Advanced Research Labs Engineering Herold Cremer Additive Manufacturing

Advanced Research Labs Engineering Herold Cremer Additive Manufacturing benefits and costs Minor Smart Industry

AM benefits Bron: Berenschot 2

AM benefits Bron: Berenschot 3

AM benefits Design and engineering • Rapid product development and prototyping • Product development • • • Agile Iterative Digital process Prototyping : Additive Manufacturing Relative fast /low cost process Bron: Desktop. Metal 4

AM benefits Design and engineering • Complex geometry Bron: Desktop. Metal 5

AM benefits Design and engineering • Complex geometry Lightweighting Bron: Desktop. Metal 6

AM benefits Design and engineering • Complex geometry Internal channels Bron: Desktop. Metal 7

AM benefits Design and engineering • Complex geometry Consolidation Bron: Siemens 8

AM benefits Bron: Berenschot 9

AM benefits Manufacturing & Tooling • Manufacturing: • Flexible manufacturing system • • • Proces workflow • • Set-up: digital process No tooling needed Relative few process steps (set-up – printing-post processing) Tooling • Flexible tooling for production Bron: Siemens 10

AM benefits Manufacturing & Tooling Set up times for conventional production processes Bron: Desktop. Metal 11

AM benefits Manufacturing & Tooling Flexible tooling for production Bron: Desktop. Metal 12

AM benefits Bron: Berenschot 13

AM benefits Stock & Inventory Digital Warehouse • AM allows for on demand production • • Short lead times Easy set-up preparation (digital process) Toolless flexible production system Just in time (JIT) production No/little need for inventory (spare part) products • • No warehousing costs Minimize transportation costs (distributed production) Bron: Desktop. Metal 14

AM benefits Bron: Berenschot 15

AM benefits Market Opportunities Customization/Personalisation • Customization/Personalistion with AM is feasible by: • • Flexible, fast, toolles production Digital workflow: Digital 3 d imaging/scanning -3 D CAD design – 3 D printing • Applications customized/personalized production: • • Medical Consumer market Bron: Desktop. Metal 16

AM benefits Market Opportunities Customization/Personalisation • Medical 17

AM benefits Market Opportunities Customization/Personalisation • Medical Personalised 3 D CAD model 18 3 D printed implant

AM benefits Market Opportunities Customization/Personalisation • Consumer Market • • Consumer designer: Printer service bureaus; Shapeways, Materialise, Oceanz Mass customization: Eye-wear, arch-support • Historical restoration projects 19 Bron: Renishaw

AM Costs Production costs can be catogarized in : • Ill-structured • Structured Ill-structured: • Build-failures • Machine set-up • Inventory Structured: • Labor • Machine • Material • Energy • Facility rent etc. 20

AM Costs Ill-structured cost benefits of AM production in terms of “lean production”: • Inventory/overproduction: AM enables “on-demand” production. • Transportation: • • • 21 supply-chain can be simplified or even omitted: in-house printing. Production near customer AM enables integrated complex parts with high degree of functionality: less parts per assembly.

AM Costs Main structured cost parameter drivers of AM production: • Material (Plastics/Metals) costs: relative high compared to traditional manufacturing • Machine (depreciation) costs: relative high and dominant cost-driver parameter for most AM technologies due to: • • • High investement machine cost Low productivity rate Energy consumption: material refinement (powder) & AM part production. • • Energy Material refinement: in general higher than traditional manufacturing AM production: Dependent of part optimalization/orientation etc. Not included: Energy consumption during life cycle=> AM part can easily be optimized/weight reduction. • 22 Operator cost: not significant en tend to decrease due to automation.

AM Costs Main structured cost parameter drivers of AM production: • Post-processing costs: Can be significant dependent on application and AM technology. 23

AM Costs Main structured cost parameter drivers of (Metal) AM production example: 24

AM Costs Main structured cost parameter drivers of (Metal) AM production example: Bron: Analyzing Product Lifecycle Costs for a Better Understanding of Cost Drivers in Additive Manufacturing C. Lindemann*, U. Jahnke*, M. Moi*, R. Koch* 25

AM Costs Main structured cost parameter drivers of (Metal) AM • Machine depreciation costs dominant (70%) • Material costs significant (>= 10%) • Postprocessing costs can be significant depending on the applicaton demands 26

AM Costs Material costs relative high Polymere: • Granulate ABS: E 2, =/Kg (For injection moulding) • ABS filament FFF-3 D printing: E 20, =/Kg Metal: • 316 L steel bar : E 2, 5=/Kg • 316 L Powder feedstock for LPBF 3 D printing: 90, = E/Kg 27

AM Costs Cost model (per build) example: Bron: Ruffo, M. , C. Tuck, and R. Hague. 2006 a. “Cost Estimation for Rapid Manufacturing. Laser Sintering Production for Low to Medium Volumes. ” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 220 28