TUV SUD Industrial Additive Manufacturing

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


7/25/2019TÜV SÜD | INDUSTRIAL ADDITIVE MANUFACTURING 5

Agenda


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


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


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


AM value proposition should match customer demands from the start


Industrial AM pioneering industries

DentalMedical



Aerospace and turbomachinery

Source: Trumpf Source: Trumpf Source: Trumpf



Automotive


Source: Bimmertoday; BMW Source: Bugatti



Railway: spare parts




Consumer goods



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


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


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


Why do we need a specific quality assurance and skills approachfor iAM?

Definition ofcomponent


processPost






processPost






processPost






processPost






processPost






processPost



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



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



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



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


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


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


“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?




Material suppliers




OEMs / users


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


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?





AM machine manufacturersMaterial suppliers


OEMs / users


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)


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



AM service providersMarketplaces andsoftware solutions


OEMs / users


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


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


First "Industrial AM production sites" in Germany audited and certified


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


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


What are the key network partners to ensure the industrial maturity level of market places and software solutions?

Material suppliersOther solutionproviders



AM service providersMarketplaces andsoftware solutions


OEMs / users


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.


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


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



Technology and innovation management



There is a wellimplemented technology

and innovationmanagement

There is no technologyand innovationmanagement

The implementation is recognisable but

expandable



Strategy for AM



There is a wellimplemented and

clever stategy for AMThere is no strategy

for AMThe strategy is not yet

mature



Implementation ofchange management



There is a wellimplemented change

managementThere is no change ofohh management

The implementation is recognisable but expandable



Personnel for AM



The personnel has a deep knowledge and

experience in AMThere is no AM-

experienced personnelThe implementation is

recognisable but expandable



Strategy for AM

Personnel for AM

Degree of industrialization (Quality, Cert., ..)

Implementationchange management



Consistency with business model

Technology and Innovation management



Strategy for AM

Personnel for AM

Degree of industrialization (Quality, Cert., ..)





Technology and Innovation management



Strategy for AM

Personnel for AM

Degree of industrialisation (Quality, certification etc.)





Technology and innovation management

Experttrainings,certification programme

Training "Status quo for decision makers" qualification and reports


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


Welcome to test our TrustinAMproject assistant:

– Go to www.trustinam.com

Enabling access to iAM for product designers


Enabling access to global markets

Over 1,000 TÜV SÜD locations in about 50 countries

Germany (HQ)AustraliaAustriaBangladeshBelgiumBosnia & HerzegovinaBrazilCambodiaCanadaChinaCroatiaCzech Republic DenmarkEgyptFinlandFranceGreece

HungaryIndiaIndonesiaIrelandItalyJapanMalaysiaMexicoNetherlandsOmanPhilippinesPolandPortugalQatarRomaniaRussiaSaudi Arabia

SingaporeSlovakiaSloveniaSouth AfricaSouth KoreaSpainSri LankaSwedenSwitzerlandThailandTurkeyUAEUnited KingdomUSAVietnam


Contact us:www.tuvsud.com/[email protected]

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http://www.tuvsud.com/additive-manufacturing

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TUV SUD Industrial Additive Manufacturing

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