Date post: | 16-Apr-2017 |
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Lowering the barriers to additive manufacturing
Marc Saunders
Director – Global Solutions Centres
AM Solutions Centres
05/03/2023 Slide 2
Why everyone is interested in AM…
Disruptive additive manufacturing (AM) benefitsInnovative product designsComplex internal detailsLightweight, optimised formsEfficient material usage with minimal
wasteImproved cooling & heat transferCustomisation for specific
applicationsShort lead timesBuild from CAD with no special
tooling
05/03/2023 Slide 3
How AM is being deployed
Low volume parts made direct from CAD
New product designs that 1. Deliver lifetime benefits in use2. Provide mass customisation
Complex parts that simplify assembly & enhance reliability
Re-production parts, that avoid complex manufacturing
Rapid prototypes & tooling
Direct part replacement
Part consolidation
DfAMoptimised
Volume production applications will come from the higher levels
05/03/2023 Slide 4
Examples – rapid prototypes & tooling
Complex bar locators for part handling
Prototype exhaust
nozzle
Conformal mould tooling for rapid cooling
05/03/2023 Slide 5
Example – direct part replacement
Significant waste reduction with AM process
Note: some finish machining still required on AM part
Example courtesy of GKN Aerospace
05/03/2023 Slide 6
Example – part consolidation
Single piece microwave guide reduces weight and improves performance
05/03/2023 Slide 7
Examples – DfAM optimized
Customised cranio-facial implant
Increased efficiency heat
exchanger
Light-weight, efficient hydraulic manifold
05/03/2023 Slide 8
Financial benefits of AM
Production benefits
£ Less materials£ Lower tooling costs£ Shorter process time£ Shorter lead time£ Simpler assembly£ Automation
Lifetime benefits
£ Less weight£ Faster product launch£ Product reliability£ Higher performance£ Better adaptation£ Product attraction£ Reduced stocking£ Higher responsiveness
Financial benefit
05/03/2023 Slide 9
Few companies are using AM in series production – why?
05/03/2023 Slide 10
Lowering the entry barrier for AM
Metal additive manufacturing technology for industrial applications
Global network of Renishaw Solutions Centres
Applications expertise in a wide range of industries
Integrated manufacturing solutions
05/03/2023 Slide 11
Solutions Centre principles
• Help manufacturers to learn to think with an AM mind-set• Apply AM thinking to process and part design• A supported learning centre for all things AM• A secure environment for prototyping, re-manufacturing,
part consolidation and design optimisation• Customers supported by dedicated engineers and
technicians• On-site finishing methods for support removal, heat
treatment, machining, metrology etc.• Assisting customers to make an educated AM investment
05/03/2023 Slide 12
Global network of Solutions CentresUK - Stone
India – Pune
China – Shanghai
Canada - TorontoGermany - Stuttgart
USA –Texas
Holland – Breda
UK - Miskin
USA – Chicago
A mutually supporting network of 9 centres, each with applications specialisms to suit local industrial demand
Opening during 2016
05/03/2023 Slide 13
Solutions Centres services
Benchmark part: benefits tangible
Concept embodies AM benefits
Optimise process & verify part
Demonstrate process stability
AM & finishing processes to make saleable product
Accelerated learning curve
05/03/2023 Slide 14
Solutions Centres facilities
05/03/2023 Slide 15
Incubator cells to nurture your idea
Your private development facility, including…Secure, access-controlled process
incubator cellDedicated additive manufacturing machineMaterials choice & option to use your own
powderDedicated powder handling accessoriesNo overheads & predictable costsAccess to Renishaw engineers and
techniciansOptional access to finishing processes,
metrology and materials analysis
05/03/2023 Slide 16
Pre-production capacity to prove your process
Ramp up towards production volumes…Access to multiple AM machines
Metrology and finishing processes as required
Contracted price per part
Support for process capability studies
Business case preparation
Integrated solutions
Design for AM AM build Gauging Machining Inspection
Proc
esse
sTo
ols
05/03/2023 Slide 18
Dallas
• 20,000 ft²
• 3 Incubator Cells
• 3 pre-production machines
• Re-modelling during H1’16
• All post processing on-site
• Full or partial applications engineering support
• 3 CMM training rooms
• DfAM training courses
05/03/2023 Slide 19
Dallas
05/03/2023 Slide 20
Chicago
• 133,000 sqft
• 4,000 sqft dedicated AM development area
• 2 incubator cells
• Dedicated Class 2 Division II material handling
• Full post-processing facilities
05/03/2023 Slide 21
AM manufacturing & medical solutions: Miskin, UK
Why choose Renishaw as your AM partner ?
• FTSE 250 plc, c $750m revenue and >4,000 staff
• Develops all aspects of AM technology in-house (machines, software, metallurgy, services)
• World-class metrology, process control, machining, electronics and assembly expertise
• Optimised solutions for your application, not just standard product that you have to adapt
05/03/2023 Slide 23
• From research lab onto the factory floor
• From prototypes & tooling to series production
• From time compression to higher product performance
• From shapes to consistent, qualified parts
• From plastics to high performance alloys
• From 3D printing to an integrated production process
Your product design
Renishaw expertise
Your AM process
Global support
Thank you