© LayerWise NV, all rights reserved 27-May-14
1 www.layerwise.com
Let Additive Manufacturing Inspire You
3D printing: hype or industrial revolution?
Peter Mercelis, PhD
2014/04/30
© LayerWise NV, all rights reserved 27-May-14
2 www.layerwise.com
Introduction to Layerwise
Technology basics – what’s in a name?
Applications of 3DP
New technology introduction process
Role of engineers within our organization
Contents
© LayerWise NV, all rights reserved 27-May-14
3 www.layerwise.com
LayerWise
Incorporated in 2008 as spin-off from university of Leuven K.U.Leuven prof. Jean-Pierre Kruth
Focus on metal AM only
Unique technological expertise in metal AM since 2001 Phd Jonas Van Vaerenbergh
Phd Peter Mercelis
12 years experience with AM titanium
Developing AM technology and applications together with our customers
© LayerWise NV, all rights reserved 27-May-14
4 www.layerwise.com
LayerWise markets
chemical pharma
pressure & gas precision mechanics
semicon tooling
food electronics
imaging
standard implants customized implants medical instruments
dental prostheses implant supported
and cemented
aviation space
ISO 9001 and ISO 13485 certified
© LayerWise NV, all rights reserved 27-May-14
5 www.layerwise.com
Technology basics
© LayerWise NV, all rights reserved 27-May-14
6 www.layerwise.com
Various technologies are today called “3D Printing”
In the past, many different names were used to refer to Additive Manufacturing technologies;
Rapid Prototyping
Rapid Manufacturing
…
Technology basics
© LayerWise NV, all rights reserved 27-May-14
7 www.layerwise.com
Basic principle; 3D object is manufactured as a stack of 2D layers that are interconnected
Technology basics
© LayerWise NV, all rights reserved 27-May-14
8 www.layerwise.com
Technology basics
Directly from 3D CAD Layer-wise production 3D components by successive
connection of thin 2D layers
© LayerWise NV, all rights reserved 27-May-14
9 www.layerwise.com
© LayerWise NV, all rights reserved 27-May-14
10 www.layerwise.com
© LayerWise NV, all rights reserved 27-May-14
11 www.layerwise.com
© LayerWise NV, all rights reserved 27-May-14
12 www.layerwise.com
3D complexity is reduced to 2D complexity! Constructing 2D geometries is easier than constructing 3D
geometries! Various methods possible to generate 2D layers
Ink-jet printing of 2D layers Laser scanning of 2D layers Moving ejector nozzles ….
Various materials possible to generate 2D layers Plastics, polymers Metals and metal alloys Ceramic materials Organic materials Food …
Technology basics
© LayerWise NV, all rights reserved 27-May-14
13 www.layerwise.com
3DP allows build ‘impossible shapes’ and assemblies
Technology basics
© LayerWise NV, all rights reserved 27-May-14
14 www.layerwise.com
Applications of 3D printing
© LayerWise NV, all rights reserved 27-May-14
15 www.layerwise.com
Consumer applications
Industrial applications
Medical applications
Applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
16 www.layerwise.com
Home use 3D printers
Available for low prices (< 1000 €)
Low entry barrier
Online 3D printing services
Shapeways, iMaterialise, etc.
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
17 www.layerwise.com
Architectural models
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
18 www.layerwise.com
Jewelry
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
19 www.layerwise.com
Design
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
20 www.layerwise.com
Fashion
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
21 www.layerwise.com
Fashion
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
22 www.layerwise.com
Online 3D printing websites give everyone access to 3DP technology
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
23 www.layerwise.com
Applications currently rather limited;
Action figures
Gadgets
Jewelry
But other things are also possible …
Consumer applications of 3DP
© LayerWise NV, all rights reserved 27-May-14
24 www.layerwise.com
Prototyping applications
Extremely short lead times possible
Visual prototypes
Functional prototypes
Industrial applications of AM
© LayerWise NV, all rights reserved 27-May-14
25 www.layerwise.com
As always, technology can be used for the good and for the bad
Industrial applications of AM
© LayerWise NV, all rights reserved 27-May-14
26 www.layerwise.com
AM of function parts; industry drivers
Industrial applications of AM
Manufacturing Cost Total cost of ownership & performance
Mostly small parts
cost weight
all size of parts
Tool-less manufacturing
Single step production
• Monolithic construction
• Reduced # components
• Flow-optimized
• Miniaturization
• Customization
• Mass reduction
Short time to market Flexible production
© LayerWise NV, all rights reserved 27-May-14
27 www.layerwise.com
Use of internal cooling channels in tooling applications
Industrial applications of AM
© LayerWise NV, all rights reserved 27-May-14
28 www.layerwise.com
Mass production of ejector nozzles in food industry
Industrial applications of AM
© LayerWise NV, all rights reserved 27-May-14
29 www.layerwise.com
Aerospace applications
Weight savings
Complex shaped
Integrated functionality
Industrial applications of AM
© LayerWise NV, all rights reserved 27-May-14
30 www.layerwise.com
Digital manufacturing is perfectly adapted to patient-specific instruments and implants!
Medical imaging (CT scans, MRI, etc. ) already provides 3D digital input!
Bio-compatible materials (e.g. titanium) can be processed with AM technology
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
31 www.layerwise.com
Patient specific hearing aids
Patient specific imprint
3D scanning and digital design
Digital printing of hearing aid housing
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
32 www.layerwise.com
Facial reconstructions; printing of soft tissue replacements
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
33 www.layerwise.com
Facial reconstructions; printing of bone tissue replacements
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
34 www.layerwise.com
First 3DP printed jawbone prosthesis
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
35 www.layerwise.com
Patient specific and standard orthopedic implants
Medical applications of AM
Co
urt
esy:
Mo
bel
ife
© LayerWise NV, all rights reserved 27-May-14
36 www.layerwise.com
Illustration of series production; veterinarian implants for treatment of dogs
> 10,000 per year
Medical applications of AM
© LayerWise NV, all rights reserved 27-May-14
37 www.layerwise.com
Current media hype on 3DP created unrealistic expectations!
Organ printing possible in the near future …
Everyone should have a 3D Printer @ home …
Everything can be 3D printed …
3D printing is cheap …
Risks of the current 3DP hype
© LayerWise NV, all rights reserved 27-May-14
38 www.layerwise.com
Importance of realistic expectations!
3DP is NOT a cheap manufacturing technology
Traditional manufacturing will not dissapear!
3DP often needs to be combined with traditional manufacturing methods
Traditional manufacturing techniques generally have higher accuracy than 3DP
Limited number of materials possible
Size limitations limit the application field
Printing of living tissue is still in its infancy!
Risks of the current 3DP hype
© LayerWise NV, all rights reserved 27-May-14
39 www.layerwise.com
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
40 www.layerwise.com
Essence: the new technology should add value to the product/service compared with the traditional technology
Added value: product/service definition Increased functionality = technical improvement Improved appearance = esthetic improvement Reduced drawbacks!
Ergonomics Safety Complexity Reliability Maintenance …
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
41 www.layerwise.com
Your technology should increase added value
of your direct customer
of the end customer only = more difficult
of your direct customer and the end customer = easiest + synergetic
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
42 www.layerwise.com
Regulation; Existing products or markets are often regulated by
government or by industry Examples:
Medical implants standards (ISO / ASTM / FDA …) E.g. ASTM F2068 - 09 Standard Specification for Femoral
Prostheses—Metallic Implants
Quality management systems (Medical / Aerospace …) E.g. AS 9000 or Aerospace Basic Quality System
Technology standards; E.g. ASTM F1472 - 08e1 Standard Specification for Wrought
Titanium-6Aluminum-4Vanadium Alloy for Surgical Implant Applications (UNS R56400)
Often no standards exist yet for a new technology in an existing market/ product category!
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
44 www.layerwise.com
Innovative technology itself can be a trigger to convince innovators!
But; this is a short term effect, in the end the it is the added value that counts to convince the early adoptors and the majority
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
45 www.layerwise.com
Strategy; try to become a chameleon after convincing the innovators Most customers are not
interested in technology, but simply want added value in their products or services
Risk aversion of most (large) companies demands full compliance to their existing technologies, habits, existing standards and personal opinions …
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
46 www.layerwise.com
Illustration; dental prosthetics Traditional technology:
Analog imprints
Wax modelling
Casting technique
Labour intensive
Inaccurate
Recent technologies: Digital prosthesis design
Digital prosthesis manufacturing; CNC milling
3D printing / Additive Manufacturing
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
47 www.layerwise.com
Dental prostheses @ DentWise
Digitalisation of the design and manufacturing process
Digital scanning at dentist practise is the logical next step
New technology introduction process
© LayerWise NV, all rights reserved 27-May-14
50 www.layerwise.com
Knowledge and expertise needed @ LayerWise Hard skills:
Machine design (mechanics)
System and control theory
Laser and optics
Software development
Metallurgy
Process engineering
Soft skills: Project management
Technical writing
(Small team) management skills
Role of engineers @ LayerWise
© LayerWise NV, all rights reserved 27-May-14
51 www.layerwise.com
Equally important but often neglected
Budget responsibility
Continuous improvement mindset
Commercial insight
‘multiple hat attitude’
IP basics; DO’s and DON’ts
Basic legal knowledge
Pragmatic approach
Boerenverstand (sorry, no englisch translation)
Role of engineers @ LayerWise
© LayerWise NV, all rights reserved 27-May-14
53 www.layerwise.com
3D printing is currently in a hype
However, application domains are all over
Although some might look as science fiction
Future outlook
© LayerWise NV, all rights reserved 27-May-14
54 www.layerwise.com
They are not that far from reality
Future outlook
© LayerWise NV, all rights reserved 27-May-14
55 www.layerwise.com
Images by LayerWise, DentWise, Materialise, Freedom of Creation, Mobelife, EOS, Concept Laser, 3D Systems, Arcam, Dizingof and Stratasys
Source files
© LayerWise NV, all rights reserved 27-May-14
56 www.layerwise.com
Let Additive Manufacturing Inspire You
Click to edit Master subtitle style
LayerWise NV Grauwmeer 14
3001 Leuven Belgium
Tel.: +32 16 94 64 00 www.layerwise.com