• Data storage and cloud computing

• Cybernetics

• Value chain and system integration

• Analysis of large data (Big Data)

• Additive manufacturing

Industry 4.0 & CPS - Drivers


Additive Manufacturing▪ Additive Manufacturing (AM) commonly known as 3D printing

(3DP) is a disruptive technology that transforms manufacturing

upside-down (it is not a metaphor)

▪ Traditional Manufacturing is subtractive in nature (start from a

block of matter, and remove the un-necessary parts to form parts)

Source: https://www.youtube.com/watch?v=7YEVcPNrQfM


Additive Manufacturing▪ AM converts digital designs into objects and

builds them layer by layer.

© 3T RPD Ltd



Source: https://www.ge.com/additive/additive-manufacturing



Digital Model Material(s)

Digital control system

Tool for laying the material

+ digitalization!


Materials for AM

• Metals,

• Ceramics,

• Polymers

+ Combinations:

• Composites,

• Hybrid,

• Functionally Graded Materials (FGMs).


WHY AM?Cost!!!

• Direct translation from design to component

• Generation of parts with greater customization with no additional tooling

• Approaching zero waste manufacturing by maximizing material utilization

• Components at their final / near final shape with minimal to no additional

processing

• Reduction in overall product development and manufacturing time leading

to quicker transfer to market

• On-demand manufacturing

Performance!!!

• Functional design with complex internal features

• Flexible and lightweight component manufacturing (hollow or lattice

structures)

• Smaller operational foot-print towards manufacturing a large variety of parts

Performance


AM Applications

5

5

8

10

7

22

23

34

0 5 10 15 20 25 30 35

Other

Hobby

Art

Marketing Samples

Education

Production

Prototype

Proof of Concept

Share per application in percent

Data for 2016


AM Integration


AM Globally

12

14

8

11

16

0

2

4

6

8

10

12

14

16

18

Germany China &South Korea

Rest ofWesternEurope

UnitedKingdom

UnitedStates

Shar

e (

%)


AM Technologies

AM does not have to be complicated!

▪ SLS

▪ SLM

▪ EBM

▪ DMLS

▪ LMF

▪ SHS

▪ LENS

▪ EBAM

▪ LMD

▪ ColorJet

▪ PolyJet

▪ 3DP

▪ FDM

▪ FFF

▪ DIW

▪ FDM

▪ FFF

▪ DIW

▪ SLA

▪ DLP,

▪ cDLM

▪ CLIP

▪ LOM

▪ UAM


Powder bed fusion Directed energy depositionMaterial jetting Binder jetting

Material extrusion

Vat photopolymerization

Sheet lamination

Channel for layer generation

Physical form of Raw material

Discrete particles

Molten/viscous

Liquid polymer

Solid sheets

SLS, SLM*, EBM*, DMLS*, LMF*LENS*, EBAM*, LMD*

SHS

3DP(*)

ColorJet, PolyJet

FDM, FFF, DIW(*) FDM, FFF, DIW(*)

SLA DB SLA DLP, cDLM, CLIP

LOM, UAM*

Source: Anders Clausen, PhD thesis, DTU, 2016

* Metal (potentially metal) oriented

AM Technologies


Source: Anders Clausen, PhD thesis, DTU, 2016

Acronyms with selected manufacturers and channel classification

AM Technologies


statista

Market share of AM Technologies

2

2

4

6

10

10

12

15

21

33

38

46

0 5 10 15 20 25 30 35 40 45 50

Selective Deposition Lamination (SDL)

Laminated Object Manufacturing (LOM)

CLIP / CDLP

Electron Beam Melting (EBM)

Digital Light Processing (DLP)

Binder Jetting

Multi Jet Fusion

Polyjet

DMLS / SLM

Stereolithography (SLA)

Selective Laser Sintering (SLS)

Fused deposition Modeling (FDM)

Market Share (%)


Manufacturers of 3D Printers

37

2422

17 16

0

5

10

15

20

25

30

35

40

Germany China Rest ofWestern Europe

UnitedKingdom

UnitedStates

Shar

e (

%)

2016


AM Challenges - ExamplesSystem:

• Self-contained,

• Robust,

• User-friendly,

• Safe,

• Precise scan (motion & speed),

• High feature-volume

• Resolution

• Dimensional control.

Products:

• Surface finish,

• Part size,

• Variations in product

quality (between

machines / batches)

• Understanding the

impact of operational

variables on part quality.


AM Opportunities

3,1

1,6

1,1

0

0,5

1

1,5

2

2,5

3

3,5

2013 2018 2023

Co

sts

in E

uro

pe

r cm

3

Cost Promise!


AM Role For (German) SMEs

39,9

45,8

10,8

30,5

6,7

28,5

43

15

6,7

0

10

20

30

40

50

no part minor role establishedtechnology

outstandingrole

keytechnology

Shar

e (

%)

today in the future


AM OpportunitiesValue chain AM Benefits Requirements

Possession • Efficient material utilization (although expensive)

• Low capital to achieve economic scale

• Components suitable for AM• Production Technology• Suitable materials

R& D and manufacturing

• Ease of concept modeling, rapid prototyping and tooling

• Weight reduction • Minimal waste• Simplified parts• Complex designs • Customizable products• New product development

• Skilled manpower and digital technologies to run AM systems

• Possibility of hybrid manufacturing• Post-processing activities• Quality check• Reduced machine changeover costs and effort• Change in recycling efforts

Deliver • Reduced time-to-market• Optimized packaging based on

prototypes

• Delivery adapted to production near the point of use

• Smaller batch size delivery

Marketing • Customization• Co-creation with customers• Benefits from premium products

• Pricing/promotion planning for superior and/or new products

• Branding of “green” products

After sales services

• on-demand approach • Faster and customizable replacements

• Customer-facing executives with hands-on AM knowledge

• Spares planning considering AM benefits and limitations


Forthcoming added value


In Conclusion• We take “Revolutions” for granted,

but we are now at an advanced

stage of the Scientific Revolution…

• Are you going to participate?

• Remember: Scientific Revolution is

more about Ignorance!

• Thanks to our recent communication

advances, Knowledge Sharepoints

(e.g. AMiCE) are a click of a mouse

away from you!


THANK YOU!!!

Documents

Additive