How 3D Printers and Rapid Prototyping Systems are Changing the Future of Product Development and Manufacturing

MANUFACTURING THE FUTURE

Stratasys, Inc.www.Stratasys.com/Future

Additive Manufacturing

Objectives Clear understanding of additive manufacturing market

Content Terminology Types of additive manufacturing approaches Application areas and benefits

Importance Foundation for identifying opportunities

Additive Manufacturing

Known by many names: 3D Printing

Rapid Prototyping

Rapid Tooling

Rapid Technologies

Rapid Manufacturing

Additive Fabrication

Advanced Manufacturing

Additive Layer Manufacturing

Direct Digital Manufacturing

Direct Manufacturing

Terminology

Additive Manufacturing Preferred term covering all 3D printing technologies/ applications Preferred replacement for rapid prototyping

Definition: Collection of technologies, directly driven by CAD data, to

produce 3-Dimensional physical models and parts through an additive process.

Primary Applications for Additive Manufacturing

Established / Traditional (Design)

Direct Digital Manufacturing(Manufacturing)

Additive ManufacturingAdditive Manufacturing

ConceptualModeling

ConceptualModeling

Functional PrototypingFunctional Prototyping

ManufacturingTools

ManufacturingTools

End-UseParts

End-UseParts

Technology Assessment

ConceptModelingConceptModeling

Functional Prototyping

ManufacturingTools

ManufacturingTools

End-UseParts

End-UseParts

3D Printers 3D Production Systems

Performance Requirements Increase

Conceptual Models & Functional Prototypes

Primary Benefits• Reduce time to market

Solidify design earlier Reduce late design changes

• Lower product development cost Make design changes earlier in process Make mistakes early and often

Secondary Benefits• Facilitate communication between teams and

vendors• Improve product design

Jay Leno’s Garage: Concept Models

1907 White Steam Car D-Valve replacement needed Not available at local automotive center

Utilized multiple technologies 3D Scanning Materialise - software 3D Printing

From broken to fixed part - quickly1. 3D scan broken D-Valve2. Concept model produced3. Validated design

Concept Models at Ducati

Design of Desmosedici Engine Saved over $1.5M in outsourcing costs

Concept to final engine design in 8 months vs. 28 months (71% time savings)

Eliminated 83 design problems

Major piston design change Started with twin oval piston Final design a four round side-by-side

“To keep Ducati at the forefront of engine design, we sought a technology that could make accurate, durable prototypes quickly.”

Piero Giusti, Ducati

Functional Prototyping at Toro

Commercial & Residential SprinklersPrototyped in few hours for testing

Validated form, fit and function Pressure testing at +100 psi

Working prototype made for each new design

Over a 2 year period & many projects Reduced product development by 283 weeks Reduced tooling costs by $500,000

Functional Prototypes at Logitech

Bluetooth Headset• Headset failure

Many iterations of functional prototypes Gave to focus groups for evaluation

• Found new, counterintuitive design fix 273% stronger

• Faster response, lower cost More functional prototypes Better products, satisfied customers

Direct Digital Manufacturing Applications

Primary benefits Lowering costs Increasing profits Decreasing time-to-market Decreasing cycle time

• Secondary advantages Design freedom Product redesign frequency Rapid response

Direct Digital Manufacturing Applications

Best fit when:• Relative low volumes

Short run production and bridge to tooling• High part complexity

Eliminate expensive tooling Reduce long lead times

• Part acceptable Aesthetics not critical Finishing processes feasible Physical properties acceptable

Manufacturing Tools

Examples: Jigs Fixtures Check gauges Drill / rivet guides Go / no-go gauges Alignment tools & guides Tooling masters & patterns

Manufacturing Tools at BMW

Emblem Headlight Alignment

Cubing Device Gage Checker

Bumper Reach

Jigs & Fixtures at BMW

Manufacturing Jigs and Fixtures with FDM• Automobile assembly & testing tools

Over 400 jigs & fixtures / vehicle Many produced on Fortus system

• Benefits to workers and processes: Improved productivity Design optimized for worker comfort Increased process ease-of-use Greater process repeatability

AUTOMOTIVE

Manufacturing Tools at Oreck

Repeatable & accurate assembly • Custom vacuum assembly pallets

• Requirements 40 – 50 / model 5 – 10 models in production

• Benefits 65% reduction in fixture costs $100,000 / fixture savings (up to) 58% reduction in manufacturing defects Replacement fixtures in hours vs. weeks Nearly eliminated worker fatigue & injuries

End-Use Parts

• Primary Benefits Lower cost Shorter lead time

• Secondary Design freedom

• Few design for manufacturing constraints Change freedom Mass customization Supports lean initiatives True JIT (just-in-time) manufacturing Reduced warehouse space/inventory cost

End Use Parts at DST Control

• Gimbal eye or camera For unmanned aerial and ground vehicles Stable images from unstable carriers

• Fortus machine produces 20 different parts Meet accuracy and quality standards Reduce delivery time for custom products

• FDM parts perform better Lower weight Better electrical insulation

• Time and cost savings Part cost reduced 66% Custom part production time reduced 63%

FDM reduces cost 66% & time 77%

Method Cost Time

Traditional Manufacturing

€2,441

11 weeks

Direct DigitalManufacturing

€830 4 weeks

Savings €1,611

(66%)

7 weeks(63%)

• Custom bezels manufactured Accept only one vial size Easy customization

• Saving $25,000 on Engineering time Tooling / bezel

• Design flexibility New product design without tooling Able to support new vile sizes Unique competitive edge

Automated Pill Dispensing System

End Use Parts at ScriptPro

Method Cost Time

Traditional $31,650 60 Days

Fortus $ 6,750 2 Days

Savings $24,900(78%)

58 Days (97%)

Summary

• Terminology AF DDM 3D Printer 3D Production system

• Business segments On Demand 3D Printers 3D Production Systems

• Applications Product design

• Concept models• Functional prototype

Manufacturing• Manufacturing tools• End-use parts

More Information

Test it, Prove it. Send 3D cad file and have Stratasys build it for you Application Engineer consultation

www.Stratasys.com/Future Download Application Guides and White Papers Fill out form to get benchmark built Get FDM sample part Request Consultation