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ADDITIVE MANUFACTURING: AN EXPOSÉ ON THE DIVERSITY OF
INDUSTRIAL USE National Academy of Engineering
German-American Frontiers of Engineering Irvine, CA
April 26, 2013
Tim Shinbara Technical Director
AMT - The Association For Manufacturing Technology
1
• Introduction • Requirements • Applications • Challenges & Opportunities • Summary & Conclusion
2
Agenda
• Introduction
• Requirements – How AM Answers the Call – Technology Alignments
• Applications • Challenges & Opportunities • Summary & Conclusion
3
Agenda
4
Requirements: How Additive Answers the Call
• 1st: Affordability – Reduce tooling, waste – Complexity = Simplicity
• 2nd: Smart(er) Manufacturing
– Integrate processes – Support RP & production
• 3rd: Optimize Product Design
– Reduce weight, Support modularity
– Multi-functional parts
Traditionally: 9 piece welded duct assembly
AM: 2-piece bonded assembly
With Additive You Can Design for Functionality
F-35 representative parts
Courtesy Northrop Grumman Corp
Copyright © 2013 Solid Concepts Inc.
Requirements: Technology Alignments
• Introduction • Requirements
• Applications • Snap Shot • Industrial Use • Diversity
• Challenges & Opportunities • Summary & Conclusion
6
Agenda
Applications: Snap Shot
• Polymeric Components – Laser Sintering (LS)
• Low-temp, non-structural (Aero, Auto) • FDA 510(k)-approved (implants)
– Hybrid Applications • Embedded sensors / continuous fiber
• Metallic Components – Laser and Electron Beam Melting
• Implants, replacements • Aerospace components
Creates Difficult to Machine Shapes
Provides Similar Mechanical Properties (NGC)
Enables Hybrid Materials
7 Improves Performance Courtesy Materialise
Applications: Industrial Use
8
Composite Interface Fitting (JWST) Traditional Manufacturing Additive Manufacturing
~500 CNC machining hours 32 build hours
~16 – 26 week lead time ~4 day lead time
Nominal 60% - 70% cost savings
~10” (25.4cm)
As-Fabricated
~8” (20.3cm)
Post Machining and NDI
Hot Air Mixer (UCAS-D) Traditional Manufacturing Additive Manufacturing
Buy-to-Fly ratio 10 – 20:1 Buy-to-Fly ratio ~2:1
Min. 4-pieces w/ 2 welds 1 piece w/ no welding
Nominal 35% - 45% cost savings
Courtesy of Northrop Grumman Corp. and CalRam Inc.
SLS Gimbal Aeryon Labs Inc. | Aeryon Scout UAV | Ontario, Canada
Courtesy of Solid Concepts Inc.
Meet all FAA (8130-3) requirements for flame, smoke, toxicity and airworthiness while remaining lightweight. (Courtesy of Solid Concepts, Inc.
Air Duct – Orbis Flying Hospital Structural Integrity Engineering | California FDM (Fused Deposition Modeling)
SLS Fuel Tanks Area-I | Georgia SLS of fuel tank, ailerons, control surfaces, mounting plates, more…
Courtesy of Solid Concepts Inc.
Applications: Oil & Gas / Automotive
12 Trending From Prototyping-Only To Now Include Production
35% Weight Savings 20% Greater Rigidity
70% Savings in Material and Cost Fuel Tanks (Solid Concepts): Internal Baffles (above)
Automotive Racing (below)
Courtesy: ExOne
Courtesy: DM3D
Courtesy: Rennteam Uni Stuttgart
Applications: Medical & Dental
13
Polymeric (PEKK) & Metallic (Ti-Al6-V4) Applications FDA-Approved
Courtesy: Society of Mfg. Engr.
Courtesy: OPM
Applications: Diversity
Additive Manufacturing: An Enabler for Next-Gen Production
Functional Furniture
Large Structures
Antennae Sensors
Multi-Functional Parts
Functional Apparel
Toys & Model Hobbyists
Weight Reductions
Complex Parts
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Traditional Machined Casting
Additive Selectively Builds
• Introduction • Requirements • Applications
• Challenges & Opportunities • Industrial Base& Maker Movement • Roadmap Summaries • NAMII
• Summary & Conclusion
15
Agenda
Challenges: Industrial Base & Maker Movement
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Need: Harness Maker Momentum to Influence Industrial Sector
325K
52K
60K 115K
$-
$1
$2
$3
$4
$5
$6
$7
$8
AM Machine Tools
Bill
ions
2011 US Market
$475M $7.3B
AM Source: Wohlers Associates 2012 Report Machine Tool Source: AMT
Challenges: Industrial Base & Maker Movement
Opportunities: Industry Metrics Source – http://wohlersassociates.com
18 Trending From Prototyping-Only To Now Include Production
PRODUCTS: Direct Part Manufacturing (19.2%) Functional Models (18.4%)
MARKETS: Consumer & Auto ~40% Aero & Medical / Dental Accelerating
Wohler’s Associates site to order “Wohlers Report”
Challenges: Technical Summaries
19
Need: Increased Understanding of Processes & Accelerated Metallic Maturation (Materials & Processes)
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Taguchi DOE for Optimized Density (>98% with bed consistency)
• Industrial Commons • Technology Transition & Commercialization • Workforce & Education
Opportunity: Collaborative Innovation Focused on Advancing AM Industry
• Introduction • Requirements • Applications • Challenges & Opportunities
• Summary & Conclusion
21
Agenda
• The Technology – No longer just “emerging” – Design for functionality – AM Is an enabler, compliment
• The Business – Increase education to non-AM communities – Prototyping to functional models to end-use production – AM discriminator: Knowing how to use AM
Summary & Conclusion
Additive Is A Compliment to Current Manufacturing 22
Tim Shinbara Technical Director, AMT
703.827.5243 (desk)
Contact Information
Questions? 23
