HP Multi Jet Fusion 3D PrintingThe HP Jet Fusion 300/500 Printer will use140+unique MJF parts

HP Multi Jet Fusion 3D Printing How to complement CNC machining with Multi Jet Fusion

1 © Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.

2

About HP

© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.

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every second

© Copyright 2017 HP Development Company, L.P. The information contained herein is subject to change without notice.3

HP’s Printing

ranks #1 or #2 in 51 of the top 55

countries (ink + laser)

of the Global Fortune 500 companies

Print & PC leadership

By disrupting manufacturingWe intend to lead in 3D printing too


The HP Jet Fusion 3D 4200prints dozens of its own plastic parts

The HP Jet Fusion 300/500 Printerwill use 140+ unique MJF parts

140+ unique

3d printed parts

Technology Overview


HP Multi Jet Fusion Technology (HP MJF)How it works


FusionApply energyApply agentsMaterial spreading

Fused


Modularity enables continual printing

HP Jet Fusion 3D Printing Solution

11

Day 1 Day 28:00 am8:00 am 12:00 pm 8:00 pm

HP Jet Fusion 3D Build UnitHP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station

Build

Software & PluginsJob preparation & submission

Printer UtilitiesPrinter management


Cool

10.5h print 10h cool1.7h

10.5h print 10h cool1.7h

10.5h print1.7h

8:00 pm12:00 pm

Prep


How it works (cont.)

HP Multi Jet Fusion Workflow


300 & 500 Series do all of thesePre-process

Loading Build Unit

Print

Printing

E2E HP Jet Fusion Solution

Secondary process

Surface finishing

Color dyeing

Post-process

Fast Cooling

Mixing

Cleaning

Bead blasting

Water jetting

Dry ice

Surface finishing

Color dyeing**Not needed for

380 & 580

Why ConsiderAugmenting CNCWith HP Multi Jet Fusion?


Why consider HP Multi Jet Fusion?

15

4 Main Reasons

Economic advantage

Time Performance increase

NewValue


CNC Machining vs. HP Multi Jet FusionCNC Machining

Part Development

16

Layout Design3D Print

Part

IterateDesign

Test ManufactureHP Multi

Jet Fusion

CNC

Layout DesignCNC Machine

Part Test

IterateDesign

Manufacture


NewValueNew

ValuePart Development

17

CNC Machining vs. HP Multi Jet Fusion

HP Multi Jet Fusion enables part designs not achievable with

CNC machining

Performance increase

TimeEconomic advantage



Days to weeks

$$

Days$

Potential Time-to-Market Advantageor

Part Design Optimization Time

Quality of CNC’ed plastic parts≠HP MJF because ofmachined in stresses

HP Multi Jet Fusion parts = production parts

Layout DesignFabricate

Part

CNC

IterateDesign

Test Manufacture


Part

IterateDesign

Test ManufactureHP Multi

Jet Fusion


This benefit accrues every

design iteration

NB: The delta increases per iteration

NewValueNew Value Example

18

Ficep S3—Automatic Paint Machine

Company background:

• FICEP Steel Surface Systems (S3) is a high tech engineering and research & development company which operates worldwide within the FICEP group.

• HP Multi Jet Fusion technology was used to overcome challenges typically faced with traditional production methods.

With HP MJF they can:

• Improve the design of an automatic paint machine arm - it is now extremely lightweight

• Optimize geometry with DFAM (design could not be machined or molded)

• Improve the machine arm performance and help enable savings for the end customer

• Reduce the height of the entire machine, as well as the volume of air that needs to be filtered, and in turn the size of the filter station.

HP MJF printed Machine Arm for FICEP S3 DaVinci

Paint Machine




Result:FICEP S3 aims to replace as much as 40% of the machine’s traditionally manufactured parts with HP MJF technology.

NewValue

Printed assembly

New Value Example: Cartridge Adapter for 4200 printer

19



Traditional Assembly Multi Jet Fusion Assembly

Operating Position Folded for production


NewValueNew

ValueCartridge adapter




CNC production workflow



CNC job-shops Today

22

CNC Production is complex - it requires skilled and experienced operators

Part DesignCustomer

DFX & Prod PlanningTechnical Office

ProductionCNC Operator

CNC Machine Shop employee CNC Machine Shop employeeCustomer

2 3


1

23

Print & MonitorPlan BuildDesign Parts

From Design to production in one step with HP MJF


CNC Machining Service Provider

Technology comparison


CNC Machining

26

Associated costs

These costs are magnified as a percentage of costs for short runs common for low volume production

• Programming of cutter paths

• Building jigs to hold parts being machined

• Fabricating custom cutters

– For when standard sizes cannot create desired geometry

• Wasted material

– Machined chips

• Set up for machining

– Multiple Machines needed to cover all operations

• Break down of machining set-ups

• Storage of jigs


NewValue

TimeEconomic advantageEconomic advantage

$

$$

$$

$

$

$

$


0

0

0

-

0

-

0

-

0

0

HP MJF

CNC Machining vs HP Multi Jet Fusion

27

Associated costsCNC

HP Multi Jet Fusion has none of these costs


NewValue

TimeEconomic advantageEconomic advantage

$

$$

$$

$

$

$

$

• Programming of cutter paths

• Building jigs to hold parts being machined

• Fabricating custom cutters


• Wasted material

– Machined chips

• Set up for machining


• Break down of machining set-ups

• Storage of jigs


This time is directly proportional to the quantity ordered

CNC Machining

28

Lead Time

• Programming of cutter paths ………………..………………..….….

• Building jigs to hold parts being machined……………..……….

• Fabricating custom cutters……………………………………..…...….


• Scheduling of multiple machines ………………..………..……..….

• Set up for machining..…………………………………………..….………


• Machining one part at a time.…………………….……………..…..…

– Includes:

• Cutting

• Tool exchange

• Transfer to other set-ups


NewValue


Time

These times are magnified as the part design becomes more complex

hours

hours/days

hours/days

hours/days

hours/days

mins/hours



29

Lead Time


NewValue


Time

HP Multi Jet Fusion has none of these delays

• Programming of cutter paths ………………..………………..….….

• Building jigs to hold parts being machined……………..……….

• Fabricating custom cutters……………………………………..…...….


• Scheduling of multiple machines ………………..………..……..….

• Set up for machining..…………………………………………..….………


• Machining one part at a time.…………………….……………..…..…

– Includes:

• Cutting

• Tool exchange

• Transfer to other set-ups

hours

hours/days

hours/days

hours/days

hours/days

mins/hours

HP Multi Jet Fusion can print multiple parts of multiple designs simultaneously


NewValueCNC Machining

30

Process limitations




A

A Section A-A

Geometry impacted by machine constraints


• Need to hold part

• Depth of cut limited by diameter of cutter

• Sharp internal corners cannot be machined

• Dimensions and shape of undercuts

• Feature formation depends on access availability for cutter

Machining process part quality issues

• Stress concentrations from removal of material by cutting

– Strength concern

• Warpage from machined in stresses

NewValueCNC Machining vs HP Multi Jet Fusion

31

Process limitations




Geometry impacted by machine constraints

HP Multi Jet Fusion can reduce or eliminate issues associated with these machining limitations


• Need to hold part

• Depth of cut limited by diameter of cutter

• Sharp internal corners cannot be machined

• Dimensions and shape of undercuts

• Feature formation depends on access availability for cutter

Machining process part quality issues

• Stress concentrations from removal of material by cutting

– Strength concern

• Warpage from machined in stresses

NewValue

Other issues to consider

CNC Machining

Machining limitations may require breaking a part into multiple pieces to achieve desired functionality




• Inventory management complexity

• Assembly costs

• Performance impacts

Complexity of part design increases number of machining operations

• Time and cost implications

– Increased set up time and/or number of machines

Scheduling of multiple CNC machines for short runs


HP Multi Jet Fusion can reduce or eliminate issues associated with these machining limitations

NewValue

Other issues to consider

Machining limitations may require breaking a part into multiple pieces to achieve desired functionality




• Inventory management complexity

• Assembly costs

• Performance impacts

Complexity of part design increases number of machining operations

• Time and cost implications

– Increased set up time and/or number of machines

Scheduling of multiple CNC machines for short runs

But CNC Machining…

34

Can meet some requirements that HP MJF cannot

Surface finish

Feature precision

Dimensional accuracy

Material range


Provide optimal output qualityCertified for

HP Jet Fusion 3D Printers

HP Branded Powder HP Certified Powder Any Powder (Fully Open)

Bringing down the barriers to advance widespread 3D printing adoption across industries through materials innovation with the HP Multi Jet Fusion “Open Platform”

OPEN PLATFORM


HP Open PlatformBringing down the barriers to advance widespread 3D printing adoption across industries through materials innovation


HP MJF + CNCOne + One > Two


Combine the advantages of both to achieve new value

HP Multi Jet Fusion + CNC Machining

HP Multi Jet Fusion

• Enable designs not achievable with CNC alone

• Consolidate production of multiple parts of same or multiple designs

• Create near net shape parts to feed CNC finishing

• Eliminate time and costs associated with low value features

– Programming cutters

– Set-up

– Material waste

CNC Machining

• Focus CNC machines on high value features

– Surface finish

– Feature precision

– Dimensional accuracy

• Make parts not achievable by either MJF or CNC alone


Part Development

39

Using Hybrid CNC/HP Multi Jet Fusion production


Part

IterateDesign

Test Manufacture

MJF

CNC

Layout DesignCNC Machine

Part Test

IterateDesign

Manufacture

Layout Design 3DP Test

IterateDesign

HP Multi Jet

Fusion+

CNC

ManufactureCNC

Finish


HP Multi Jet Fusion enables part designs not achievable with

CNC machining

Days to weeks

$$

Days$

Potential Time-to-Market Advantageor

Part Design Optimization Time

Quality of CNC’ed plastic parts≠ HP MJF because ofMachined in stresse

MJF/CNC parts = production parts

This benefit accrues every

design iteration

NB: The delta increases per

iteration

NewValueNew

ValuePerformance

increaseTimeEconomic

advantagePerformance

increaseTimeEconomic

advantage

Summary

40

Advantages of augmenting CNC Machining with HP Multi Jet Fusion

Schedule

– Faster TtM or more time for design optimization

Development cost

– Less expensive parts for development and production

Design freedom

– Combine multiple parts into one

– Make parts that cannot be made by machining only

• e.g. lightweight lattice structures

Reduce assembly cost

– Print parts already in assembled state

Plastic Part Quality

– Multi Jet Fusion parts do not have the machined in stresses that machined plastic parts have


NewValue



Hypothetical ExampleLow-volume,

Low-load Bearing Parts


Select Eq. Program Set-up Calibrate Produce

Equipment dedicated

CNC Part Production

30 50

CUSTOMER ORDER

75

Technical Office

What’s the best machine, Is it available?


CNC ProductionSequential

CNC Part Production

Machine Ready for Next Job


50u

75u

30u

43

CNC Part Production

CNC Part Production

Parts Frequently require

more than 1 pass to machine different planes


Part 2Plane B

Part complexity has consequencesLonger Lead-times or more machines

Part 1 – Plane A

Part 1 – Plane B

Part 1Plane A

Part 2 – Plane A

Part 2 – Plane B

Part 2Plane A

Part 2Plane B


Part 3Plane A

Part 3Plane B

Part 2 – Plane A

HP Multi Jet Fusion Production

Preflight Load Print Cool Clean

HP Jet Fusion 3D part production

75u

30u

50u

Nest all the parts in 1 unique build

155uHP JET FUSION 3D Printing

Machine Ready for Next Job

Equipment dedicated

Consolidated


High Dimensional Accuracycan be achieved withHybrid Production

High Precision is frequently not required on all sides

Accuracy > 0,2mmAccuracy < 0,2mm

But Multi Jet Fusion may not meet all requirementsCNC needed to finish parts


Hybrid ProductionMore efficient use of machines and faster delivery of parts

Printer Ready for Next Job

155u


HP JET FUSION 3D Printing

+Critical Features

Critical Features

Critical Features

Actual HP ExampleLow-volume,

Low-load Bearing Parts


Real HP parts CNC machined during product development


3 Parts of different complexity

Duct

Feet

ActuatorSupport

Simple Medium Complexity Difficult

Actual quotes to CNC machine these HP parts


HP spent this time and money

$1760 $2340 $65,140Cost:

2 Weeks 2 WeeksTime: 4 weeks

Duct

Feet

ActuatorSupport

9 (3 sets of 3)Qty: 3080

Considering the entire order


That’s ~$582 per part

Duct

Feet

ActuatorSupport

Total Qty: 119 Total Cost: $69,240 Time to Parts: 4 Weeks

Few (if any) features require CNC


The rest could be printed

Duct

Actuator SupportHole diameters and locations require high precision and accuracy

FeetNo features require CNC machining

Duct:Surface finish and flatness of sealing surface

Three HP MJF builds


All 119 (near-net-shape) parts

60 ActuatorSupports & 9 Feet

(3 sets of 3)

15 Ducts &10 Actuator

Supports

15 Ducts &10 Actuator

Supports

Assuming Fast Print Modeand Fast Cooling

6.9h cool

All 119 near-net-shape parts in <2 days


First parts ready for CNC finishing in less than one day

HP Jet Fusion 3D Build Unit

HP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station

Build

Cool

Prep

* If have only one processing station, then third partial build will cool naturally for 1.8 hours until processing station is available

4.17h cool1.7h

1.7h Ready to CNC10.25h print 9.75h cool

1.7h Ready to CNC10.25h print 9.75h cool

6.25h print Ready to CNCInQueue* <6.9h cool

Conservative estimate from HP TCO tool


An average of $24.22 per near net shape part

$970.9025 parts

$970.9025 parts

$940.5869 parts

Total Qty: 119 Total Cost: $2,882 Time to Parts: <2 days

Delta available to CNC critical features based on conservative estimate


Potential for significant savings in time and money

Duct

Feet

ActuatorSupport

CNC Total Cost: $69,240 Time to Parts: 4 Weeks

MJF Cost: $2,882 Time to net-shape parts: 2 Days

Delta: $66,358 Delta: 26 Days

Assuming Balanced Print Modeand Natural Cooling

All 119 near-net-shape parts in 3 days


First parts ready for CNC finishing in <2.5 days

HP Jet Fusion 3D Build Unit

HP Jet Fusion 3D Printer HP Jet Fusion 3D Processing Station

Build

Cool

Prep

Ready to CNC1.7h 14. 8h print

Ready to CNC1.7h 14. 8h print

Ready to CNC9h print1.7h 22.5h cool

38.75h cool

38.75h cool

Conservative estimate from HP TCO tool


An average of $30.72 per near net shape part

$1,230.0325 parts

$1,230.0325 parts

$1,195.7469 parts

Total Qty: 119 Total Cost: $3,656 Time to Parts: 3 days




Duct

Feet

ActuatorSupport







Duct

Feet

ActuatorSupport




Summary of opportunities if hybrid CNC/HP MJF fabrication used


Faster, Cheaper, More robust

Actuator Support<1 week delivery

instead of 4

FeetNo machined in stresses

enables earlier qualification testing

Duct:Part cost reduced

order(s) of magnitude down from >$2K

PotentialHP MJF Applications


Potential HP MJF applications from CNCLow volume production of low load bearing parts


Prototypes

Visual modelsFunctional prototypes

Manufacturing Aids

Jigs & Fixtures

New products

Interior parts: supports & bracketsGrippers/end effectors

Fluid vessels

Spare parts


HP Example: Drill extraction shoeManufacturing process tooling application

POST PROCESSINGBead Blasting

DIMENSIONSX: 3.91 in / 9,93 cm Y: 3.72 in / 9,45 cmZ: 2.68 in / 6,82 cm

TOTAL COST PER PARTCNC Machined part: $450HP 3D MJF part: $18

95% Overall cost reduction

WEIGHT REDUCTIONCNC Machined part: 575 g.HP 3D MJF part: 52 g.

90% Overall weight reduction

DELIVERY TIMECNC Machined part: 3-5 DaysHP 3D MJF part: 24 h.

MATERIALHP 3D High Reusability PA 12

Turbulent flow

Laminar flow

DESIGN OPTIMIZATION

HIGH REUSABILITY: 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

CNC MACHINED ASSEMBLY MULTI JET FUSION PART

Assembly unification(from 7 parts to 1)

&Topology optimizaton

Flow optimization

Process to analyze business opportunity using HP Multi Jet FusionCan be applied to: New products, Manufacturing Aids, Spare Parts

Engineering analysis

Plastic partsMetal parts with low load requirements

Can it work

Does it make sense

Opportunity size

Size/Weight Mechanical Properties

part #’s addressable to HP MJF

Materials

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

part #’s: based on ROIFinancial analysis

Where to look

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


Application

Possible CNCpost-process

68

Surface FinishDimensional Accuracy

reasons


to consider investing in

HP Jet Fusion 3D printing


To consider adding HP Multi Jet Fusion to your tool box

Four Reasons

Diversify and grow your businessFocus CNC investment on value added features not achievable by HP Multi Jet Fusion

Improve delivery timesConsolidated manufacturing of HP Multi Jet Fusion combined with accuracy of CNC

Reduce costReduce costs associated with programming, machining and materialPrototype the final part before cutting it to minimize errors

Add valueDeliver parts unachievable with CNC aloneHelp customers to solve design problems

Thank you

Unrestricted © Siemens AG 201771

Documents

HP Multi Jet Fusion 3D PrintingThe HP Jet Fusion 300/500 Printer will use140+unique MJF parts