How 3D printing adds up for Business Aviation .How 3D printing adds up for Business Aviation

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  • How 3D printing adds up for

    Business Aviation

    PRESENTED BY:

    James Kulp, CAM

    May 3, 2017| 10:45 12:00

  • 2

    Beam me up, Scotty

    Theres no sign of intelligent life

    Tea

    Earl Grey, Hot

    3D printing

    or

  • 3

    What is 3D printing

    3 Dimensional printing is a process of making physical parts from a digital file

    3D printing is some times called Additive Manufacturing, AM, which describes the

    printing process

    Additive process is the joining of materials to objects in successive layers to form the

    shape of parts

    Additive manufacturing is a synonym with metal 3D printing

    Enables rapid prototyping to make parts or molds for parts

    With new designs, allow freedom to innovate complex designs and geometries

  • 4

    Hype versus reality

    Technology

    breakthrough

    Increasing

    expectations

    Technology shake out

    2nd & 3rd gen

    breakthroughs

    MainstreamInnovation TriggerPeak of

    Inflated

    Expectations

    Trough of

    Disillusionment

    Slope of

    Enlightenment

    Plateau of

    Productivity

    Gartner Hype Cycle: Emerging Technologies

    4D Printing

    Commercial

    UAVs

    Connected

    homes

    Brain computer interface

    Autonomous Vehicles

    Source: Gartner

    Virtual reality

    Augmented reality

    Exp

    ecta

    tion

    s

    Time

    5 10 Years

    More than 10 Years

  • 5Source: Gartner

  • 6

    Pace of change

    Evolutionary versus revolutionary

    2,000,000 bc

    Stone tools

    Bronze tools

    3,300 bc

    Iron tools

    1,200 bc 1780 1848 1895 19401969 2017

    Source M. Hilbert, University of California

    Water

    wheels

    Steam engines

    Electrical

    engineering

    Automobile

    Aircraft

    Cyber

    Digital & Physical

    convergence

  • 4th3rd

    7

    Industrial revolution

    The dawn of the 4th industrial revolution

    Source: World Economic Forum

    2nd1st

    Mechanization: Railroads & steam

    power

    1784

    Mass Production: Division of labor, mass

    production & electrical power

    1870

    Computer & automation

    1969

    Cyber-physical systems

    Now

    Deg

    ree

    of

    com

    ple

    xity

    Industry 4.0

    Industry 3.0

    Industry 2.0

    Industry 1.0

    Combines

    communication,

    IT, data &

    physical

    elements

    integrating a

    number of

    technologies

  • 8

    3D printing

    Architecture

    Automotive

    Consumer

    HealthcareEntertainment

    Apparel

    Education

    Industrial

    Food

  • 9

    3D printing

    Additive versus subtractive

    Subtractive

    Additive

    Machined

    Layer deposition

    Pro

    ce

    ss

    Volume Cost/Unit Time to Market Cost of Complexity

    Attrib

    ute

    s

    Material Scrap / Waste

  • 10

    3D printing for product development

    Prototyping

    Cost reduction

    Innovation

    Efficiency

    All new productNew sub-systemNew componentDesign verification

  • Category "Ink" Power Source

    Thermoplastics

    Ceramic slurries

    Metal paste

    SLS Selective Laser Sintering Polymer

    DMLS Direct Metal Laser Sintering

    DMLM

    Electron Beam

    Vat PhotopolymerizationSLA Sterolithography

    Photopolymer

    CeramicsUltraviolet Laser

    MJ Metal Jetting Plastic

    NPJ Nano Particle Jetting Metal

    DOD Drop on Demand Wax

    Polymer powder

    Ceramic powerer

    Metal powder

    Gypsum

    Sand

    Plastic film

    Metalic sheet

    Ceramic tape

    Composite

    Paper

    LENS Laser Engineering Net Shape

    EBAM Electron Beam Additive Manf.Laser BeamMolten metal powderDirected Engergy Ddeposition

    Thermal EnergyMaterial Jetting

    Thermal EnergyIndirect Injet PrintingBinder Jetting BJ

    Sheet Lamination LOM Laminated Object Manufacturing Laser Beam

    Technology

    FDM Fused Deposition ModelingMaterial Extrusion

    High-powered laser BeamPowder Bed Fusion

    Atomized metal powered

    Stainless steel

    Cobalt Chromium

    Titatinium

    Ceramic powder

    Selective Laser Sintering

    Direct Metal laser Melting

    Electron Beam MeltingEBM

    SLM

    Thermal Energy

    3D printing technology types

    Source: 3Dhubs.com, Explainingthefuture.com

  • 12

    Additive in aerospace

    Source: 3D Printing industry.com, Investors Business Daily

  • manufacturing cost

    DECREASES

    design complexity

    INCREASES

    WITH

    ADDITIVE

    MANUFACTURING

  • 14

    GE Additive

  • GE Additive

    Power Aviation Transportation Oil & Gas Healthcare Medical Automotive

  • 16

    GE Aviation Additive examples

    All new productNew sub-systemNew componentDesign verification

  • Capabilities of full production35,000 40,000 per year

    LEAP fuel nozzle

    PARTS

    DURABLEMORE

    WEIGHT REDUCTION

    LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines

    20 1

    525

    17

    Solution for traditional

    engine shut-down fuel coking

    19 additive fuel nozzles per engine

  • Advanced Turboprop engine (ATP)

    PARTS

    WEIGHT REDUCTION

    Combustor test schedule reduced from 12 months to 6 months

    LOWER MISSION

    FUEL BURN

    5

    20

    855 1218

  • 19

    GE Additive examplesHeat exchanger journey

    All new productAdvanced traditionalTraditional

  • GEs additive global network

    20

  • 21

    Competency and skills associated with 3D printing technologies

    Function Importance Degree of skill change

    required

    New skills Evolution of existing skills

    Engineering 3DP operations: ability to operate & perform task to run new printers

    Maintenance repair & training: leverage current skill set to support 3DP

    Education 3DP teaching: understand fundamentals & trends (tech & business)

    3DP curriculum: create courses concept to application

    New product design

    3DP design: convert 3D from 2D. 3DP fundamentals: process & capability

    Design velocity: software support for customization

    Sales & marketing

    3DP market education: promote 3D products Activity velocity: rapid rate support new product launches

    Human Resources

    3DP high-level understanding: communicate capabilities

    Employee retention: create strategies to maintain 3DP qualified employees

    Procurement Sourcing strategy: understand market for materials, software, hardware

    Supplier qualification: new criteria for 3DP

    Aircraft Maintenance

    Maintenance & support strategy: Understand3DP repairability, logistics, material, technology

    Integration of 3DP into maintenance plan. Supplier & employee development

    Workplace implication

    Source: Adapted from Technology and Innovation for the Future of Production: Accelerating Value Creation: World Economic Forum

    High Low

    DO

    M

  • 22

    Ready for the next revolution?

    Source: Future of Jobs Report: World Economic Forum

    35%Skills change

  • Thank You