ADDITIVE AND SUBTRACTIVE MANUFACTURING

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1 ADDITIVE AND SUBTRACTIVE MANUFACTURING Jose Coronado Creo Manufacturing and Simulation Product Manager November, 2017

2 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive play together? Remarks 2

3 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive play together? Remarks 3

4 OPPORTUNITY FOR ADDITIVE MANUFACTURING The industry is expected to triple in size over the next 5 years Sale of AM products and services Medical Dental Source: Wohlers Report 2017: 3D Printing and Additive Manufacturing State of the Industry Annual Worldwide Progress Report, Wohlers Associates, Jewelry Aerospace 4

5 OPPORTUNITY FOR SUBTRACTIVE MANUFACTURING CIMdata values for 2016 end-user payments for CAM software showed an increase by 6.5% to $1.93 billion from the previous year Mold/Tools/Dies/Prototypes machining account for ~ 65% of the market Production machining (prismatic) account for ~20% 5

6 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive play together? Remarks 6

7 ADDITIVE MANUFACTURING FOR DESIGNERS AND CAD Designing for Additive Manufacturing creates new requirements Lightweight Structures Tray Assemblies Connectivity 7

8 LATTICE OPTIMIZATION FOR STRUCTURAL PERFORMANCE Maximum stress limit Original design Reduce weight Initial:18.2 Kg 8

9 LATTICE OPTIMIZATION FOR STRUCTURAL PERFORMANCE Hexagonal cell 70x70x70 mm Diam 5 mm 1 st Lattice Weight 7.0 Kg 9

10 LATTICE OPTIMIZATION FOR STRUCTURAL PERFORMANCE Initial Static Analysis Stress: 354 MPa 10

11 LATTICE OPTIMIZATION FOR STRUCTURAL PERFORMANCE Hexagonal cell 70x70x70 mm Stress Vm limited to 220 Mpa Beam Diam=? Calculated Beam Diam mm 11

12 LATTICE OPTIMIZATION FOR STRUCTURAL PERFORMANCE After Optimization Stress: 180 MPa 12

13 ADDITIVE MANUFACTURING EXTENSIONS (CREO 4.0 > CREO 5.0) Capability 3D printing from part or assembly mode Connectivity with GrabCAD Print and 3DS Print Tray Assembly creation (Printability, Nesting ) Freemium Creo Additive Manufacturing Freemium AMX. Lattices, Tray Assy and Connectivity Creo Additive Manufacturing Extension AMX Plus. Metal Printing Metal Extension Materialise Creo 4.0 Creo 4.0 Creo 5.0 Topology Optimization Topology Optimization Lattice modeling Build processor framework (Plastic printers) Creo 5.0 (Materialisepowered) Build processor framework (Metal printers) Creo 5.0 (Materialisepowered) (Materialisepowered) Support Generation (Materialisepowered) Topology Optimization Semi-Auto Geometry conversion Creo

14 BETTER LATTICE GEOMETRY Improving 3D Intersection algorithm for more robust lattice creation Additional lattice cell type (Truss) Improved simplified visualization Additional control on lattice and its link with Simulate Support of conical beams in Creo Simulate Apply thermal properties on idealized beams 14

15 IMPROVED SIMPLIFIED VISUALIZATION. LOW DENSITY LATTICE 15

16 IMPROVED SIMPLIFIED VISUALIZATION. MID DENSITY LATTICE 16

17 CREO 5.0: NEW PRODUCT INTRODUCTION Build Processor Framework Creo BPI Powered by Materialise Profile Manager Machine profiles & Build Configurations Connectivity between Creo and the Build Processor via APIs The BPS Framework is the backbone, each individual Build Processor should be purchased directly to Materialise. In partnership with: 17

18 TRAY ASSEMBLY. BUILD PROCESSOR FRAMEWORK Compatible BP's Version Models Metal/plastic SLM HL Metal 250 HL Metal 280 HL Metal 500 HL Metal HL Metal 250 HL Metal 280 HL Single Metal 280 HL Twin Metal 500 HL Quad Metal 500 HL Twin Metal EOS M100 Metal EOSINT M250 Metal EOSINT M250 Extended Metal EOSINT M270 Metal EOSINT M280 (200W) Metal EOSINT M280 (400W) Metal M290 Metal M400 Metal M400-4 Metal P350 Plastic P360 Plastic P380 Plastic P385 Plastic P390 Plastic P395 Plastic P396 Plastic P700 Plastic P730 Plastic P760 Plastic P770 Plastic P800 Plastic Formiga P100 Plastic Formiga P110 Plastic Compatible BP's Version Models Metal/plastic Renishaw AM250/AM400 Metal RenAM 500 Metal Additive Metal industries Additive Industries Machine BLT BLT S300 Metal Metal Beta BLT S300 BLT S310 Metal BLT S500 Metal Trumpf Truprint 1000 Metal Truprint 1000 Metal Truprint 3000 Metal Metal Beta Truprint 1000 Truprint 3000 Metal Demo BP Instance 1000 Metal Large, square platform, metal powder Metal Beta bed printer Large, square platform, plastic powder Plastic bed printer Small, round platform, metal powder Metal bed printer Small, square platform, metal powder bed printer Metal Small, square platform, plastic jet fusion Plastic printer Arcam A1 Metal A2 Metal A2x Metal Q10 Metal Q20 Metal HP 1.0 Beta Jet Fusion 3D 3200 Plastic Jet Fusion 3D 4200 Plastic Creo 6.0+ Creo 6.0+ Creo

19 CREO 5.0: NEW PRODUCT INTRODUCTION Support Generation (Metals) Creo Support Generation Extension Fully-integrated in PTC Creo Powered by Materialise Materialise Magics is the de facto standard to generate AM supports. The SG+ kernel integrated into Creo produces the same supports than Magics. Semi-automatic support generation for metal In partnership with: 19

20 CREO SUPPORT GENERATION EXTENSION Materialise-based Support structures Scope in Creo 5.0: Block, Line, Point, Web, Contour, Gusset, Tree (only manual) and Combi The supports are generated in the Tray assembly, after the parts have been positioned The support parameters are dependent of the Metal Printer selected. 20

21 GENERATING SUPPORT STRUCTURES FOR METAL 3D PRINTING The support structure is associative to the part and can be controlled by the user either by: Manipulating hundreds of parameters (delivered by Materialise) Creo native operations Powered by 21

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23 CREO 5.0: NEW PRODUCT INTRODUCTION Topology Optimization Creo Topology Optimization Powered by VR&D Fully-integrated in PTC Creo Semi-Automatic CAD Reconstruction Easy to setup and use In partnership with: 23

24 TOPOLOGY OPTIMIZATION Fully embedded into Creo, results converted into freestyle object Optional image 24

25 3D SYSTEMS DIRECT MANUFACTURING Connect directly to 3DS ODM from Creo Get immediate quotes 25

26 STRATASYS DIRECT MANUFACTURING Connect directly to Stratasys Direct Manufacturing from Creo Get immediate quotes 26

27 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive play together? Remarks 27

28 FUNCTIONALITY FOR NEW/OCCASIONAL USERS Usability Toolpath highlighting by click on it on the model tree Pre-requisite: perform play-path before Highlight references by clicking on a particular toolpath on the model tree 28

29 PREDEFINED NC PARAMETERS. BASED ON TOOL SELECTION Provide a way to set pre-defined parameters formulas and relations Settings depending on the tool selected STEP_DEPTH SPINDL_SPEED CutterDia/5.0 (for CornerRadius = 0.0) Or CornerRadius/5.0 (for Ball Nose tool) Or CornerRadius/3.0 (for other tool) /(PI*CutterDia) Meters/Minute Suggestions are welcome CUT_FEED Spindle_Speed *Feed per Tooth * Number of tooth. Number of tooth by default = 2; for drilling it is 1. Feed Per Tooth = CutterDia / 80.0; The goal is that a new or occasional user can have the minimum parameters filled up to display a toolpath on the screen He can modify any parameter at any time PECK_DEPTH STEP_OVER CLEAR_DIST THREAD_FEED THREAD_DIAMETER CutterDia/10.0 Suggestions are welcome CutterDia/5.0 Suggestions are welcome Suggestions are welcome Suggestions are welcome 29

30 FUNCTIONALITY THINKING ON ADVANCED/EXPERT USERS Roughing toolpaths enhancements Volume Milling improvements Slice by Slice option Trochoidal To create cycloidal toolpath movements along a curve Toolpath based on side or center of a curve Profile stock allowance 30

31 UI MODERNIZATION Conventional milling. Surface milling modernization Creo 5 Creo 6+ 31

32 CMM UI MODERNIZATION FOR REF CSYS AND CONSTRUCT 32

33 CREO 5.0: NEW PRODUCT INTRODUCTION Mold Machining Creo Mold Machining Extension Powered by Moduleworks Fully-integrated in PTC Creo, Easy to setup and use High Speed Machining toolpaths Multi-Core and Multi-threaded for high speed calculation Lightweight toolpaths data structure Various levels of caching High data processing capacity In partnership with: 33

34 MOLD MACHINING EXTENSION Moduleworks-based Mold Machining (3 axis in Creo 5.0) Advanced Roughing: Adaptive, Rest Rough, Support for Stock Model Advanced Finishing: Rest Finishing, Flatlands, Combination Cycles This extension includes 3 axis trajectory toolpath, comprehensive holemaking sequences and NC process automation functionality (XML templates) Concurent material removal simulation of Creo NC and the new MW-based toolpaths 34

35 PTC CREO PRODUCTION SOLUTIONS - OVERVIEW Tooling Integrated Injection Molding Simulation Automatic Core/Cavity Design Mold Base Design Progressive Die development NC programming Automatic tool path generation for: 2 to 5 axis milling for production machining 3 Axis milling for mold machining (new in Creo 5.0) 2 to 4 axis turning and live tooling 2 to 4 axis wire EDM Sheetmetal Manufacturing (Punch, Press, Laser- &Flame cutting) Quality Assurance CMM Programming First article inspection 35

36 Post & Sim. Mfg. productivity tools NC Machine type Expert Machinist/CAM Lite Prismatic & Multisurface milling Moduleworks-based Mold Machining. New in Creo 5.0 Production Machining Complete Machining CREO NC PROGRAMMING EXTENSIONS COMPARISON CHART Functionality 2 ½ axis feature base machining 3 Axis Milling for Production Machining (Creo 5.0) Functionality to produce efficient High-Speed 3 Axis roughing toolpaths (Creo 5.0) Multi-core processing of high quality 3 axis surface finish toolpaths (Creo 5.0) Adaptive Roughing strategies for constant cutting conditions (consistent tool load) 3 axis trajectory toolpath Comprehensive holemaking capabilities 4/5 Axis positioning Milling 2-4 Axis turning 2-4 Axis Wire EDM Live Tooling for Turning (Mill/turn : CBY) 5 Axis continuous milling and contouring machines (laser,..) Extraction of Manufacturing Annotation Features Tool and Fixture library Multi-Task Machines Synchronization Dynamic tool axis definition Manufacturing Process Documentation Creo/NC-GPOST : NC Post-processor generator Moduleworks-based Material Removal 36

37 MANUFACTURING RIBBON TAB Later, on a MOR 37

38 MILL RIBBON TAB HSM Rough HSM Rest Rough HSM Finish HSM Rest Finish High Speed Milling? 38

39 COMPARISON OF PRODUCTION MACHINING TOOLPATHS AND MOLD MACHINING TOOLPATHS 39

40 COMPARISON OF PRODUCTION MACHINING TOOLPATHS AND MOLD MACHINING TOOLPATHS 40

41 COMPARISON OF PRODUCTION MACHINING TOOLPATHS AND MOLD MACHINING TOOLPATHS 41

42 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive work together? Remarks 42

43 THE ADDITIVE MANUFACTURING PROCESS FLOWS Additive manufacturing is leveraging existing technologies like NC and CT Scanners Scanner/ CT Scanner Photogrammetry 3D Imaging / Modeling 3D Surface Reconstruction Point-cloud Processing Meshing PLM CAD CAE Printer Hybrid Machine tool Polishing, deburring, painting Post Processing CAM Scanner/ CT Scanner 6 1 Or CAM (hybrid AM) Scanner 6 END USE Part 1.- Design to print 2.- Design -> Optimize -> Print 3.- Topology Optimizaiton 4.- Hybrid manufacturing 5.- Post-processing of a 3D printed part (machining) 6.- Create the as-manufactured digital models 43

44 AGENDA The Opportunity Additive Manufacturing Subtractive Manufacturing How additive and subtractive play together? Remarks 44

45 REMARKS 3D Printing is a complement of current manufacturing technologies 3D printed parts still need postprocessing operations, like: drilling, facing, deburring etc. There is a group of considerations to be observed in the post-processing of 3D printed parts - The force of machining operations can deform the workpiece - The material can be flammable - - Creo additive and subtractive solutions are evolving to respond to the new requirements. 45