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UL and the UL logo are trademarks of UL LLC © 2014
Making the Transition to 3D Printing for Mainstream
Manufacturing
Simin Zhou VP & Managing Director UL Corporate Ventures
August 2017
UL Overview
2
Safety, Sustainability and Security
Transformation in Product Commercialization
Mass
Production
Economies
of Scale Product
Distribution
Mass
Customization Economies
of Scope
Distributed
Manufacturing
Design for
Manufacturing
Current State :: Mass Production & Centralized Manufacturing
Emerging State :: Mass Customization & Distributed Manufacturing
Design for
Use
3
The 3D printing industry includes:
• Machine manufacturers
• Part producers
• Material companies
• Service bureaus
• Software creators
Rapidly expanding
Impacting multiple market segments
4
3D Printing is a Multi-Billion Dollar Industry
5
3D Printing Industry Growth
Annual growth rate is
30 – 40% for the industry $80,000
$70,000
$60,000
$50,000
$40,000
$30,000
$20,000
$10,000
$
OEM Parts
Service Bureaus
Software
Materials
Personal Systems
Industrial Systems
Design Freedom
• Complex structures • Reduce # of parts
6
Light Weight
• Light weight structures
7
Materials
• Polymers
• Metals
• Ceramics
• Concrete
• Glass
• Paper
• Food
• Bio
• Nano
• …
8
New Applications and Business Models
9
2015 Global Production Capacity (% of installed units)
10
SOURCE: Wohlers
NORTH AMERICA
39.7%
EUROPE
28.2%
ASIA/ PACIFIC
27.5%
OTHER
4.6%
AM Adoption
Aerospace Automotive Medical & Dental
• Orthopedic Implants, dental
applications, surgical
guides, and medical
instruments.
• Orthopedics and prosthetics
will exceed $3.5 billion by
2025
• 90 % of the hearing aid
shells in US and 17 million
clear aligners are produced
by AM every year
• Helps to reduce cost of
increasing number &
complexity of product
variants
• BMW has used AM in series
production to make more
than 10,000 parts
• Mainly for high performing
cars and spare parts
• Can be adopted for the
production of engine
components, chassis parts
and decorative elements
• Optimize the shape &
create light weight
structures to improve fuel
efficiency
• Customize aircraft interiors
• Make spare parts quickly
and efficiently
• Can be adopted for making
components of propulsion
systems and Jet engines,
cabin interiors, hydraulic
and pneumatic systems
Case Study: Surgical Planning & Implants
• Diagnostics
• MRI / X-ray
• Data
• Planning
• Manufacturing
• Surgery
• Recovery
12
• Prototyping
• Complex shapes
• Low volume production
• Customized manufacturing
• Tooling and fixtures
• Engineering education
13
Typical Uses of 3D Printing
3. Powder Bed Systems
4. Material Jetting
5. Binder Jetting
6. Sheet Lamination
7. Directed Energy Deposition
1. Material Extrusion
14
7 Distinct 3D Printing Technologies
2. Vat Polymerization BUILD MECHANISMS
MATERIALS USES
Case Study: Tooling
A manufacturer of electronic component parts for
the household appliance, commercial vehicle
and automotive industries.
Challenges:
• New molded parts needed for functional testing
• Must be injection molded and not 3D printed
• Molded in final material
• Need quick turn around for possible design tweaks
16
Tooling delays:
• Steel production tools 56 days
• Mold costs $52,725
• Aluminum sample tools 2 weeks
17
3D printed tooling
18
3D printed tooling:
• Polyjet tools 2 days
• Mold costs $1,318
• Savings
• 54 days (96%)
• $51,406 (98%)
19
20
3D Printing Benefits
Design Complexities
Cost Reductions
Product Customization
21
3D Printing Tradeoffs
Speed
Post-processing
Appearance
Cost
Materials
Material properties
Selection of representative
parts
Assessing the opportunities
Quantifying the potential
Implementing the technology
Transition to Mainstream
23
Identify Key Technical Drivers
24
Accelerated Simulation for Metallic Laser
Powder bed Additive Manufacturing
Develop predictive tools for metal AM to reduce time
and money and to reduce build failures
Leverage Software Tools
Questions?
UL Additive Manufacturing Initiatives
Workforce
Development
Safety &
Compliance Materials &
Process
Partnering to Advance Innovation, Safety and Quality