031213 Low Volume Manufacturing DISTRIBUTION

8/13/2019 031213 Low Volume Manufacturing DISTRIBUTION

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2013

Low Volume Manufacturing

3rdDecember 2013Polymer Innovation Team, WMG

University of Warwick

[email protected]@benjaminmwood
mailto:[email protected]:[email protected]


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2013

Welcome

#IIPSI #PolymerInnovation


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2013

Agenda

0830-0900 Registration, tea and coffee PI Team

0900-0915 Welcome and Introductions Ben Wood

0915-0930 Why low volume manufacturing? Paul Milne

0930-1045 Making parts with Additive Manufacturing Greg Gibbons

1045-1100 Refreshments Break -

1100-1230 Designing a 3D Printed mould toolCAD Practical Ben Wood

1230-1315 Lunch -

1315-1445 Injection Moulding practical session PI Team

1445-1500 Refreshments Break -

1500-1545 Options for low volume manufacturing PI Team

1545 on 1 to 1s with the Polymer Innovation teamprojects PI Team


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Introductions

Greg Gibbons

Ben Wood

Paul Milne

Martin Worrall


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Why Low Volume Manufacturing?

Paul Milne

IIPSI


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2013

Issues for manufacture

DESIGN

PRODUCT

Number of Parts

Form and function

Materials

Methods

Specification

Cost

Partners

Scale-up

Customers

Investors

Time

Quality

Market readiness

Prototypes

AcceptanceOrders

Risk

DevelopmentTrials

Requirements

Technology readiness

Technology transfer

QualificationProduction

End of life

Product facilities

Investment

Manufacturers


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Lifecycle for Polymer development

Prototyping

Low VolumeManufacturing

Adding

FunctionalityRecycling

FormulatingNew Materials


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Product Lifetime

Prototype Low volume Mass Production

Sales

End of Life


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Process Comparison

ProcessCapital

EquipmentCost

Production Rate Tooling Cost Part Volumes

CompressionMoulding

Low Slow Low 100 1 mill

Rotational

Moulding

Medium Slow Medium 100 1 mill

Vacuum Forming Medium Medium Medium 10,000 1 mill

Extrusion Medium Fast Low Medium Med - High

Blow Moulding Medium Medium Medium 1,000 100 mill

Injection Moulding High Fast High 10,000 100 mill

High Volume Injection Moulding
https://www.youtube.com/watch?v=WHwTHarf8Ckhttps://www.youtube.com/watch?v=WHwTHarf8Ck


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Mass Production

72 parts every 3 seconds

750 million parts per year

VERY expensive tooling/equipment

~500,000

But

750million x 0.1p = 750,000

Payback in 8 months


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Low Volume Manufacturing- recap

Part of product development

Finalise design , secure funding/orders, user trials.

Bridge between prototype and production

Highlighting production issues helps refine methodsbefore moving to scale up production

Cost effective manufacture

Routes to reduce risk, time and cost of manufacture

Several low volume manufacturing routes possible

Machining, casting, low cost mould tools etc


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ALM for Low volume manufacture

How can additive layer manufacture help?

Very good at going from design (CAD) to part

but Only makes one part at a time

Cant compete with mass production methods

No economies of scale


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The Problem

Tooling

Cost

Number of Parts

10,000 100,0001 1,000,000+1000100

ALM

Injection Moulding

Low VolumeManufacturing


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Rapid Tooling

Early definition of Rapid Tooling:

a process that allows a tool for injection moulding and die casting

operations to be manufactured quickly and efficiently so the resultant

part will be representative of the production material. - Karl Denton

1996

With Rapid Tooling now covering a wider range of

applications, this has generalised to:

a range of processes aimed at reducing both the cost and time for themanufacture of tooling.


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Rapid Tooling with ALM

Indirect

Use of a Rapid Prototype (RP) pattern to manufacture a tool in a

secondaryoperation

Direct

Directlyproduce the tool using a layer-additive process

ALM original Mould toolfrom original

Make parts

ALM toolMakeparts


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ALM tooling

ALM tooling has potential to reduce manufacturing

time and cost

Developing technology area

Increased technical risks- currently limited bycomplexity, size, resolution and material

Useful additional method for low volume

manufacture


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Making Parts with Additive

Layer Manufacturing (ALM)

Dr Greg Gibbons


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Contents

Current processes, materials

Process economics

Barriers and needs to achieving market penetration

18


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CURRENT PROCESSES, MATERIALS,ECONOMICS

19


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Polymer Processes

20

Most Common

Primary Processes

Stereolithography (SLA)

Selective Laser Sintering (SLS)

Fused Deposition Modelling (FDM)

3D Printing (3DP)Multi-Jet Modelling (MJM)
http://intl.stratasys.com/fdm_products.aspx?id=2234


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Stereolithography

21

How?

Laser scan of each layer andsolidification of a liquid resin by

UV light

Capability?

Up to 1500 x 750 x 550 mm

0.05-0.15 mm thick layers

0.76 mm resolution

Materials?

Thermosets (e.g. epoxies) that

replicate thermoplastics (e.g PP, ABS)

Stiff and flexible materials

Investment castable materials

Transparent materials

Applications? Form, fit, function

Snap fits, living hinges

Master patterns for PU casting

Investment casting patterns

Summary:

High resolution

Good surface finish

Relatively complex parts

Large parts possible


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Selective Laser Sintering

22

How?

Laser scan of each layer andsolidification of a thermoplastic

powder by IR heat

Capability?

Up to 700 x 380 x 560 mm 0.1-0.15 mm thick layers

0.1 mm resolution

Materials?

Thermoplastics (PA, carbon-filled PA,

aluminium-filled PA, PEEK)

PS for investment casting

All opaque



Investment casting patterns

Summary:

High resolution Complex parts

Relatively large parts

Mostly PA-based material

No transparent materials


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Fused Deposition Modelling

23

How?

Polymer wire feed Melted in hot nozzle

Extruded out onto platform

Capability?

Up to 914 x 610 x 914 mm 0.178-0.33 mm thick layers

0.1 mm resolution

Materials?

Thermoplastics (ABS, PC, PC-ABS, PEI,

PPSF)

Mostly opaque, some translucency



Tooling (metal, composites, plastics)

Jigs and fixtures

Summary:

Medium resolution Complex parts

Large parts

Range of thermoplastics

http://intl.stratasys.com/fdm_products.aspx?id=2234


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2013

Multi-Jet Modelling

24

How?

Liquid resin polymer inkjet

printed onto a build plate

and solidified using UV light

Capability?

Up to 1000x800x500mm High resolution

16micron layers

600x600 dpi

Materials?

Acrylates

PP, ABS, rubber like

Transparent and opaque

Multiple flexibilities in one part

Applications? Functional prototyping

Simulating over-moulding

Tool patterns

Summary:

Very high resolution Very complex parts

Large parts

Multiple materials in one part

Transparent and opaque

Generally poor thermal

tolerance


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3D Printing

25

How?

Liquid binder ink jet printed ontopowder bed, selectively

solidifying the powder

Capability?

Up to 4x2x1m 0.08-0.2mm layers

600dpi resolution

Materials?

PMMA (Voxeljet)

Ceramic/polymer composite (3D Systems)

Applications? Functional prototyping

Tool patterns

Summary:

Very large parts

Fast build rates

Limited range of materials



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Other Polymer Processes

26

Multitude of other

competing processes

Micro Light Switch

Digital Light Processing (DLP)

Selective Mask Sintering (SMS)

Laminated Object Manufacture (LOM)

Selective Heat Sintering (SHS)

Digital Wax

freeformer


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Metallic Processes

27

Most Common

Metallic Processes

Powder Bed Laser MeltingPowder Bed Electron Beam Melting

Laser Direct Metal Deposition

Electron Beam Direct Metal DepositionPowder Bed Metal 3D Printing


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Powder Bed Laser Melting

28

How?

Powder layer deposited ontoplatform

Laser selectively melts powder

which subsequently solidifies

Capability?

Around 250x250x320mm 200W-1kW laser

20-100micron layers

70 micron resolution

30 micron accuracy

Around 0.2kg/hr

Materials?

Practically any metal Tool steel, stainless steel

Aluminium

Inconels,

Titanium

Applications? Additive Layer Manufacturing

Autosports

Aerospace

Medical

Tooling

Summary:

High resolution

Small part size capability

Slow build rates


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Powder Bed Electron Beam Melting

29

How?

Powder layer deposited ontoplatform

Electron beam selectively melts

powder which subsequently

solidifies

Capability?

Around350x380mm 3.5kW electron beam

100micron layers

0.2mm resolution

0.2mm accuracy

Around 0.4kg/hr

Materials?

Practically any metal, but commercially: Titanium

Ti 6Al 4V

Co-Cr alloy


Autosports

Aerospace

Medical

Tooling

Summary:

Medium build rate

Medium resolution

Medium accuracy


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Laser Beam Direct Metal Deposition

30

How?

Powder feed into laser beamfocus, melting metal

Clads molten metal in layers

Capability?

Around 3x3m x 360

o

1-10kW laser

1.2mm accuracy

0.8-1.5kg/hr

Materials?

Practically any metal Tool steel, Stellites, Inconels, Titanium

Multiple material feeds for material

combinations


Restoration of components

Shafts, blades, diaphragms, tools

Summary:

Relatively high build rates

Low accuracy

Mix materials during build

Add material to existing parts


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Electron Beam Direct Metal Deposition

31

How?

Wire feed into electron beam

Clads molten metal in layers

Capability?

Around 6x1x1m

1mm accuracy

Up to 9kg/hr

Materials?

Practically any metal Tool steel

Stellites

Inconels

Titanium


Restoration of components

Shafts, blades, diaphragms, tools

Summary:

Very high build rates

Very large parts

Low accuracy

Add material to existing parts


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Powder Bed Metal 3D Printing

32

How?

Deposit layer of metal powder(coated)

Ink-jet print binder onto powder

Post-sinter in furnace

Capability?

Around 780x400x400mm

60 micron resolution

0.1mm layers

Up to 15kg/hr

Materials?

Limited proprietary metals

Stainless steel

Bronze

Tungsten


Aerospace

Energy / Oil / Gas

Automotive

Summary:

Large build volume Very high build rates

Medium accuracy

Requires furnace consolidation


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The 3DPrinting Promise

Reduced need for tooling

Enables low volume production

Simplified supply chain and reduced capital investment

Enables complex geometries Part consolidation

Optimised geometries

Personalisation and customisation

Enables new business and supply chain models Distributed manufacture with reduced transportation

Production closer to the consumer

33


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Component Cost Barriers and Needs

ComponentCosts Too

High

DepositionRates Too

Low

3DP systemstoo small

High capitalcosts

High materialcosts

Non-optimalbusinessmodels

34

ReduceComponent

Costs

New scanningmethodologies

or energysources

New largermachines and

formats

Reduce BOMthrough supply

chain

New powdersupply

methods

Sharedownership

New businessmodels formaximising

usage


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Process Robustness Barriers and Needs

3D PrintingProcessesAre NotRobust

Inconsistencybetweenbatches

Lack of in-process

monitoringand control

Post-processingrequired tomeet spec

Lack ofcapable NDT

/ QA

Lack ofstandards

35

Make 3DPrintingRobust

Consistentmaterials

supply

Materials andprocess

standards

In-processmonitoringand control

New in-processthermalcontrol

New in-process stress

relieving

In-processmachining


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Process and Product Data Barriers and Needs

Lack of

Process andProduct

Data

Limitedperformance

data forcomponents

Limitedperformance

data formaterials andparameters

Lack oftraining fordesigners to

design for3DP

Poor,fragmented

supply chains

Lack ofawareness of

3DP

36

ProvideAccess to

Process andProduct Data

Developshared

performancedatabase

Open sourceaccess to

materials data

Develop bestpractice guides

and training

Developnetwork to

develop 3DPend-user

supply chain

AM awarenessevents


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THE REAL DEAL

Additive Manufacturing


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Additive manufacturingthe real deal

Materials

Accuracy

Resolution

Sizes

Time

Costs

non added value activity


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Polymers Most common thermoplastics are:

SLS (PA, PS)

FDM (ABS, PLA, PC, PEEK)

Most common thermosets are:

Acrylic (MJM)

Epoxy (SLA)

Wax-like (for investment casting)

The HDT of FDM materials is equal to the IM grade

The HDT of other polymers is usually lower than 500C

High temperature polymers are available

PEEK (SLS)

PPSF, ULTEM (MJM)

Transparency is available but not for FDM and SLS

Translucency is available for FDM (ABSi - Methyl methacrylate-acrylonitrile-butadiene-stryrene copolymer)

Fire retardancy is available (most systems)

Biocompatibility is available (non-implantable) for most systems


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Metals

Most metals processed using SLS

Wide range of commercial materials

Ti, Ti alloys, stainless steel, Inconels, CoCr, Maraging steel,

tool steel, aluminium Now systems processing Ag, Au, Pt (EOS-Cookson

Metals tie-up)

Mechanical properties usually approach or match

those of wrought materials


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Accuracy, Resolution

Resolution and accuracy are not the same!

Accuracy and resolution are complex and are highly

dependent on system and component size, and on quality of

calibration

Accuracy Resolution

x y z x y z

SLS

metal

30 30 20 100 100 20

SLS

polymer

100 100 100 50 50 50

MJM 20 20 16 40 40 16

3DP 250 250 89 100 100 89


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Size

Polymers

Wide range of size capabilities (50mm-3m+)

Small bed sizes often have higher resolution

Large bed sizes often have faster build rates

Metals

Most metals systems have beds


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Time

Time is very difficult to assess from an STL file since:

Time is dependent upon:

Part volume

Part dimensions Part orientation

Material used (even in the same process)

Level of finishing required

How much you want to pay (premium for queue jumping)


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Costs (using a bureau)

Not easy to assess just from an STL file since:

Cost is very much dependent upon:

Volume of the component (amount of material)

Part dimensions

Cost of the material

Amount of support material

Resolution required (number of slices)

Orientation required (taller the dearer)

Number of parts required (often cheaper per part to havemultiplesespecially for SLS)

Level of finish required


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Costs (in-house)

If you have system in-house, need to consider: Maintenance costs

Material costs (including scrap, waste)

Consumables costs

Infrastructural costs

Labour costs (set-up and clean-down)

Costs can vary widely depending on the system System - 500-1m+

Maintenance10030k PA

Material - 1 - 600 /kg

Infrastructural - 0 - 100k +

Labour - 5 - 200 per part


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HOW TO 3D PRINT AN INJECTIONMOULD TOOL

Low Volume Manufacturing


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ALM Tooling

Why ALM Injection Mould Tooling?

1. Directly produce the tool using a layer-additive process

2. Quick to manufacture; hours rather than weeks

3. Lower cost than metal tooling

4. Easy to update/modify component designs during NPD

5. Make parts in proper plastics

6. Try out different tool designs for maximum production efficiency


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ALM Tooling

Additive Manufactured tooling isnt new

But

SLA can pricey, slow and not that durable

FDM doesnt give us the resolution we need

ALM has moved on!

Higher accuracy

Rapid build times

Choice of materials


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ALM Tooling

Concept:

Manufacture a tool overnight (


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ALM Tooling

Inserts are comparatively cheap

Less durable than metal tooling

Easy to change geometry/design

Suited to low volumes

Crossover point depends on material, part

design, etc


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Material Compatibility


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ALM Tooling

0

2000

4000

6000

8000

10000

12000

14000

0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

TotalProductionC

ost

[]

Number of Parts

Polypropylene

ALM Tooling

Metal Tooling


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HANDS-ON SESSION

Time to split into groups


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Insert Tool Design

Things to think about:

Draft

Ejection

Minimum thickness

Split line

Weld lines

etc etc


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OPTIONS FOR LOW VOLUMEMANUFACTURING

Whats the right solution for your product?


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Options for Low Volume

ALM mould tools arent a perfect process

Dont suit every component

Dont suit all materials

There are other options available in the

market for low volume manufacturing


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Options for Low Volume

Direct manufacture:

Additive manufacturing (see this mornings notes)

CNC machining http://youtu.be/PbdgUBwKcsg

Indirect rapid tooling

Investment casting http://youtu.be/1rgfT-PlXqU

RTV silicone mould tooling http://youtu.be/ciQQb9L5JBM

Direct Rapid Tooling

Metal rapid tooling http://youtu.be/3ciyG_hidhE

ALM rapid tooling
http://youtu.be/PbdgUBwKcsghttp://youtu.be/1rgfT-PlXqUhttp://youtu.be/ciQQb9L5JBMhttp://youtu.be/3ciyG_hidhEhttp://youtu.be/3ciyG_hidhEhttp://youtu.be/3ciyG_hidhEhttp://youtu.be/3ciyG_hidhEhttp://youtu.be/ciQQb9L5JBMhttp://youtu.be/ciQQb9L5JBMhttp://youtu.be/1rgfT-PlXqUhttp://youtu.be/1rgfT-PlXqUhttp://youtu.be/1rgfT-PlXqUhttp://youtu.be/1rgfT-PlXqUhttp://youtu.be/PbdgUBwKcsghttp://youtu.be/PbdgUBwKcsg


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Low Volume Options

Process Price per Part Production Rate Tooling Cost Parts per Tool

ALM Medium/High Slow Zero N/A

CNC Machining Medium/High Slow Medium N/A

RTV SiliconeTooling

Low/Medium Slow Low 20-50

ALM Tooling Low Medium/Fast Low 50-250

MachinedAluminium Tooling

Low Fast High 5000+

Metal LaserSintered Tooling

Low Fast Very High 10,000+


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Summary

Many potential manufacturing routes for low

volume

Making the right choice depends on product

ALM mould tooling can work for ~1500 parts

Between 40-150 shots per insert

Not suitable for really complex tooling


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[email protected]@warwick.ac.uk

go.warwick.ac.uk/iipsi

#IIPSI #POLYMERINNOVATION

@wmgsme@benjaminmwood

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mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

Documents

031213 Low Volume Manufacturing DISTRIBUTION