3D Industry Quick Snapshot. Survey of SE WI Manufacturing. 3D Technology Options and Scaling for Manufacturing

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1 Joe Jones President Big Systems, LLC 3D Industry Quick Snapshot Survey of SE WI Manufacturing 3D Technology Options and Scaling for Manufacturing Case Studies Look Forward

2 Rapid growth: $12B industry with +20.5% CAGR reaching $20B by 2021 Healthcare and Aerospace are leading the way Transformational technology: Forecasted to become 30% of all manufacturing $3 trillion in worldwide GDP U.S. leadership: Significant American intellectual property Much is made in the USA The majors (Apple, Google, GE, Boeing) are placing big bets Source: 2016 Wohlers Report, ZD Net.com, 3D Systems

3 Survey Objectives: Identify specific additive manufacturing technologies that manufacturers are using today Top priorities for 3D printing during the next year to year and a half The benefits of 3D printed parts Local manufacturers current applications of 3D printing The extent to which 3D printing represents a competitive advantage

4 What are your top 3D printing priorities in the next months? Accelerate product development and time to market Reduce tooling cost and risk Increase production flexibility Eliminate design constraints Improve internal and external customer service What benefits of 3D printed parts are of greatest interest to you? Each rated on a scale from 1 to 5 where 1 is not interested and 5 is very interested

5 Executive Summary: Nearly 80% of manufacturers surveyed believe 3D printing represents a competitive advantage Almost two thirds are using it to produce prototype parts, followed by presentation models and jigs and fixtures Over 50% of manufacturers cited accelerating product development as one of their highest priorities for 2018 Executive Summary: 34% are focused on reducing tooling costs by 3D printing molds Respondents gave high marks to producing complex parts that cannot be made using conventional machining and milling 30% of respondents said their budget for 3D printing will remain the same in 2018 as it was in 2017; an additional 20% plan to increase their spend during the next year 3d results report/

6 Models available: Markforged Onyx One Markforged X3 Many FDM models from numerous OEM s worldwide FFF uses a string of solid material (filament), pushing it through a heated nozzle and melting it in the process. The printer continuously moves this nozzle around, laying down the melted material at a precise location, where it instantly cools down and solidifies. This builds up the model layer by layer. A unique professional grade filament made of chopped carbon fiber named Onyx is used. By far the most popular technology based on units in use worldwide Markforged Solution

7 FFF: Custom Wrench Materials: Nylon and Fiber Glass Print time 4 hours vs several days for traditional machining. Cost $10 vs $ Models available: Markforged Onyx Professional Markforged Mark Two Markforged X5 Markforged X7 Fiber reinforced FFF printing was introduced by Markforged as the world's first CCF printer. Combining carbon reinforced nylon with revolutionary continuous fiber results in amazingly strong (as aluminum) parts. Print end use reinforced parts in lightweight continuous Carbon Fiber, Kevlar and (High Temp) Fiberglass with remarkable strength and dimensional stability

8 Traditional Machining: 1) Stock Material Cost 2) Program/Machine Time 3) Internal Lead Time 4) Post Processing CFF Printing: 1) $20 Material Cost / Jaw 2) 15 hrs Print Time / Jaw 3) 5 Min. Operator Setup Time 4) Completely Unattended operation Models available: 3DS ProJet CJP 360 (mono) 3DS ProJet CJP 260C (CMY) 3DS ProJet CJP 460 Plus (CMY) 3DS ProJet CJP 660 Pro (CMYK) 3DS ProJet CJP 860 Pro (CMYK) CJP involves two major components: core and binder. The core material is a premium composite spread in thin layers over the build platform with a roller. After each layer is spread, color binder is selectively jetted from inkjet printheads over the core layer, which causes the core to solidify. Multiple printheads provide the best range of accurate and consistent colors, including gradients. The build platform lowers with every subsequent layer, resulting in a full color three dimensional model

9 Shortened design cycle Improved product quality Realistic color prototype (left) and actual toothbrush (right) Early massing models Detailed design models Design Reviews Clash Detection Lighting, solar and energy Analysis Construction Phasing

10 3D color bone model quickly and accurately created in Bespoke Modeling from CT scan Affordable 50% scale printed model helps patient communication and assists surgery practice sessions DICOM data 3D color bone model Full color 3D printed model I found the 3D model invaluable in patient education, surgical planning, and physician training. Dr. Howard Goodman Models available: 3DS ProJet MJP DS ProJet MJP 2500 Plus 3DS ProJet MJP DS ProJet MJP 3600 Max 3DS ProJet MJP 5600 MJP builds up an object by jetting a photopolymer though a printhead before solidifying it using a UV light. It combines professional grade 3D printing capabilities with an affordable price, an office friendly footprint and easy part processing. Advantages include true to CAD quality and accuracy, superior edge fidelity, smooth surface finish, and rigid or elastomeric materials for true functional testing

11 In house prototyping: keeps developments confidential Higher Quality Flexible use: directly produce assembly fixtures "With the high precision 3D printed mock ups of our wristwatch designs, we improved quality and saved three times the installation costs of our ProJet 3500 HD within six months." Mr. Naito Product Development, Citizen Watch Models available: 3DS ProJet DS ProJet DS ProX 800 3DS ProX 950 Stereolithography is a 3D printing technology that works via a process called vat photopolymerization. Objects are built in layers using a laser beam to trace out and solidify each successive layer of an object on the surface of a vat of liquid photopolymer

12 3D Systems Figure 4 Solution

13 0.25 mm mm walls, holes and features

14 Product Design at Laser Speed Engineering Innovation April 2005 Page 27 Models available: 3DS ProX SLS 500 3DS spro 60 HD HS 3DS spro 140 3DS spro 230 SLS technology uses a laser to harden and bond (fuse/sinter) small grains of plastic, ceramic, glass, or other materials into layers in a 3D dimensional structure. The laser traces the pattern of each cross section of the 3D design onto a bed of powder. After one layer is built, the bed lowers and another layer is built on top of the existing layers, until every layer is built and the part is complete

15 The Systems Digital Scanning Ease of use Statistical Process Control Closed Loop System The Materials Tough Rigid Elastomeric Fiber filled Flame Retardant SLS machines have been around for years Why all of the new focus on Additive Manufacturing now? Leader Innovator Partner Builder

16 Production Seat SLS Seat Performance sensor data almost exactly the same! Leader Innovator Partner Builder Component Consolidation Redesigned SLS Approach 1 Part 1 SKU 0 Custom Tools 1 Assembly Check Leader Innovator Partner Builder

17 Component Consolidation Traditional Approach 15 Parts 5 SKU s 3 Custom Tools 10 Assembly Checks Leader Innovator Partner Builder Over 200 brackets fabricated in one build. Delivery of inspected and certified brackets in one week. Leader Innovator Partner Builder

18 Plastic cable bracket 75 x 10 x 10 mm (3 x ½ x ½ inch) 1 batch = 198 parts Build time = 6 hours : 35 minutes Part cost = $ 1.63 Leader Innovator Partner Builder Models available: Markforged Metal X An industrial metal printing method by Markforged, using metal powders encased in plastic binders. When the plastic is melted off, the metal powders can be arranged in exquisite shapes. The plastic dissolves and the metal is sintered into a design. The process works layer by layer as metal crystals pass through the bonds of the printed layers. This allows for an entire part to be created seamlessly with immense structural durability, speed and accuracy

19 Models available: 3DS ProX DMP 100 3DS ProX DMP 200 3DS ProX DMP 300 3DS ProX DMP 320 3DS ProX DMP 100/200 Dental DMP (just like SLS) uses a laser to selectively heat and fuse a bed of fine metal powder, in order to build up a 3D object in layers. Also referred to as Direct Metal Laser Sintering (DMLS). DMP printers create chemically pure, fully dense metal parts, delivering accuracy and repeatability of about 20 microns in all three axes. Materials include stainless steel, tool steel, super alloys, nonferrous alloys, cobalt chrome, titanium and aluminum

20 DMP 8500 Factory Solution What Precision Metal Printing Delivers Weight reduction Topology optimization Customization Enhanced fluid flow Lattice structures Component consolidation/ increased functionality

21 Customer Profile Molding / Tooling subcontractors Plastic injectors Foundries Suitable Materials Maraging Steel , Stainless Steel 17 4PH, AlSi12 Challenges Difficult internal conformal cooling channels Surface finishing Rockwell strength Typical parts Injection & blowing molds Tooling inserts Casting cores Customer Profile Suitable Materials Engine manufacturers Structure parts subcontractors Ti6Al4V, Ni alloys, Al alloys, stainless steels Challenges Superior mechanical properties (fatigue strength, high temp) Metallurgical structure, large dimensions, topological design feasibility Typical parts Turbine parts, structure parts, nozzles, heat exchangers

22 DMP: Monolithic Design Transform complex assemblies into a single part Save logistics and assembly time and cost Single burner component with nine under cuttings and six internal cavities Objectives: Reduce cost of chamber material Reduce manufacturing time Improve strength to mass ratio Improve heat dissipation Reduced chamber wall thickness Added scaffold support structure End product has less material, lower mass Material waste compared to conventional machined forging is significantly reduced

23 Optimization of material layout within a given design space Constrictive engineering / design Subsection of light weight designs This aerospace bracket reduces weight by 35% Major advancements in the next 2 3 years Manufacturing: Major move from prototyping to production currently 70/30 mix. Machine makers are focused on improving speed, volume and automation. Materials Advancement: Strength, Durability and Heat Resistance. Recent introduction of materials such as Carbon Fiber, Kevlar and higher heat resistant polymers and resins

24 3D CAD Design Improves: A new consortium driven by the software industry to further standardize the 3D printing process to create more data capacity/information in a rich file format. (3MF Consortium) Miniturization of Technology: Scaling down technology into efficiency needed for mass production. Compare this to full color 2D printing which started with high end commercial presses and has moved to desktop systems in offices and homes. Many More Users! Primary : STEM focus FDM technology penetrating at rapid rates FIRST Lego League teaches mechanical and 3D principles Secondary Resurgence in technical skills training Accessibility and training in CAD + 3D Design FIRST Robotics Post Secondary 3D literacy and competency is increasing dramatically

25 Resources & Guides Free 3D Applications Guide bigsys.com Quick read, this 12 page eguide packed with helpful information to help understand the impact 3D printing could have on your business Discover how other industries are using 3D printing and imagine how 3D could change your business See how 3D is a game changer in manufacturing, automotive, aerospace & defense, medical and dental industries Big Systems 3D Experience Center Markforged Mark Two Markforged X7 Industrial 3D Systems ProJet 6000 SLA 3D Systems ProJet 660Pro CJP 3D Systems ProJet MJP

26 3dprintingindustry.com Timely and extensive updates on all major 3D happenings worldwide