APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

3D-Printing: Becoming State-Of-The-Art in Remanufacturing

Miroslav Pochop

ZF Aftermarket,TRW Automotive Czech

Prof. Dr.-Ing. Rolf Steinhilper, Christian Bay

University of Bayreuth, Chair Manufacturing and Remanufacturing Technology

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

How would you make this part?

Mold injection Machining 3D-Printing

5000 pcs

3 pcs

need

Cost:

6000 €

Duration:

4 weeks

Cost:

1 €

Duration:

15 seconds

Not

possible

Cost:

15 €

Duration:

6 hours

2,20 €/pc

3667 €/pc

15 €/pc

15 €/pc

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Obama (2013): „3D-Printing is a key for

new growth of the production industry of

the US.“

3D-Printing Hype

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Technologies and materials

FLM

Fused Layer Modeling

SLS

Selective Lasersintering

SLA

Stereolithography

+ low cost printer

+ wide range of materials

+ fast

– poor surface quality

– poor temperature stabilty

Dedicated for prototypes and

spare parts with low

mechanical stress

+ high accuracy

+ wide range of materials

+ high temperature stabilty

– rather poor surface quality

– long printing duration

Dedicated for spare parts with

low surface quality

+ high accuracy

+ high temperature stabilty

– one material (model and support)

– long printing duration

– long manual post processing

Dedicated for small and complex

spare parts

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

ZF Aftermarket Frýdlant

5

3D Printing applications of plastic parts

Pre-pilot build of the prototype caliper, there is existed only

prototype 3D model from customer.

By the 3D printing technology we are made a cheap plastic

prototype which was very good and fast solution, how try the

tooling and start pre-pilot build without time delay.

Saving time

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

ZF Aftermarket Frýdlant

6

3D Printing applications of plastic parts

Saving money

Electronics workstation need a special ESD material (very expensive, long

delivery time)

By the 3D printing technology we can make ESD jigs without long delivery time,

shape limitations, expensive cost.

Saving

time

140 EUR/pc

1 mont delivery time

14 EUR/pc

10 hours delivery time

Tooling

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

ZF Aftermarket Frýdlant

7

3D Printing applications of plastic parts

Tooling

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

ZF Aftermarket Frýdlant

8

3D Printing applications of plastic parts

Components

3D printing low volume forecast for some parts is a good way how to save money.

There is not necessary make a expensive injection molding form!

This parts are using for indicating right position valve of the steering gear, it is

not funcional part.

Saving money

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Cover of a thermostate for earlier

series of trucks @ DAIMLER

3D-Printing @ automotive industry

Cover of a compartment for notes in buses @ DAIMLER

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Machine (Ø300x400 mm) 600.000 Euro

Sieving, powder handling,

powder storage 150.000 Euro

Heat treatment, saw, manual

post processing 60.000 Euro

Generation of nitrogen

Housing

Work safety

…

Implementing metal 3D-Printing: total capex volume

Source: TRUMPF

Total capex volume for

implementing

~ 1 M €

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Outlook on costs in metal 3D-Printing

Source: AUDI

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

Is 3D-Printing the best technology?

• Where is the part needed?

• How many parts are needed?

• When is the part needed?

• How much can the part cost?

Organization

• Are the CAD data available? Reverse Engineering

• Can the CAD data be used for 3D-Printing?Data/CAD

• Which material is needed? Can the original material be used for 3D-Printing?

• Which quality aspects are mandatory?

• Which technology is the best?

Part andTechnology

Adding a new value by topology optimization and integration of functions

APRA European Symposium 2018

3D-Printing: Becoming State-Of-The Art in Remanufacturing

3D-Printing: Becoming State-Of-The-Art in Remanufacturing

Miroslav Pochop

ZF Aftermarket,TRW Automotive Czech

Prof. Dr.-Ing. Rolf Steinhilper, Christian Bay

University of Bayreuth, Chair Manufacturing and Remanufacturing Technology