tuv sud industrial additive manufacturing
TRANSCRIPT
July 2019
Industrial additive manufacturing –are you ready?
7/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING
Mr. Gregor ReischleHead of Additive Manufacturing
Responsible for the global activities within this segment. Over 10 years of experience in the field of additive manufacturing. Auditor and AM implementation consultant. Audited, trained and consulted more than 60 additive manufacturing
centres worldwide since 2008. One of the founding members of the Additive Minds consulting unit, where
he codeveloped and managed EOS GmbH Dental Process Chains and wrote several patents within this field.
Meet the speaker behind the voice
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Agenda
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The quick check assessment for iAM implementors 5
The TÜV SÜD AM services4
The industrial AM ecosystem and the iAM readiness3
Risk overview of processes and workflows2
The use case for industrial additive manufacturing (iAM)1
From 3D printing to additive manufacturing and industrial use
TÜV SÜDIndustrialisation of systems and the AM supply chain continues throughout the
world↓
International standardisation of processes and materials
19883D Systems
First commercial AM facility -Stereolithography (SL)
2005Z corporation
First high-resolution 3D printer realised
2010Stratasys
First 3D printed car producedOrganovo Inc.
First fully organically printed blood vessels
Today
1990EOS
First Stereolithography (SL) system sold
1991Material Extrusion (MEX)
and Sheet Lamination (SHL) commercialised
1992DTM
Powder bed fusion laser-beam (PBF-LB)(also known as Selective Laser Sintering)
becomes available
1997AeroMet
Directed Energy DepostitionElectron-beam (DED)
is developed
2017AM disrupting otherindustries 3D printed houses Aerospace components Prostheses in the
medical sector
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Difference between 3D printing and industrial additive manufacturing
Business model:Functional parts, high-risk parts industrial (series) production1. Reproducibility and traceability
– very important2. Exact definition of manufacturing process necessary
Industrial additive manufacturingBusiness model:Rapid prototyping and only low-risk parts1. Reproducibility and traceability
less important2. Manufacturing process manually adjusted for each
batch
3D printing
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Most important sectors:
End components have surpassed prototypes
Education/Research 9.90
Other 4.40
design models 10.70
functional prototypes 27.90
Polymer Moulds 7.70
Metal mould making 4.70
fastening elements 6.10
end components 28.40
Automotive Mechanical engineering
MedicineAviation
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AM value proposition should match customer demands from the start
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Industrial AM pioneering industries
DentalMedical
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Industrial AM pioneering industries
Aerospace and turbomachinery
Source: Trumpf Source: Trumpf Source: Trumpf
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Industrial AM pioneering industries
Automotive
Source: Trumpf Source: Trumpf Source: Trumpf
Source: Bimmertoday; BMW Source: Bugatti
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Industrial AM pioneering industries
Railway: spare parts
Source: Trumpf Source: Trumpf Source: Trumpf
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Industrial AM pioneering industries
Consumer goods
Source: Trumpf Source: Trumpf Source: Trumpf
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Some other strategic decision criteria
low Implementation effort
Bene
fits fo
r the
comp
any
low
high
12
34
5
6
7
8
9
10
11
1213
141516 17
1819
Part assessment 1
Part suitability (printability, risks, tests and approvals) 2
Printing partners qualification 3
No stock keeping necessary 4
Reduced delivery times 5
No tools necessary 6
Storage size can be reduced 7
Costs independent of quantity (lot size 1 possible) 8
Reduced personnel costs necessary 9
Internal 3D printing competencies to be expanded 10
Adaptation of knowledge for new products 11
Process for potential analysis of 3D printable spare parts 12
Preparation for increasing importance of AM 13
Competences for in-house production are built up 14
Integration of functions in components 15
Complex geometries can be produced 16
Customised products can be manufactured 17
Growing importance of 3D printing for the "digital factory“ 18
Autonomous additive machining centres increase flexibility 19
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iAM Part selection procedure
iAM Part score card
Part profile: raw
Excel evaluation
Decisionmatrix
Screening
Assessment
Identification
Selection
iAM Part score card
Part profile: detailed
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AM process chain is long, complex less automated and always slightly different and has to be matched with the product requirements
Where are the risks and challenges?
Definition of component
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Why do we need a specific quality assurance and skills approachfor iAM?
Definition ofcomponent
requirementsCAD process CAM process 3D printing
processPost
processing Quality control
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Status quo of key success factors for excellence in AM
Reproducible raw material
featuresReproducible
system construction
Systemsafety
Calibration
Validated process parameters
Quality assurance stepsInstallationqualification In-process
powder qualification
Minimization of contamination risks
Reproducible high-end additive manufacturing attributes
Machine Material Method
1. Hard & Software 2. Feedstock &Material
3. Process Chain Certification 4. Product TIC
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Status quo of key success factors for excellence in AM
4. Product TIC
Combining and bundling TÜV SÜD's knowledge to realize new ideas and products / certifications for our customers.
Existing products produced with AM » core expertise in industrial AM is required.
3. Process Chain Certification
Material supplier certification
Raw material certification Resulting properties
certification (after printing: material + machine combination)
2. Feedstock & Material
Certification of reproducibility (suitability for industrial use)
Connectivity 4.0 Software security
1. Hard & software
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Status quo of key success factors for excellence in AM
8.AM Standards7. Next Generation AM6. Training Program5. Company certification
Milieu
Industry-specificregulations
Legal regulations
AM-specific standards
Quality assurance-oriented
AM trainingAM-specific corporate governance
Team of innovators & experts
Innovation-drivenbusiness case Industrial AM
expertise
ManpowerManagement
Reproducible high-end additive manufacturing attributes
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Status quo of key success factors for excellence in AM
TÜV SÜD specifications and best practice
DIN SPEC 17071 ISO/ASTM JG 75
» PWI 52920
8.AM Standards
Data management Industry 4.0 Automation IP rights and data security
7. Next Generation AM
AM quality and production manager
Status quo of AM Standards Risk assessments Health and safety And others...
6. Training Program
AM production facilitiescertification “additive manufacturer”
System certification similar to ISO 9001 but with AM technology specifications
5. Company certification
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To establish a working iAMsolution, an aligned network towards iAM readiness is mandatory.
Who are the players within the AM ecosystem?
Design-ownersand final users
Other solutionproviders
Marketplaces andsoftware solutions
Material suppliers
Training & education services
AM machine manufacturers
AM service providers
OEMs / users
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What does the Ecosystem require? Result from the early adopters…
36%
26%
15%
14%
9%
QualityReliabilityUsabilityPrice/PerformanceSupport
33%
35%
14%
18%
ReproducibilityReliabilityUsabilityConnectivity
Survey result of 3D hubs “consumer“ printer
Survey result of TÜV SÜD industrial AM Systems
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“OEMs&Users” need to start to set up demands towards Hardware manufacturers.
Who are the key network partners to assure the industrial maturity level of hardware and what are their major challenges?
Design-ownersand final users
Other solutionproviders
Marketplaces andsoftware solutions
Material suppliers
Training & education services
AM machine manufacturers
AM service providers
OEMs / users
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Testing and validation of the machine by TÜV SÜD as an independent testing organisation
What are the solutions to enable industrialization within the hardware segment?
Certification of AM machines by TÜV SÜD to confirm machine’s capabilities Based on the requirements of AM users, our requirements and the current standards Reduced qualification expense by specific requirements from regulated industries Basis for scaling production with several machines within one machine type
Joint development of the international standard for machine performancewith AM users, machine manufacturers and independent testing organisations
ISO/ASTM 52920-1 within the JG 75 of the ISO/TC 261
Technical Report
ISOStandard
Certification
Request certified machines to assure validation
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Next step for iAM readiness: Users need to start set up demands towards material & feedstock suppliers.
What are the key network partners to ensure the industrial maturity level of materials?
Design-ownersand final users
Other solutionproviders
Marketplaces andsoftware solutions
Training & education services
AM machine manufacturersMaterial suppliers
AM service providers
OEMs / users
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Define market by certified materials and reduce own qualification audits
What are the solutions to enable industrialization withinmaterial and feedstock ?
Material validation (EN 10204)
Metal powder supplier
certification
Feedstock verification
Material validation (EN 10204)
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OEMs and users need to start set up demands towards hardware manufacturers.
What are the key network partners to ensure the industrial maturity level of production quality?
Material suppliersOther solutionproviders
Training & education services
AM machine manufacturers
AM service providersMarketplaces andsoftware solutions
Design-ownersand final users
OEMs / users
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AM specific certification scheme assures reproducibility and reduces own qualification audits
What are the today available solutions to qualify AM production sites?
AM production site
AM production site
AM production site
AM production site
AM production site
AM production site
Status quo reportfor investment
purposs
Industrial manuf.site certificationDIN & ISO/ASTM
standard
Product designverification
reports& trainings
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What is the certification content?
Quality assurance
Pre-Processing In-Processing Post-Processing
Additive manufacturing process
Data preparation
System related pre processing
Process guidance
System related post processing
Part related post processing
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First "Industrial AM production sites" in Germany audited and certified
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Assuring reproducibility will come automatically with cost & time savings due to “AM-specific“ certifications.
What our customers are saying?
TimeR&D
Design
Manufacturing
Testing
Certification
Certification Process based onAM specific standards
Fast ramp up Motivation for outstanding quality State of the art Process reproducibility
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Summary iAM approval and certification pyramid for implementors
Liability
Standards
Authorities
ProcessChain
Hardware, Material,(OQ,PQ)
Additive Manufacturing Production Site Certification
DIN SPEC 17071ISO/ASTM PWI 52920-2
Management CertificationISO 9001 / ISO 13485 /
ISO 9100
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What are the key network partners to ensure the industrial maturity level of market places and software solutions?
Material suppliersOther solutionproviders
Training & education services
AM machine manufacturers
AM service providersMarketplaces andsoftware solutions
Design-ownersand final users
OEMs / users
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How to enable “parts on demand” trustful printing services?
iAM Sealed Cloud
Today’s global “parts supplies on demand business cases” struggle with the data security due IP risks.
Case study:– iAM readiness for
decentralised additive manufacturing
Tomorrow, the iAM sealed cloud will provide data security.
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The future of automised, digital quality assurance by TÜV SÜD
iAM SupplierNetwork
AMA ProductsDigital Test StandsPart-Report | CertificationProcess Chain QualificationSoftware penetration testsCybersecurity and software safety
Research and Developmentwith renowned partners ProSi-3D Holi-Quali-AM
Part-Report
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Assessment of iAM maturity for decision makers
Consistency withbusiness model
Ready for industrial AM
Not ready for AM 653210 4
There is full consistencywith the business model
There is no consistencywith the business model
There is recognisableconsistency with the
business model
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Assessment of iAM maturity for decision makers
Technology and innovation management
Ready for industrial AM
Not ready for AM 653210 4
There is a wellimplemented technology
and innovationmanagement
There is no technologyand innovationmanagement
The implementation is recognisable but
expandable
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Assessment of iAM maturity for decision makers
Strategy for AM
Ready for industrial AM
Not ready for AM 653210 4
There is a wellimplemented and
clever stategy for AMThere is no strategy
for AMThe strategy is not yet
mature
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Assessment of iAM maturity for decision makers
Implementation ofchange management
Ready for industrial AM
Not ready for AM 653210 4
There is a wellimplemented change
managementThere is no change ofohh management
The implementation is recognisable but expandable
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Assessment of iAM maturity for decision makers
Personnel for AM
Ready for industrial AM
Not ready for AM 653210 4
The personnel has a deep knowledge and
experience in AMThere is no AM-
experienced personnelThe implementation is
recognisable but expandable
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Assessment of iAM maturity for decision makers
Strategy for AM
Personnel for AM
Degree of industrialization (Quality, Cert., ..)
Implementationchange management
Ready for industrial AM
Not ready for AM 653210 4
Consistency with business model
Technology and Innovation management
497/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING
Assessment of iAM maturity for decision makers
Strategy for AM
Personnel for AM
Degree of industrialization (Quality, Cert., ..)
Implementationchange management
Ready for industrial AM
Not ready for AM 653210 4
Consistency with business model
Technology and Innovation management
507/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING
Assessment of iAM maturity for decision makers
Strategy for AM
Personnel for AM
Degree of industrialisation (Quality, certification etc.)
Implementationchange management
Ready for industrial AM
Not ready for AM 653210 4
Consistency with business model
Technology and innovation management
Experttrainings,certification programme
Training "Status quo for decision makers" qualification and reports
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How to ensure that the professionals within the industry use the state of the art know how?
AM Quality Manager AM BuyerAM Designer AM Manufact. Expert AM Approval Expert AM Manager
527/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING
Welcome to test our TrustinAMproject assistant:
– Go to www.trustinam.com
Enabling access to iAM for product designers
537/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING
Enabling access to global markets
Over 1,000 TÜV SÜD locations in about 50 countries
Germany (HQ)AustraliaAustriaBangladeshBelgiumBosnia & HerzegovinaBrazilCambodiaCanadaChinaCroatiaCzech Republic DenmarkEgyptFinlandFranceGreece
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SingaporeSlovakiaSloveniaSouth AfricaSouth KoreaSpainSri LankaSwedenSwitzerlandThailandTurkeyUAEUnited KingdomUSAVietnam
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25/07/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING