Quinn Hachey

Prospects for Micro-Factory Retailing of Automobiles : A Case Study of 3D Printed Electric Cars

Quinn HacheyM.Sc. Candidate

May 29, 2017

Quinn Hachey

Research Question

• Could micro-factory retailing be a viable alternative for Canada?

– What is micro-factory retailing (MFR)?

– How might such a model improve

sustainability?

– What technological innovations could enable a transition towards MFR?

– Case studies to demonstrate the feasibility of these technologies

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Micro-Factory Retailing A Potential Alternative

A theoretical business concept rooted in distributed/

decentralized economics that aims to improve upon the

industry’s current economic and environmental sustainability.

• Small scale, low volume, local manufacturing

• Emphasizes flexibility and customization

• Tight integration of manufacturing and retailing

• OEM involvement in downstream activities

• resource utilization & product longevity

• Requires a shift away from current production technologies

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Enabling MFR withSustainable Innovations

Additive Manufacturing

• Replaces traditional manufacturing methods

• Pressing, injection molding, drilling, and milling

Electric Mobility

• Replaces diesel & gasoline powered ICEs

• PHEVs & BEVs: PEVs

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Manufacturing Methods

Subtractive

• 3D objects are created by successively removing material from areas where it is not needed to create a desired shape

• More material waste

• e.g. Drilling and CNC milling

Additive

• 3D objects are created by successively joining thin layers of material to create a desired shape

• Often requires some level of post-processing

• Synonymous with 3D printing & direct digital manufacturing

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Additive Manufacturing

• Already being used for rapid prototyping by global OEMs

• Ford is the 1st OEM to test large-scale 3D printed parts

• Democratizes manufacturing

• Quantum leap for design freedom

• One-off and short-run manufacturing

• Economies of scope for true mass customization

• Benefits align closely with the goals of MFR

• Weight reduction could benefit EV range & efficiency

• Reduced overheard could be used to lower cost of EVs

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Electric Mobility A mobility ecosystem based on the use of electrified vehicles.

• Requires a new ecosystem of actors & stakeholders

• Significant barriers (e.g. Cost, Range,…)

• Compatible with other major automotive trends

• Could fulfill a key goal of the MFR model

• Micro-factories could be used to propel EV adoption

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In the News

Rethinking Transportation 2020-2030

• A report by Stanford University Economist Tony Seba predicting the demise of the ICE.

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Timeline for a Technological Transition

Rogers Diffusion of Innovation Theory

Cumulative Adoption

Relative Adoption

Tipping Point

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Business Model InnovationA Business model refers to “the manner by which an enterprise delivers value to its consumers, entices consumers to pay for value, and converts those payments into profits”.

• Product-Service system (PSS)

• Growing prevalence of mobility-as-a-service

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Urbee – KOR EcoLogic (Winnipeg, MB, CAN)

First 3D printed car body created in partnership with StratasysDirect Manufacturing Fortus 3D production system.

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Aerodynamic Shape Cd = 0.149

vs. 2017 Prius Cd = 0.24

Design Rendering of Urbee 2’s 3D Printed Interior

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Strati – Local Motors (Phoenix, AZ, US)World’s first fully 3D printed car (body & Chassis) using big-area additive manufacturing (BAAM) developed by Oak Ridge National Laboratory(receives funding from the US DOE).

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ITMS 2014 Chicago

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Blade – Divergent 3D (Los Angeles, CA, US)World’s first 3D printed 700 HP supercar. Founder & CEO, Kevin Czinger, previously co-founded EV car company Coda Automotive.

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3D Printed Alloy Nodes

Lightweight Carbon Fiber

Tubing

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CSE 2017

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When to expect this Transition?

• Business model innovation and PSS

– E.g. GM’s Maven ride sharing platform/service

• Widespread PEV adoption & electric mobility ecosystem

• Production worthy 3D printed vehicles

– Mostly in prototyping phase, many hurdles remain

• Global network of DDM enabled micro-factories

– In its infancy, LM Rally Fighter

– Likely several decades away

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Suitability for Canada

OEMs could forge a path towards “LIGHT” MFR

• Explore & experiment with new business models

• Embrace new mobility concepts

• Develop stronger direct consumer relationships

• Rely on existing knowledge & brand power to drive innovation

• Develop a charging network for PEVs

• Continue to explore & develop capabilities in AM

• Partner with manufacturers of 3DP

Quinn Hachey

Quinn HacheyM.Sc. Candidate hacheysq@mcmaster.ca

May 29, 2017