From metal to plasticProcess to analyze business opportunity using Multi Jet Fusion New product introductions Engineering analysis • Plastic parts • Metallic parts with low requirements

From metal to plasticNovember 2017

© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.1


Session objectives

Identify metal parts that can be replaced by HP Multi Jet FusionTM.

Explain the different opportunities that the use of MJF technology offers.

3

Agenda

5. Success stories

3. Opportunity size identification

1. Opportunities to use MJF parts

© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.

2. Part selection process

4. Engineering analysis

1. Opportunities to use MJF parts


HP Multi Jet FusionTM technology

5

How does it work?


HP Multi Jet FusionTM technology

SPEED QUALITY COST

RELIABILITY


3D Printing within the PLC


Volu

me

of

pa

rts

DesignLong-tail /

SpareParts

ProductionDesign

Iteration& Tooling

Opportunity size

• Plastic parts

• Metallic parts with low mechanical requirements

8

Spare partsNew products Manufacturing aids


New products


Custom plastic parts of the

HP Jet Fusion 3D Printing Solution manufactured using HP Multi Jet Fusion technology

New products

Lower total cost per part1

1Lowest Cost-Per-Part

Based on internal testing and public data, HP Jet Fusion 3D printing solution average printing cost-per-part is half the average cost of comparable FDM & SLS printer solutions from $100,000 USD to $300,000

USD on market as of April 2016. Cost analysis based on: standard solution configuration price, supplies price, and maintenance costs recommended by manufacturer. Cost criteria: printing 1-2 buckets per day/ 5

days per week over 1 year of 30 grams parts at 10% packing density using HP 3D High Reusability PA 12 material, and the powder reusability ratio recommended by manufacturer.

Spare parts


Why this presents an immediate opportunity

• Reduce/eliminate inventory and warehouses

• Financial implications

Manufacturing aids


Why this presents an immediate opportunity

• 3D printing and CNC machining already utilized extensively, but it is extremely costly

• 3D printing current technologies represents potential saving of 50-75% of tooling cost, MJF represents 50% in addition

• 3D reduces significantly TAT


2. Part selection process

Process to analyze business opportunity using Multi Jet FusionNew product introductions

Engineering analysis

• Plastic parts• Metallic parts with low requirements

Can we make it work

Does it make sense

Opportunity size

Size/Weight Mechanical Properties

part #’s addressable to MJF

Dimensional Accuracy Materials Surface Finish

3D Part cost better than alternatives Design-for-AM (Several Parts combined into one)

part #’s: based on ROIFinancial analysis

Where we look

Account for benefits of time-to-market Design flexibilityPostponing tooling of unstable design


Application

• Possible post-process

• Redesign options

Process to analyze business opportunity using Multi Jet FusionNew product introductions

Engineering analysis

Can we make it work

Does it make sense

Opportunity size

Size/Weight Mechanical Properties

part #’s addressable to MJF

Dimensional Accuracy Materials Surface Finish

3D Part cost better than alternatives Design-for-AM (Several Parts combined into one)

part #’s: based on ROIFinancial analysis

Where we look

Account for benefits of time-to-market Design flexibilityPostponing tooling of unstable design


Application

• Possible post-process

• Redesign options

• Plastic parts• Metallic parts with low requirements


3. Opportunity size identification

Jigs & fixturesInterior parts

Opportunity size from metal to plastic



Potential additional added value of MJF• Integration of components

• Weight reduction vs metal parts• Good chemical resistance with PA family




Plastic is the new metal

Interior parts

For low volume products or machinery, some parts are done by machining or sheet metal instead or injection molding because it is not worth it to manufacture a mold.

Type of potential MJF 3D parts

• Brackets and supports that withstand small loads (e.g. sensor support) are manufactured with metal.

• Unification of sheet metal assemblies.

Why MJF?

✓ MJF offers a lower cost compared to CNC or sheet metal.

✓ Time to part faster than traditional manufacturing.

✓ Compared to sheet metal, tolerances of MJF are better.

✓ Assemblies optimization.


Jigs & Fixtures in the production line

Jigs and fixtures are manufacturing and assembly aids that provide repeatability, accuracy, and interchangeability in the manufacturing of products.

Benefits

✓ Ergonomic and lighter for the employee in the production floor.

✓ The plastic avoids scratching the part during the assembly.

Why MJF?

✓ Lower cost compared to CNC machining.

✓ Specific very high accurate features can be machined (e.g. to achieve 50 µm of tolerance).

✓ Freedom of design and higher flexibility.

✓ Assemblies unification.



4. Engineering analysis


It all depends on the part / application

Engineering analysis criteria


Application criteria Design criteria Factory

• Current Material

• Cosmetic requirement

• Surface finishing

• Color

• Storage Temperature

• Operation Temperature

• Chemical resistance

• Flammability UL

• RoHS

• Conductivity

• Part size

• Dimensional accuracy (X/Y/Z)

• Tensile strength

• Impact resistance

• Elongation

• End of support date

• Coverage of existing inventory

• Distribution centers and factory capabilities for logistics

Material selection

22

Additional options to consider


Surface roughness improvements- Tumbling- Chemical treatments- Electroplating, etc.

Printing big parts- Gluing and welding

Color- Painting

Additional properties improvements- Coatings for FDA- Coatings for conductivity,

etc

Re-design Post-process Assemblies unification

- Simplification of number of parts in the product

- Minimization of assembly operations

Lattice structures

Topology optimization

Usages and PropertiesHP 3D HR

PA12Vestosint

Z2773 PA 12HP 3D HR

PA11HP 3D HR PA12GB

Visual aids & Presentation models

Functional prototyping

End-Use Parts*

Dimensional Stability

Functional Rigid Part ( higher stiffness)

Flexible Part (higher elongation)

Impact

HDT

Medical Bio-compatible (USP Class I-VI)

Look and Feel

Reusability/TCO

Excellent

Good

Fair

Not Recommended

On testing process

*Depending on final part specific use case

HP Multi Jet Fusion Materials Portfolio selection guide


HP Confidential

HP 3D Materials Portfolio Roadmap

NEW!

NEW!

NEW!

Three waves of design for additive thinking


Part replacement Performance improvement Additive design

Part-by-part analysis to weigh the pros & cons of additive manufacturing vs traditional methods

Simplifying designs and lowering costs by using additive capabilities to combine multiple parts & functions into a single piece

3D as an equal participant in development process to create products that are optimized for business results, not just price/performance

Fitting additive into procurement Fitting additive into design Additive changing the way we think

Not recommended

Additional design options with MJF

• Topology optimization• Lattice structures

Performance improvement | Cartridge adaptor example


Multi Jet Fusion Assembly

Operating Position Folded for production

Performance improvement | Cartridge adaptor example


Traditional Assembly

Additive design | Interior support example


Additive design | Interior support example


Manuf. technology: Machining

Material: Aluminium

Volume: 129.44 cm3

Weight: 355g

Cost: 22$

>70%Cost reduction

>80%Weight reduction

1. Original – 3.7 cu in – 100% material

2. TopOpt – 1.47 cu in – 39,7% material

3. Lattice – 1.29 cu in – 34.8% material

4. Top+Lattice – 0.99 cu in – 26.7% material


5. Customer success story




Plastic is the new metal

Customer success story | Sag Tubi

• Experts on pipe solutions since 1969.

• Tube bending process to create fluid systems.

• Tools made of metal and manufacture manufactured with CNC.

• They need several steps (CNC, welding, polishing) to have the final part and with MJF they reduce them to only one.


Customer success story | Sag Tubi

34 © Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.

Multi Jet Fusion bending moldTraditional tube bending metallic mold

Image to use!Source of image

Customer success story | Ficep S3


Customer success story | Ficep S3

• The main structural components of the new painting arm in the DaVinci Automatic Paint Machine is being designed directly for MJF.

• The challenges they have overcome with this design are:

– Extremely light weight

Cost reduction of motors, gearboxes, etc.

– Geometry optimization:

• Y axis reduction.

• Z axis reduction from 1,5 to 0,3m (80%)

• Filter station reduction.


Pie de Foto

CAF overview

CAF Digital Manufacturing

CAF is a train manufacturing Company with worldwide presence

Pie de Foto

Contacto

[email protected]

+34 953640200

+34 660485993

mailto:[email protected]

Design exampleCAF Digital Manufacturing


Train door bracket• Objective:

Substitute current sand casted aluminium part for MJF.

• Cost of manufacturing a unique part like this one as spare part is around 600€ with the sand casting manufacturing process.

• Mechanical requirements: Withstand more than 750 N per Support.

• 2 different interations of the design with FEA analysis have been done in order to get the best design to meet the defined requirements.

Train doors

Designing for additiveCAF Digital Manufacturing


First FEA analysis is done only by replacing the

original material (aluminium) by the HP 3D High

Reusability PA12 to detect the weak areas.

Case 1: Original design

Case 2: Design iteration 1


the second design iteration adds additional material

an introduces a rib which help to reinforce the weak

spot of the part. The FEA confirms the design is now

inside specifications.

The first design iteration is done with the

introduction of an internal lattice structure who

reinforces the part. It is stronger than the previous

one, but still needs to be improved.

Designing for additiveCAF Digital Manufacturing


Von Mises stresses analysisCase 1: Original design



The FEA analysis helped toiterate in the design in a proper way, by identifying and reinforcing the weakest areasof the part.

The comparison of the VonMises stresses of all of themproofs that the 2nd designiteration is able to withstandthe requirements of the part, as the yield stress is notoverpassed and there is a highsecurit coefficient.

Designing for additiveFinal design


The part is already assembled in one train and working without any issue.


Lowest Cost-Per-Part

Based on internal testing and public data, HP Jet Fusion 3D printing solution average printing cost-per-part is half the average cost of comparable FDM & SLS printer solutions from $100,000 USD to $300,000 USD on market as of April 2016. Cost analysis based on: standard solution configuration price, supplies price, and maintenance costs recommended by manufacturer. Cost criteria: printing 1-2 buckets per day/ 5 days per week over 1 year of 30 grams parts at 10% packing density using HP 3D High Reusability PA 12 material, and the powder reusability ratio recommended by manufacturer.

Up to 10 times faster/Breakthrough Productivity

Based on internal testing and simulation, HP Jet Fusion 3D printing solution average printing time is up to 10x faster than average printing time of comparable FDM & SLS printer solutions from $100,000 USD to $300,000 USD on market as of April 2016. Testing variables: Part Quantity -1 full bucket of parts from HP Jet Fusion 3D at 20% of packing density vs same number of parts on above-mentioned competitive devices; Part size: 30g; Layer thickness: 0.1mm/0.004 inches.

Fast Cooling is enabled by HP Jet Fusion 3D Processing Station with Fast Cooling, available in 2017. HP Jet Fusion 3D Processing Station with Fast Cooling accelerates parts cooling time vs recommended manufacturer time of SLS printer solutions from $100,000 USD to $300,000 USD, as tested in April 2016. FDM not applicable.

HP High Reusability PA12

HP Jet Fusion 3D print solution with HP 3D High Reusability PA 12 has the highest post-production surplus powder reusability with 80% reusability vs any other powder based 3D printing technology using PA 12 material. Consistent performance with only 20% powder refresh rate.

The information contained herein is provided for information purposes only. The only terms and conditions governing the sale of HP 3D printer solutions are those set forth in a written sales agreement. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty or additional binding terms and conditions. HP shall not be liable for technical or editorial errors or omissions contained herein and the information herein is subject to change without notice.

Questions and answers


44 © Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.

Documents

From metal to plasticProcess to analyze business opportunity using Multi Jet Fusion New product introductions Engineering analysis • Plastic parts • Metallic parts with low requirements