How Does Additive Manufacturing Complement Injection Molding? · An Injection Molding Design also...

How Does Additive Manufacturing Complement Injection Molding?

© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.

David Tucker – HP Manufacturing System FocusJustin Hopkins – HP Application EngineeringBrian Garvey – Linear AMS

Leading the next industrial revolution

200019001800

Today1784 First mechanical loom

1780s to 1860s 1870s to 1960s 1970s to 2010s 2010s - Future

Industrial revolution Mechanical production.Water and steam power1

Mass production Electric power, labor division and assembly line

2Production automationElectronics and IT3

Digital manufacturing and smart production 3D printing, digitalization and capital efficiency

4

© Copyright 2018 HP Development Company, L.P. The information contained herein is subject to change without notice.2

History is littered wrong predictions, often made by very smart, tech savvy people

3

1889: ‘No one will

ever.’ THOMAS EDISON

1903:

Horace Rackham, bank advisor warning

Henry Ford

1959: ‘World potential for

is 5,000 at most’

IBM CEO to founders of Xerox

1981: ‘

won't replace wire phones:

MARTY COOPER, inventor of

mobile phone

1992:

are a pipe dream’:

ANDY GROVE, former Intel CEO

1995: ‘ will

…catastrophically collapse’

ROBERT METCALF, Founder of 3COM

1966: ‘’

…will flop’

TIME MAGAZINE

Disruptive Technologies are not always obvious

““

1932…not the slightest indication

will ever be obtainable…

- Albert Einstein

Plastics Design based on Decades of Experience


1872First Injection Molding Machine

1956Reciprocating Screw for Performance Jump

2016HP Jet Fusion 3D 4200 printer

Six levers for disrupting the $12T manufacturing sector


$12T

Manufacturing

3D Printing

Manufacturing Sector offers great potential for 3D Printing Six keys to transform the $12T Market

Product capabilities

Material price Material selection

Design for additive

New supply chain

Standards and policy

Accelerate

Unlock

5

Let’s talk process

Over 30 years of

HP Inkjetinnovation…

7 HP Confidential

HP Multi Jet Fusion platform

Basic elements of the process

Fused FusedFused

Fused

Apply energyApply agentsMaterial coating


Let’s talk science

Material properties defined by:

1) Part density• Layer must fully melt

2) Intermolecular diffusion • Polymer chains must cross

layer boundary and entangle

THEN…

3) Intrinsic polymer properties.• Molecular structure

Accuracy controlled by:

• Resolution of 2D print

• Thermal boundary growth

• Uniformity of crystallization Step and repeat

Intended output

Absorber Ink

Pattern with ink

Fusing lamp

Fuse

“Sintered”plasticSolidify

Layer of pigment

Polymer powder

Build platen

Spread powder

Layer N

Molecular diffusion, reaction and entanglement

Layer N+1

Multi Jet Fusion: “molds” one layer at a time

Area based melting throughput

Energy

Pattern

Heat signature

White powder temperature < melt

Selectivity

The more energy we put into black, the more energy goes into the white.

Materials must melt and consolidate QUICKLY in order to work. • Low melt viscosity• Highly crystalline

However, this comes with a catch…

IR spectrum

Visible spectrum

Differential energy absorbed is achieved by differential IR absorptivity.

Part temperature > melt

200

190

180

170

160

150

140

130

120

1 10

100

˚C

Let’s talk Applications

Manufacturing aids: Jigs, fixtures, and tooling

Spare PartDigital Inventory


Development Manufacturing Service, MRO, Aftermarket

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Time along product lifecycle

PrototypingDesign Acceleration

Equipment fixtures and nests

• 2K parts for tooling

• Lead time reduction: 13 weeks to 2 weeks

• 90% cost reduction

• Reduce changeover time


Insight: Saving in Ongoing Production Cost / Lightweight

95%Cost reduction

90%Weight reduction

Manufacturing technology:

Material:

Weight:

Cost:

MOQ:

TAT:

Manufacturing technology:

Material:

Weight:

Cost:

MOQ:

TAT:

Consolidated from 7 parts to 1

Better performing, Easier-to-build ToolsHP printheads manufacturing line: Drill extraction shoe

Machining

Aluminum

575g

450$

13

3-5 days

HP Multi Jet Fusion

HP 3D HR PA12

52g

18$

1

1-2 days


Bridge Production





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Product and Tooling Development

From Prototype into production


Nu

mb

ero

f p

arts

Early prototypes Final prototypes Ramp production Heavy production

Production

HP Z 3D CameraBrand new market space

Priority on speedand learning

3-in-1 foot

Socket Top

Lower Housing

Upper Housing

Arm Skirt (hidden)Thermal Duct (internal)

Thermal Duct

Intro MJF parts

• Cost avoidance

• Reduce design cycleby 6 weeks


Addressed Engineering, Manufacturing and Industrial Design issues

Rapid iterations

HP Case Study

>A dozen iterations of design in less than the time to T1 of a molded part


Full Production

Bridge Production





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Why Use Additive Manufacturing for Production

• Balanced capacity

• Flexible manufacturing platform

• Limited fixed cost investment

• Schedule flexibility

• Scalable

• Minimal waste

• Parts delivered ‘just in time’


22


So we started from scratch – and created a new systemBy ordering in complete sets we were able to

1 Set

Kanban [kahn-bahn] Noun 1. a just-in-time method of inventory control, originally developed in Japanese automobile factories.

Better match supply and demand

Lower our costs

Control inventory

3 Sets

KANBAN BUILDS VS. INJECTION MOLDING

80* parts

*72 unique components


Accelerated Product Development

Enable New Capabilities


2

3

Design For Mass Reduction

1

24


Optimized Fluid Management SystemsReplacing complex assemblies with a single part provides economic, logistical, and performance improvement

Invented by: Samuel Jeong

>30%total cost reduction

>$190kin capital expense

avoided

Injection Molded VersionMulti Jet Fusion

• No tooling spend or assets to manage • No assembly / testing required • Simplified supply chain and qualification • Time savings for designer

Functionality LossAn Injection Molding Design also would have functionality tradeoffs to get around molding constraints

Blades were too thin for material to be able to flow. Molding would requires much thicker structure, interfering with flow

Side walls would require draft, increasing assembly size, or decreasing flow volume


95xMass reduction

93%Mass reduction

Designing to Reduce Mass


77%Mass reduction

Plastic 3D MJF PrintingTopological design

23g

Note: this example is from HP Latex Printer

355g

Aluminum machinedTraditional design

80g

Plastic 3D PrintingBlock design

55g

Plastic 3D PrintingLight design

DesignEvolution

No design for plastic tooling 4 - 6 weeks

Internal MJF vs outsourced 1 day vs. 5 day turn for testing

2 - 3 weeks

Avoid tooling and toolingchanges

5 - 7 weeks

Ramp with tested design 0 - 6 weeks

Mfg lead time2 weeks vs 5 weeks

2 - 4 weeks

Total savings 13 – 26 weeks

Accelerated Product Development


New subsystems required

Design for functionality inMulti Jet Fusion only

Enables focus on “how it works” not “how to make”

Design for 3D guiding principles

Design strategy

• Commodity and custom parts

• Simple sheet metal

• Minimize custom tool partsfreeze and commit early

• Complexity and design changes in Multi Jet Fusion parts

• Don’t design to be tooled later

• Complexity through integration

• Change in Multi Jet Fusion

Schedule enablers

Results

Enables focus on integration testing


Accelerated DevelopmentCritical path was no longer defined by tooling

Part Redesign

TestBuildToolFabrication

Tool DesignProcessSimulation

DFMPart Design

TestBuildDFMPart Design

Part Redesign

Innovative Tooling Solutions that Make Better Parts. Faster.

Linear AMS History

➢Linear Mold & Engineering Founded in June 2003

➢Specialized in prototyping of plastic injection molds & low volume production molding

➢Led the industry as an early adopter of DMLM technology

➢Combined DMLM Technology with mold-making capabilities for cycle time improvements

➢Used DMLM technology to print production parts for Oil/Gas & Energy Industries

➢Company Sold to Moog Inc in December 2015 for Metal AM Production Capability

➢Company founder purchased tooling and manufacturing business back from Moog Inc in July 2017

About Linear AMS LLC

Locations:

- 12163 Globe Street Livonia, MI 48150

- 35450 Industrial Road Livonia, MI 48150

Employees: 65

Services:◦ Additive Manufacturing

◦ Metal -DMLS – Powder Laser Bed – EOS M280

◦ Plastic - HP – Multi jet Fusion - 4210

◦ Plastic Injection Molds and Tooling

◦ Conformal Cooling using DMLM technology

◦ Laser Marking

◦ FEA Analysis for injection molds

◦ Injection Mold Part Manufacturing ◦ 9 Presses (110 ton -1650 ton)

◦ Product Design & Engineering

◦ Models & Fixtures


Development Production Service, MRO, Aftermarket

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Conformal CoolingInjection Molds

Steel Injection Molds

Aluminum Injection Molds Aluminum Injection Molds

Conformal Cooling

What is Conformal Cooling?

➢ It is the optimization of cooling or heating channels that follow the shape of the molded part surface for productivity and quality improvements

➢ It is a way of reaching area in a mold that have hot or cold spots to help control the part temp. during molding.

How does Conformal Cooling help make a mold more Lean?

➢ Reducing Scrap

➢ Reducing Cycle Time

➢ Increased Capacity

How are Conformal Cooling inserts built?

➢ Simulation

➢ Design and Optimization

➢ Laser Sintering (A.K.A. Additive Manufacturing)

➢ Post Processing


Development Production Service, MRO, Aftermarket

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Prototype and RampPoduction

Conformal CoolingInjection Molds

Steel Injection Molds

Aluminum Injection Molds Aluminum Injection Molds

Low VolumeProduction

Aftermarket and Service Parts

HP MJF Enables SpeedMJF Version

◦ Delivery Time = 3 Days

Injection Mold Version◦ Delivery Time = 42 Days

1. Reduce Risk of Tool Changes

2. Validates Design During Tool Construction

3. Augments Production Ramp

The Continuing Importance of Process Expertise

Additive manufacturing experts will bridge the gap from design to production


Identify the build direction

Avoid sudden changes in printed surface area

Think about packing density

Constant wall thickness 2

Think about press size 3

Identify die draw 1

Multi Jet Fusion designIM design

Changing our thinking

Design evolution


Sample Part from Internal HP analysis

Setting Manufacturing Specifications


Understanding requirements for functionality and cost will be vital for optimizing performance

Surface Finish

Tolerances Affordability

Ductility

Thresholds

Orientation Options and Tradeoffs


Optimized for Surface Finish & Strength Optimized for Cost

Accuracy Affordability

Ductility

Surface Finish


Ductility

Surface Finish


Ductility

Surface Finish

Optimized for Accuracy


1

3

2

Accommodating Variability to Improve Economics Multi-directional build layouts can






Identify die draw 1



Design evolution


Understanding Thermal and Physical Behaviors on a layer-by-layer basis

Control printedarea, and keeping

it consistent


Before - Flat

Dome

Corrugation


Controlling Layer-to-Layer Printed Area

45






Identify die draw 1



Design evolution


SOLVING FOR CAPACITY & EFFICIENCY

A high-value, highly optimized part, was creating supply chain issues

Three per build

Using design collaboration to help alleviate supply chain issues

As originally designedPrinting these three-at-a-time created supplier capacity issues at production volumes

The large number of additional builds also meant there weren’t enough other production parts to fill the unused space, drastically increasing cost per part

A Redesigned version, split into two separate parts, enabled assurance of supply and cost targets, without sacrificing functionality

1

2

As two parts

Eight per Build

A Redesigned version, split into two separate parts, enabled assurance of supply and cost targets, without

sacrificing functionality

SOLVING FOR CAPACITY & EFFICIENCYUsing design collaboration to help alleviate supply chain issues

2

As two parts

The Result was the ability to produce eight assemblies per Build

1

Chosen as the best path forward for its benefit, and low risk-profile


QUESTIONS

3D Printinghp.com/go/3Dprint+1 (877) 468-8369David Tucker – [email protected] Hopkins – [email protected]

linearams.com(734) 422-6060Brian Garvey – [email protected]

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How Does Additive Manufacturing Complement Injection Molding? · An Injection Molding Design also...

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