Why 3D Printing in Automotive Beyond Prototyping

Transcription

1 Why 3D Printing in Automotive Beyond Prototyping 1

2 Gartner s 3DP Hype Cycle Source: Gartner

3 Materialise Today GROWING OUR 3D PRINTING EXPERTISE SPEAKING YOUR LANGUAGE PASSIONATE ABOUT INNOVATION EMPLOYEES D PRINTERS 24 OFFICES IN 18 COUNTRIES +200 PATENTS GRANTED +180 PATENTS PENDING

4 Speaking your language USA UK BELGIUM SWEDEN GERMANY JAPAN INDIA POLAND UKRAINE CHINA COLOMBIA FRANCE CZECH REPUBLIC MALAYSIA AUSTRIA SPAIN ITALY AUSTRALIA OFFICES PRODUCTION CENTER COMPETENCE CENTER

5 Materialise Core Business Materialise offers software and services that form the backbone of the Additive Manufacturing eco-system. Our solutions are open and neutral, allowing all players to better manage the 3D printing process and build more meaningful 3D printing applications. 5

6 Three Core Competences 3D PRINTING ENGINEERING SOFTWARE DEVELOPMENT Date Firstname Lastname 6

7 Creating innovation and competitive advantage across industries Materialise Software Materialise Manufacturing Materialise Medical Managing of complete 3D printing processes Certified end parts manufacturing Image-based planning and 3D printing Getting the most out of 3D printing machines Prototyping Patient-specific guides and implants Design and data preparation for 3D printing Design and engineering Engineering on Anatomy

8 Co-Creation 3DP ACADEMY In a full-day program our experts inform you on the strengths and weaknesses of the most relevant technologies and materials. Furthermore we share best practices in design & engineering and analyze a number of groundbreaking AM cases. GOAL: Get your team up to date on all things AM LEARN CREATE FIND CO-CREATION LAB 3DP SCAN The Materialise CO-CREATION LAB is an interactive session in which experts from your company join forces with ours. The result is a multidisciplinary dream team that will unlock the hidden potential of 3D Printing in your company. GOAL: Create innovative concepts for your market The 3DP SCAN is an AM audit, held at your premises. A Materialise AM consultant will look for potential applications on the spot and provide you with a full report afterwards. GOAL: Spot parts that can benefit from AM

9 Our Partners 9

10 AM Industry Adoption & Challenges

11 Current Applications and Future Potential of 3DP by Industry Source: EY 11

12 Barriers to Implement BAAM (upto 6 m x 1m x 0.75m build platform) - Cincinnati Industries and Oak Ridge National Lab EBAM (upto 5.8m x 1.2m x 1.2m build platform) - Sciaky Mammoth SLA m/c (2.1m x 0.8m x 0.7m) - Materialise Greater co-operation with service providers In-process QC tools 3 rd party material vendors Automation, integration and continuous production technologies Redesign for AM mindset growing Source: EY 12

13 Optimization in next gen AM systems Source: Roland Berger 13

14 Innovations Across the Entire AM Process Chain Source: Roland Berger 14

15 Hybrid Systems Higher build rates Lower manufacturing costs Large build chambers Both laser powder bed and powder feed with 5-axis CNC milling possible Source: Roland Berger 15

16 Automation Concept Manual Unloading Automated Unloading - (build set-up and process monitoring) Source: Roland Berger 16

17 Integration Concept High productivity by continuous production (2 build chambers) Integrated postprocessing (HT) increases process stability and product quality Automated handling Instant switching between multi materials gives high flexibility Source: Roland Berger 17

18 Material Costs (metal only) OEMs offer material specific parameter sets and powder quality control Must weigh initial implementation speed and reliability vs. higher cost and lock-in effect Source: Roland Berger 18

19 Post-processing Costs Highly part dependent Must be factored in while evaluating overall costs for AM Could be avoided to some extent during design for AM stage Source: Roland Berger 19

20 Prototyping to Manufacturing?

21 Evolution of 3DP Applications To most companies: AM ~ Rapid Prototyping Future (and growth potential) lies with Direct Manufacturing For full impact, AM must be used in Serial Production for enduse products 38% of companies expect to use 3DP for production of end-use parts by 2021 Germany is most conservative (25%) China/S. Korea are most optimistic (50%) 21 Source: EY

22 From prototyping towards manufacturing Rapid prototyping is well established Transition to manufacturing, new challenges arise 34% Rapid Prototyping Laborious process Rapid Manufacturing 14% 34% 2% 16% Pioneers Early Adopters Early Majority Late Majority Laggards 22

23 Manufacturing requirements Standardization Monitoring and logging One integrated solution Open platform Allows R&D Repeatable quality Pre-build In-build Post-build 23

24 Quality Management Goals Repeatability Accuracy Traceability Sustainability Compliance Repeatability Accuracy Repeatability and accuracy Efficiency

25 Manufacturing costs Part costs in M3DP primarily depend on The melted volume and not the complexity Size part / build height Material & finishing Part orientation Reduction of part volume leads to reduced costs Hollow structures Lightweight structures Thin walls

26 Proto Time Reduction across industry Source: EY 27

27 Proto Cost Reduction across industry Source: EY 28

28 Core Functions expected to be benefited by 3DP Source: EY 29

29 3DP Expectations by Industry Next 5 years Source: EY 30

30 Additive Manufacturing Solutions for the Automotive Industry

31 Applications of AM in an Automobile 32

32 Prototyping

33 Prototyping for the Automotive Industry Design verification Form, Fit & Function testing Scale models and concepts

34 Lear Automotive Car Seat Frames Customer needs: better alternative for sheet metal prototypes Faster Less expensive More representative More reliable during testingphase Materialise solution: metal plated prototypes Mammoth stereolithography components with metal lamination of copper and nickel

35 Ossa Show Model Customer needs: Famous Ossa brand needs show vehicle To present the rebirth of the Ossa at the Milan Motorcycle Show To show and explain their new motorcycle concept : design and position of chassis, engine, fuel tank, etc. 30

36 Ossa Show Model Materialise solution: Complete bodywork exists of stereolithography and laser sintering components, assembled and finished by the customer From files to productsin 10 days Sintered swing arm Stereolithography bodywork & covers Sintered fuel tank plug Sintered fender support Sintered clutch cover Sintered cylinder and cylinder head 31

37 R&D

38 Optimized Pressure Valve From Traditional Design to Metal 3D Printing

39 Optimized Pressure Valve Traditional Valve straight and circular drillings auxiliary drillings that need to be plugged afterwards (risk of leakage) initial weight: 2.5kg

40 Optimized Pressure Valve Meshing Hypermesh Optimization OptiStruct 1st Simulation OptiStruct Remeshing Surface data 3-matic STL Manufacturing SLM Solutions Analysis Hyperworks

41 Optimized Pressure Valve 600g of mass compared to the original 2.5kg (74% lower) No need for auxiliary drillings, less chance of leakage Improved flow because of smooth transitions between the internal channels The time from optimization to final design was greatly reduced by working immediately on the TO data with 3-matic STL

42 Altair brake pedal : TO + Texturing Altair topology optimization software reduces the volume of object, without compromising strength. In past they applied this technique to lower down weight of a race car brake pedal. However re-designing organic models at CAD level can be time consuming and difficult job. But with 3-matic, it is very easy to do design modification at STL level. 43

43 Altair brake pedal : TO + Texturing 3-matic was further used to- Add thickness at thin sections Rim designing To apply a functional texture to improve the grip Final outcomes- 20% lighter with same strength Less production time, no tooling required 44

44 Toyota car seat: TO + LWS Toyota Central R&D labs wanted to create a car seat with minimal volume & optimal heat capacity. They have a topology optimized part. We incorporated LWS to make it more lighter. 45

45 Toyota car seat: TO + LWS The input received from Toyota is a model containing high density & low density areas. To populate low density areas, we developed a new unit cell (truncated octahedron), that allows more heat flow. A pattern of elastic beams were added at edges to increase the comfort. 46

46 Toyota car seat: TO + LWS After all these modifications, we cut the seat into 2 parts using our STL editor Magics, with dowel connections. Needless to say, the outcome was a 250 GB STL file, it was processed by our build processor technology (resulting into 36MB) and finally sent to machine for printing. Final result:- Weight from 21.6 kg to 6.3 kg Heat capacity from 35.4 J/K to 14.5 J/K 47

47 Robirds ensuring human safety 48

48 3D printing used for design freedom and production optimization Laser Sintering process Glass-filled polyamide All internal fixation points for mechanical components directly printed inside the body 49

49 Catalytic part for Bosal Supporting the Research Phase of Product Development

50 Catalytic part for Bosal to reduce exhaust gas pollutants Original Production Process Part design Milling Turning Welding With Metal 3D Printing We consistently choose Materialise because Materialise is easy to do business with. Bosal Part design Production

51 Small-Series Production (OR) One-Off End-Use Parts

52 InMotion Electric Race Car Titanium Wishbones for Suspension

53 InMotion Race Car: Titanium Wishbones Wishbones for the suspension of an electric race car, printed in titanium

54 InMotion Race Car: Titanium Wishbones Requirements No internal support structures Technology Metal 3D Printing Material Titanium (TiAl6V4) Finishing n/a

55 InMotion Race Car: Titanium Wishbones Manufacturing Post machining From CAD to assembly in 10 days Assembly

56 Date Firstname Lastname

57 World Solar Challenge Hold 432 Lithium-ion cells Co-creation with Materialise D&E team Modular open frame design to ensure optimal air flow for cooling Honeycomb structure to reduce weight while keeping a strong structure Date Firstname Lastname

58 Date Firstname Lastname

59 3-D Printed Upgrade Upgrade designs Customise parts Zero tooling investment Seat, housing for display screen, front and rear indicators, iconic detachable headlight Lighter bike that s faster and more cost-effective to manufacture I believe that 3D Printing is the future. I can imagine the Bicicletto in years, completely prototyped and produced with 3D Printing. - Mr. Juliano Imprescia, Nuova SPA s CEO Date Firstname Lastname

60 Jun Race Car Textured Steering Wheel

61 Textured Steering Wheel for June Race Car Requirements Functionality, textures, cost-effectiveness Technology Laser Sintering Material PA Finishing Color Dyed

62 Date Firstname Lastname

63 Open Structure Mobility Concept Challenge - create a light but safe car, avoiding mold creation, allowing mass customization Combine different car body designs on a small standardized platform Optimized structures to reduce weight but maintain stability Date Firstname Lastname

64 Optimization of car frame design Smoothen and redesign TO design on STL level Lightweight structures in pillars Optimization of car seat design Lightweight lattice structures Scale and readjust beam thickness Date Firstname Lastname

65 Concept Cars

66 Sintesi Concept Car Stereolithography components

67 Parts for Pininfarina Sintesi Concept Car Requirements Customized design; complexity, functionality Technology Stereolithography Material Poly1500 Finishing Translucent

68 Production Tools

69 Production Tools for the Automotive Industry Jigs Fixtures Assembly aids

70 Production Tools for the Automotive Industry Highly customizable Allow complex internal and external geometries Light and modular Fast and economical modification

71 RapidFit Automotive Fixtures Locators for Customized Fixtures

72 Locators for RapidFit Custom Fixtures Flexibility Cost Integrated Functionality Speed Customization Modularity Complexity Precision

73 Locators for RapidFit Custom Fixtures Requirements Integrated functionality Technology Laser Sintering Material PA Finishing Painted

74 Volvo Jig Logo Gluing Jig

75 Goals, Solutions, Results Lightweight gluing jig that ensures accuracy and repeatability, while protecting the paintwork Reduce weight Increase the accuracy Decrease cost and lead time PA connectors with integrated gluing channels PC-ABS Pads - covered with leather Milled positioning points (POM) 0.2mm accuracy 64% weight reduction 48% cost reduction 67% lead time reduction

76 Volvo Gluing Jig Solution PA connectors with integrated gluing channels PC-ABS Pads - covered with leather Milled positioning points (POM) Technology Laser Sintering Fused Deposition Modeling Material PA PC-ABS Carbon Tubes Finishing Color Dyeing Assembly

77 Spare Parts

78 Mercedes 300 SL Re-Engineered Instrument Backlight Panel

79 Instrument Panel Backlights by ClassicTacho Requirements Re-Engineered Spare Part Technology Laser Sintering Vacuum Casting Material PA, HMPU13 Finishing Color Dyed Image credits: Mercedes 300 SL Cabrio by DOMINIK BARTSCH is licensed under CC 2.0

80 Spare Parts for the Automotive Industry Re-engineering allows for function integration Cost-effective small series production On-demand (no stock risks)

81 Additive Manufacturing Solutions for Production Lines

82 Production Tool Applications Fixtures Casting Patterns Vibratory Feeders Quality Control Aids Brackets Jigs and Working Aids Nozzles Grippers

83 How additive manufacturing can help Component Performance Supply Chain Innovation Reduce Weight Reduce Lead Times Shorten Time to Market Improve Air or Liquid Flow Reduce Costs Meet Handling Requirements Increase Product Quality Reduce Stock Facilitate New Product Introduction

84 Nozzles Optimise flow of air, gas or liquid Complex or intricate designs Cost efficient small series End-product innovation

85 Flexible Grippers Improved gripping Flexible material Delicate products Different shapes Customizable

86 Vacuum Grippers Complex shapes Lighter and faster Integrated channels Customizable Less assembly

87 Finding your applications Identify the main challenges Component Performance Cycle Time Locate your problem areas - Long lead times - High failure rate - Complex parts Health and Safety Product Quality Efficiency & Productivity New Product Development Could another design and technology solve this?

88 Sample News Clips ( ) AM in Automotive Audi 89

89 Conclusion Way we manufacture products for automotive is changing, not just protos. Critical to identify the right application for AM in automotive and manage benefit expectations AM mindset adoption and AM application specific know-how is key Via partnerships Via right investments 90

90 Come join us in turning future into present!