An introduction to. the Additive Direct Digital Manufacturing (DDM) Value Chain. Terrence J. McGowan Associate Technical Fellow Boeing
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1 An introduction to the Additive Direct Digital Manufacturing (DDM) Value Chain Terrence J. McGowan Associate Technical Fellow Boeing Copyright Boeing. All rights reserved. GPDIS_2015.ppt 1
2 Intro To Additive Direct Digital Manufacturing (DDM) Key Benefits of DDM Include: Reduced buy-to-fly ratios Reduced material cost Reduced part lead times No tooling needed Part consolidation (Unitization) Part weight reduction Improved thermal material properties Improved electrical material properties Replicating out of production parts Days Hours DDM Offers considerable value to current product value streams GPDIS_2015.ppt 2
3 Intro To Additive Direct Digital Manufacturing Additive Manufacturing = Rapid Manufacturing > Direct Digital Manufacturing (DDM) DDM is a value chain: Employs advanced design methods and tools Utilizes additive fabrication 3D printing technology Exploits advanced inspection tools DDM is not a process revision DDM is a paradigm shift that fundamentally changes the manufacturing value chain and offers compelling business value The Society of Manufacturing Engineers (SME) has endorsed DDM DDM is a data driven value chain DDM is a revolution not an evolution GPDIS_2015.ppt 3
4 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 4
5 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 5
6 DDM Part Specifications What does the component need to do? (design for function) Initial considerations prior to design: Allowables Dimensions Interfaces Loading Boundary Conditions Material Type Conductive/Non-Conductive Finish Type Environment Print To Part! DDM design considerations begin with design for function GPDIS_2015.ppt 6
7 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 7
8 DDM Design Engineering and Analysis Design For DDM Exploits the Fabrication Capabilities of 3D Printing System Level Design Consideration of other characteristics (i.e., mounting brackets, wire clips, supporting structure, attachment points for other items, etc.) Structures in Nature (organic) Organic structures excellent examples of max strength min mass Optimized designs from trial and error of loading conditions Multi-Functional Design Combined functions into single component Mount structure + heat exchanger Component Consolidation (Unitization) Integration of multiple components to monolithic component Internal Channels Fabrication of internal channels into component Square Channels/Holes Hole geometry can be shaped in a way that optimizes the design DDM unlocks design constraints based on producability GPDIS_2015.ppt 8
9 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 9
10 Digital Product Data Quality Assurance Digital Product Data Quality is Essential To The DDM VS CAD Model Geometry Must Use 3D Closed Solids Component Assemblies Must Be Merged To Solid CAD Validation &Verification Check Manifold Geometry Topology File Format Conversion Verification and Validation Conversion errors Machine Code Verification and Validation Sliced Data G-Code ISO Standards Compliant Data Specifications STL ASCII File AMF - XML 3MF - XML DDM requires robust data specification compliance GPDIS_2015.ppt 10
11 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 11
12 DDM Data File Format Sharing and Distribution DDM Product Authority Must Be Managed As High Value Capital Assets STL Legacy File Spec. for 3D printing (tessellated) Adopted in the eighties Inadequate for continued use AMF Contemporary ISO/ASTM File Spec. XML structure Uses advanced optimized tessellation (curved triangles) Supports advanced attributes and metadata with DRM 3MF Industry consortium Cloud deployable Advanced print descriptions Supports DRM Digital Rights Management Loss of authority data = IP escape Strictly controlled distribution is key DDM file sharing and distribution exposes IP GPDIS_2015.ppt 12
13 DDM File Sharing STL Postscript GPDIS_2015.ppt 13
14 AMF Sub-D Surface Geometry Sub-Division N GPDIS_2015.ppt 14
15 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 15
16 DDM Fabrication Process (3D Printing) 3-Dimensional Printing (powder based, polymers and ceramics) Selective Laser Sintering (powder based, thermoplastics and composites) Direct Metal Laser Sintering (powder based, steels and titanium) Stereolithography (resin based, photosensitive polymers) Fused Deposition Modeling (filament based, amorphous thermoplastics) Laser Additive Manufacturing (filament based, steels and titanium) Laser Freeform Manufacturing (powder based, steels, invar and titanium) Direct Write Electronics (deposition of conductive materials) GPDIS_2015.ppt 16
17 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 17
18 DDM Fab Post Processing De-burring Support Structure Removal HIP Hot Isostatic Pressing Annealing Controlled heat Stress Relief Controlled cooling Surface Finishing Machining, tumbling, shot peening, sanding, sand blasting, etc Coatings Painting, fillers, epoxy or urethane sealants, and metallic plating DDM does requires post processing touch labor GPDIS_2015.ppt 18
19 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 19
20 Quality Inspection & Certification Optical Inspection 2D white light photogrammetry Time of flight laser scanner Radiologic Inspection X-Ray MRI Neutron Backscatter CT Inspection Internal channels and voids Other Inspection methods (Quality Record) Build process slice recording Computer Imaging Thermal Imaging DDM will challenge the limits of inspection capabilities GPDIS_2015.ppt 20
21 DDM Data Driven Value Chain Notional DDM Value Chain Stages Part Specifications Digital Product Data Quality Assurance Fabrication Inspection and Quality Certification Design Engineering & Analysis Data File Format Sharing and Distribution Post Processing Supply Chain Management The DDM additive value chain is interdependent of its parts GPDIS_2015.ppt 21
22 DDM Supply Chain The DDM Supply Chain Disrupts Traditional Sourcing Models In-House Factories Large footprint environmental, safety, material storage, energy Scheduled maintenance servicing, repairing, calibrating High quality production parts Quality and certification inspection Laboratories Short run parts Prototypes form, fit, function Manufacturing aids safety, tools, covers, etc. Desktop On-demand printing Tactile iterative component design Printer Farms External Suppliers Specialized Fabricators Metals Polymers Large Size Printing Large Scale Printer Farms Cloud Based Dispatching Service Bureaus DDM supply chain optimized for automation and efficiency GPDIS_2015.ppt 22
23 Serialization & Anti Counterfeiting Lost IP results in lost revenue, counterfeit parts and safety risks. Serializing Parts: Etched Coating Paint Embedded Micro Markers Nano-Doping Trace Element Nuclear Digital Rights Management Higher fidelity of authority part information is shared Security of 3 rd Party Suppliers Unknown DDM IP protection is key to success GPDIS_2015.ppt 23
24 Conclusion Direct Digital Manufacturing value stream planning must be done holistically with all functions being interdependent to each other. Equal and balanced development of the DDM constituent functions offers maximum value to production. When mature, the DDM value stream will supplant most other manufacturing norms. GPDIS_2015.ppt 24
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