mission: to advance economic prosperity, health and
TRANSCRIPT
MISSION: TO ADVANCE ECONOMIC PROSPERITY, HEALTH
AND
QUALITY OF LIFE IN INDIANA AND BEYOND.
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KYLE SQUILLACETechnology Acceleration Specialist
• Certified Additive Manufacturing, Technician - SME
• Additive Mfg operator and trainer on technologies including
FDM, Polyjet, and SLS for 10 years
• Managed job shop focused on product development, rapid
prototyping, and low volume production
• Logged over 10,000 build-hours on additive equipment
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Image Credit: Deloitte University Press
3D PRINTING PROCESS OVERVIEW
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ADDITIVE MANUFACTURING
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Can be defined as 3D Printing + SUBSEQUENT PROCESSES
REQUIRED to support production manufacturing
(rather than prototypes or R&D)
PROCESS MAP – FUSED FILAMENT
Machine
Digital Build Setup
Unload/Load Matl.
Post Process
Inspection
Pre-Build Setup
Print bed TransferPart
Removal
Printbed Return
Support Removal
PRIMARY CATEGORIES
1. Stereolithography (SLA)
2. Material Extrusion (FF or FDM)
3. Material Jetting
4. Binder Jetting
5. Powder Bed Fusion (SLS, MJF, DMLS)
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CATEGORIES OF 3D PRINTING
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Fused Filament
In FF/FDM, an object is built by selectively depositing melted material in a pre-determined path layer-by-layer. The materials used are thermoplastic polymers and are loaded as filament spools or pellets that extrude out as a continuous bead.
FDM is the most widely used 3D printing technology: it represents the largest installed base of 3D printers globally and is often the first technology people are exposed to.
Real world plastics such as ABS, PLA, PC/ABS, PETG
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Stereolithography (SLA or DLP)
Relies on Laser or UV light to locally harden a vat of liquid resin formulated to mimic common plastics
Highly accurate, smooth/resolute surfaces are achievable. UV post curing is requiredRelatively high cost vs. other 3D techMost resins not suitable for outdoor exposure
Common resins include Poly-Pro, ABS, Polycarbsimulators
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Material Jetting
Material Jetting (MJ) is an additive manufacturing process that operates in a similar fashion to 2D printers.
In material jetting, a printhead (similar to standard inkjet printing) dispenses droplets of a photosensitive material that solidifies under ultraviolet (UV) light, layer-by-layer.
The materials used in MJ are thermoset photopolymers (acrylics) that come in a liquid form.
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Powder Bed Fusion (MJF, SLS)
Energy source such as a laser beam or IR source fires down onto a heated bed of fine polymer or metal powder; melting and fusing features together
Common materials include Nylons, Thermoplastic Urethanes (TPU)
Relies on thermal energy to locally fuse a bed of powdered material without any support other than surrounding powder cube
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LIFE CYCLE ADOPTION IN MFG
Prototyping Beta Testing Production Spare Parts
Pro
du
ct V
olu
me
Life Cycle Phases
3D Printing Introduced
Technology Improves, Cost goes
down
Material Improves,
Automation and
Software grow
End Use Parts are
the ultimate
goal
ADDITIVE MANUFACTURING AND LEAN
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1. Most AM technologies operate on minimal waste and energy – less processing, less non-value add activity
2. Complexity is not a driver of cost vs. traditional mfg, add value not cost3. Compress the value stream – prototyping obvious, other areas too4. Digital workflows- AM among others- reduce inventory, lead time,
overproduction5. Pull-based supply chain based on demands, not forecasts, easier to adopt
with a lean process like AM6. Continuous Improvement – 3D Printing of prototypes and production assist
tools allows you to fail fast, fail cheaply, iterate and improve
OPERATOR TRAINING TOOL
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◼ Exploded assemblies or cutaways, as
shown at right, add value for technicians
◼ Launches can be much smoother if a
prototype exists prior to finished parts
arriving
◼ Supports the Lean motto of work
smarter, not harder, continuous
improvement
PROCESS VERIFICATION TOOL
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◼ Cost avoidance is justification enough
to produce prototypes for internal use
◼ Handing over a pre-production part to
the team in charge of the mfg process
Give team early opportunity for detection of
errors without delaying production
Proves out machines and process design
before there’s a potential problem and
shutdown
◼ These custom fixtures can be made more quickly and with less operator time vs.
traditional tool room fixtures
◼ Fixtures can be digitally modeled in CAD to fit unique part geometries before being
sent to a printer that can add entities such as color, texture, ID tags, etc
Image source: http://blog.stratasys.com/2014/06/27/3d-printed-jigs-fixtures-webinar/
Jigs and Fixtures
Jigs and Fixtures
◼ Can be a simple holder but also feature-rich.
◼ A snap-fit release post was added to aid in this 2-piece housing disassembly.
◼ Created an efficiency gain of
more than 25% from a single
print.
◼ Could consist of multi-durometer
surfaces for sensitive part areas.
Image source: https://printparts.com/materials/grey/
Gauges
◼ Gauges may appear a bit different than traditional milled versions, for example
◼ Design freedom is greater when using 3D Printing so traditional profiles like blocks
and circular holes can be made in other profiles while adding no cost or time.
Image source: Formlabs
• Assembly fixtures and tools
• Visual Aids
• Robot end of arm tooling
• Gages and fixtures
• CMM support through fixtures
• Go/No-Go gages
Gauges
Gauges
◼ Text can be embossed or debossed without a secondary operation
◼ 3D Printed gages can be given color, identification tags, and dual durometer features
much more easily and cost effectively than traditional gauges
Image source: HP
Bespoke Operator Tools
–On demand
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In stock?
Warehouse
Order Picked
Order Shipped
Customer
Order Placed
Traditional
Fulfillment Process
Supply chain
No
Yes
Mfg performed
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✓ Reduce physical
inventory
✓ Offer customization ✓ Reduce lead time
✓ Reduce warehousing
Pull System – Build to Order
SPARE PARTS ON DEMAND FOR THE BEVERAGE INDUSTRY
• Component count reduction creates a supply chain independence
• Fewer failure points translates to improved performance and lifespan WEIGHT
REDUCTION
35%
MANUFACTURING TIME
DECREASED
1 wk
Source: Jung & Co. Gerätebau GmbH via concept
Laser
8 wk
Industry example
29https://ctl.mit.edu/sites/ctl.mit.edu/files/library/public/2014ExecSummary-BhasinBodla.pdf
Total part cost
• According to a recent study, supply chain costs (non-value add) avg. 10-15% of total part cost in manufacturing and industrial distribution (Sum of bottom 3 contributors)
• Therefore, a 80%+ savings within the supply chain as shown above using Additive vs. Traditional improves the total part cost by 8-12% -before any warehouse space/labor savings are seen
ADDITIVE MFG IS HERE TO STAY + NEW APPLICATIONS DEVELOPING
IMPORTANT TO UNDERSTAND AM IS NOT A FIT FOR EVERY APPLICATION - PURDUE MEP PROVIDES A SOLUTION - NOT A SALE
MACHINE FEATURES, SPEEDS, AND MATERIALS ARE CONSTANTLY IMPROVING- DIFFICULT TO KEEP UP
VIRTUALLY EVERY MFG CO. CAN BENEFIT FROM 3DP OR ADDITIVE
SEEING MFG FROM THE ADDITIVE VIEW IS KEY TO OPENING UP NEW OPPORTUNITIES AND BUSINESS MODELS
KEY TAKEAWAYS
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MEP TECHNOLOGY PRODUCTS
• Additive Manufacturing Site Assessments
• Additive Manufacturing Workshops and Training
• 3D Scanning Demos and Benchmarking
• Automation Assistance – evaluations, reports, training opps
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ADDITIVE MFG ASSESSMENT
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Objectives
• Integrate Additive Manufacturing within the shop floor
• Integrate Additive Manufacturing into your supply chain
• Choose the right technology and machine to fit your business
objective and capabilities
Why Purdue MEP?
Our team offers an experienced, neutral, and solution-based approach
taking into account all relevant systems available - rather than a portion
of the market sold by a traditional reseller.
ADDITIVE MFG ASSESSMENT
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DeliverableA detailed report covering client applications discovered during the site visit including:
• Best Fit Technologies
• Training and resources required
• ROI and Payback Period
• Benchmark parts of your own
ADDITIVE MFG TRAINING
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Fundamentals of Fused Filament 3D Printing – 4 hrs
Includes hands-on activities and covers topics such as technology strengths,
limits, applications for manufacturing, workflow, materials, and design principles.
Additive Mfg and Quality Core Tools – 8 hrs
This technology has made its way up the chain and closer to the end customer,
which means additive requires the same quality systems put in place for
traditional manufacturing. The goal of this workshop is to unite the worlds of
additive and quality through a combined workshop.
THANK YOU FOR PARTICIPATING
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Contact Info for Kyle Squillace
www.mep.purdue.edu