2011 11-15 themadag am voor metaal en keramiek - direct spare - a european approach for spare parts...
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DirectSpare: A European Approach
for Spare Parts on Demand
Karel Brans – MaterialiseAM Conference Loughborough 2011
DirectSpare
Content
• Spare Parts on Demand, the Dream
• Identification of Barriers and Research Objectives
– Selection of Case Studies
– Design
– Materials
– Processes
– Quality Assurance
– Business Models
• Demonstration
• Conclusion
2
DirectSpare
Spare Parts on Demand, the Dream
12
Online Shop
Web
Local
3
5
6
√
4
3
DirectSpare
Spare Parts on Demand, the Dream
The impact of the DirectSpare concept
Warehouses stacked with
spare parts...Software Databases!
4
DirectSpare
Spare Parts on Demand, the Dream
The impact of the DirectSpare concept
Ordered spare parts
transported around the globe...Local production of spare
parts at customer site!
5
DirectSpare
Spare Parts on Demand, the Dream
The impact of the DirectSpare concept
Millions of unused spare parts
being reduced to scrap...Only on demand production
of required parts!
6
DirectSpare
Spare Parts on Demand, the Dream
The impact of the DirectSpare concept
Obsolete equipment
because of unavailability of
spare parts...
Reverse engineered spare
parts, produced by AM!
7
DirectSpare
Spare Parts on Demand, the Dream
The impact of the DirectSpare concept
Manufacturing at low wage
countriesManufacturing in Europe
Production of Spare Parts for Europe
8
DirectSpare
Spare Parts on Demand, the Dream
12
Online Shop
Web
Local
3
5
6
√
4
9
DirectSpare
Identification of Barriers – Project Structure
10
Prototypes Spare Parts
Product Life Cycle
Demand
Part Selection Design
DirectSpare
Identification of Barriers - R&D Objectives
DESIGN
AM materials are different
The original part has failed
► AM spare parts need to be redesigned How can redesign costs be minimized?
What if only a damaged original part is available?
How to collect design specifications?
11
DirectSpare
Identification of Barriers – Project Structure
12
Prototypes Spare Parts
Product Life Cycle
Demand
Part Selection MaterialsDesign
DirectSpare
Identification of Barriers - R&D Objectives
MATERIALS
Selected cases reveal limitations in AM material
Both polymer and metal
Improved properties open wide range of possible
new applications for spare parts
► New AM material is required How to optimize without starting from scratch?
Focus on which properties?
13
DirectSpare
Identification of Barriers – Project Structure
14
Prototypes Spare Parts
Product Life Cycle
Demand
Part Selection Materials ProcessesDesign
DirectSpare
Identification of Barriers - R&D Objectives
PROCESSES
Coping with new materials
Fulfill high requirements for spare parts
► AM processes need to be modified Which part properties to focus on?
How to evaluate the process?
...
15
DirectSpare
Identification of Barriers – Project Structure
16
Prototypes Spare Parts
Product Life Cycle
Demand
Part Selection Materials Processes Business ModelsDesign
DirectSpare
Identification of Barriers - R&D Objectives
BUSINESS MODELS
Not just replacing traditional manufacturing by AM
Complete business model and supply chain
change
► New Business Models are required What are the different business model scenarios?
Maximizing the gains of manufacturing with AM?
Which investments and how do they pay off?
Costs for switching to AM?
Should you partner or go for it alone?
...
17
DirectSpare
Identification of Barriers – Project Structure
18
Prototypes Spare Parts
Product Life Cycle
Demand
Part Selection Materials Processes Business Models QADesign
DirectSpare
Identification of Barriers - R&D Objectives
QUALITY ASSURANCE
Functional parts are made
Repeatable quality must be guaranteed
Traceability and certification are required
► New Quality Assurance guidelines and
methodologies are required What are the main quality parameters?
How can we guarantee quality at an acceptable
cost?
Which quality guidelines can we formulate?
...
19
DirectSpare
Identification of Barriers - R&D Objectives
A project Structure to tackle these challenges
General AssemblyChaired by Project CoordinatorPresent: All Partners
EIIGPresent: External Industries
Steering CommitteeChaired by SME (BPO)Present: All SMEs + Project Coordinator
WP7: Dissemination and Exploitation
Inspire
Management BoardChaired by Project CoordinatorPresent: All WP leaders + Project Coordinator
WP1: Case Studies
FCUB
WP2: Design and Simulation
BPO
WP3: Material Development
EVO
WP4: Process Development
EOS
WP5: Business Model, ICT and TQM
FHG
WP6: Demonstration
+90
20
DirectSpare
CASE STUDIES
Application driven project: Case Study Selection
Automotive Aerospace Domestic
Appliances
Energy Industry
21
DirectSpare
Application driven project: Case Study Selection
Automotive
Front Grill
Aluminium (Al99,9 Mg 0,5 F10)
Obsolete tools
24h delivery time within EU
Head Light Cover
Plastic (PP Copolymerisat)
Running out of stock, tools
24h delivery within EU
CASE STUDIES
22
DirectSpare
Application driven project: Case Study Selection
Aerospace
Command Support
Composite + coating (+inserts)
No CAD file, Obsolete tools
Red Gimbal
Composite (using moulds)
Running out of stock
Actual delivery time > 2 weeks
CASE STUDIES
23
DirectSpare
Application driven project: Case Study Selection
Domestic Appliances
Energy Industry
Drive Pedestal
Polymer (PA) + Rubber (NR)
AM is alternative, avoiding assembly
Heat Shield
Metal (Inconel 939, cast)
AM is alternative
CASE STUDIES
24
DirectSpare
CASE STUDIES
Which Parts are potential DirectSpare parts?
RM-Part ?Engineering
Constraints
Material
Constraints
Process
Constraints
Economic
Constraints
Product Quality
Constraints
RM-Part feasible ! RM-Part not feasible
Ecological
Constraints
25
DirectSpare
DESIGN
Design Scenarios
Pre-production
Spare part design
Flexible Pre-production
Spare part design
Post-production
Spare part design
Parallel engineering original and AM spare part “Independent” Engineering
26
DirectSpare
DESIGN
When no 3D file is available
Scan the damaged original part
Back to
CAD?
27
DirectSpare
DESIGN
When no 3D file is available
Advanced
hole filling
tools
Sketching
tools on STL
files
Wrapping
tools = “1 click
fix + offset” + macros
28
DirectSpare
DESIGN
Automating redesign for AM spare parts
Test Case Specifications:•Composing specs is important, but difficult.
• “Obvious” things are ignored.
•Often, specifications are unknown.
•There is no “generic” specification sheet.
• Expensive process!
Proposed Solution: “Copy part method”:•The original part was designed according to specs
•Copy its behaviour to the AM Spare part
•Derive typical properties such as:Mass
Stiffness (in x, y, z)
Strength (in x, y, z)
Natural Frequencies.
29
DirectSpare
DESIGN
Application of new methods and state of the
art engineering on test cases
30
DirectSpare
MATERIALS
Which properties to focus on?
Polymers (PA based):
1. Elongation at break
Metals:
1. High Temperature: Hastelloy X
2. Aluminium
Optimising PA
powder
composition
Post treatment
of PA powder
Optimisation of
powder composition
and morphology
Optimisation
of process
and post
treatment
31
DirectSpare
MATERIALS
Optimizing powder material
SEM image showing particle shape and size of the new Evonik PA
Increased elongation at break measured
Processing Challenges:• Sinter behaviour (DSC measurements)
• Formation of agglomerates
• Sticking to blade
• ...
Analysis of composition, morphology and flowability of EOS AlSi10Mg powder
PA based
Al based
Processing Challenges:• Residual stresses
• Surface finish
• ...
32
DirectSpare
MATERIALS
Post Treatment of PA Parts
1. Influence physical ageing: rejuvenation by
• Heat treatment resulting in rejuvenation.
• Swelling in liquids
2. Improve cohesive strength by:
• Application of 4 different filling materials.
• Exposure to gamma radiation to crosslink
amorphous material
Specimens to evaluate dimensional stability
Objective:• Increase ductility
• Maintain dimensional stability
33
DirectSpare
PROCESSES
Laser Sintering of Hastelloy X
Optimization of process parameters ( + post processing routines)
Scan speed (mm/s)
Ha
tch
dis
tan
ce
(m
m)
34
DirectSpare
PROCESSES
Laser Sintering of Aluminium
Optimization of process hardware: preheating
Optimization of process parameters
35
DirectSpare
PROCESSES
Laser Sintering of Aluminium
Optimization of process hardware: preheating
Preheating
36
DirectSpare
PROCESSES
F-Cubic Metal Printing Process Optimization
Goal: To investigate if AM can produce parts equal to
traditional processes (MIM, machining) considering:
• Surface finish
• Dimensional accuracy
• Material properties
• Cost
Approach• New printer with linear
encoder for better print
accuracy
• New device to add
powder to the platform
37
DirectSpare
QUALITY ASSURANCE
Identification of quality parameters
Resulted in long list of recommendations
Cost calculations of recommended procedures (focus on material analysis and
automatic finishing)
38
DirectSpare
QUALITY ASSURANCE
AM Data Management and Tracking
Data management system
Magics Link
Shop
Online Shop
ConvertFix
Label
...
Plugins
39
CRM
12
Online Shop
Web
Local
3
5
6
√
4
DirectSpare
QUALITY ASSURANCE
Standards and certification
40
DirectSpare
Aspects
High Low
Volume
As Is Improved
Product
Multiple RM only
Manufact
On stock On demand
Supply strat
31 2
3 scenario’s
BUSINESS MODELS
Identification of scenarios
41
DirectSpare
BUSINESS MODELS
Customer
Demand &
Intake
Engineering
Manufacturing
Assembly Service Use Aftersales
Layering Processing Finishing
Volume & Cost Topics
Product requirements
Process requirements (incl. warehousing & transportation. IT issues))
IPR/Liability issues
Environmental impact
Number of stakeholders
Quantifying DirectSpare impact on Business Models
1. Currentsituation and
scoping
2. Alternativesolutions
3. Technical feasibility
• Long list alternatives
• AM possibility• Set up Techni-
cal feasibility
• Market issues & requirements
• Project Set Up& timing
• SWOT
•Short list alternatives
• AM solution•Set up Commer-cial feasibility
4. Commercialfeasibility
• Business Case• Supply chain• Partners and
investmentsrequired
5. Actionplan
• Roll out
• Activities:
• Market research• Customer demand• Current design
production and marketplaces
• Legal issues• Environment• Patents
• Activities:
• Solution long list • Selection criteria• Outsider input
• Visualisation of solution
• Highlight plan with milestones
• Go/no go planning
• Activities:
• Benefit/constraint• Physical principles• Function & process
• Data capturing• Decide on solution
• Determine technical feasibility
• Activities:
• Sketch proposed supply chain
• Research benefits
over alternatives• Make business &
investment plan• Determine com-
mercial feasibility
• Activities:
• Select marketplace and business model
• Contract partners• Agree on
introduction plan• Secure investment
Week1 Wk 3 Wk 5 Wk 8 Wk 11 Wk16
42
DirectSpare
Conclusion
• DirectSpare, the Dream
• The Impact of DirectSpare
• Identification of Barriers and Research Objectives Selection of Case Studies
Design
Materials
Processes
Quality Assurance
Business Models
• Demonstration
43
DirectSpare
DEMONSTRATION
Example, Red Gimbal
Movie of First test flight new Flying Cam Helicopter
44
DirectSpare
Danke!
Merci!Bedankt!
Tack!
Teşekkür Ederim!
45
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