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Lecture 2
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- 1What is the biggest material segment in AM?Photopolymers (45.5%) -> prototyping
LS polymer powders, 22.8%
Filaments, 15.1%
Metals, 11.5% - rapidly growing - 2Who leads the world in adoption of AM? Where do most of the AM machines come from?North America, 39.7%
US, 50.6% (Europe: 16.8%) - 3How will the served markets develop until 2022 (CAGR)?-Automotive: 24%
-Aero & Defense: 35%
-General industries: 34%
-Power generation: 37%
-Oil & gas: 32%
-Medical: 33% - 4What are the key printing technology players?Stratasys, 41.1%
3D Systems, 15.3%
Mcor, 15.1%
Envisiontec, 10.0%
EOS, 2.9% - 5In which field do European manufacturers dominate?Metal AM
e.g. EOS, 33.8% - 6What do companies mainly use AM technology for?Functional parts, 32.5%
(Then: Fit & assembly, 16.2% Education/research, 10.1% etc.) - 7How does the readiness differ by AM application?1) Medical (9&10): low-rate & full-rate production
2) Aerospace (5-7): basic capabilities shown & system produced in simulated environment, capability in operational env. demonstrated
3) Automotive (4&5): technology validated in laboratory env., basic cap. shown in sim. env. - 8What are the challenges for the Aerospace industry?-Individual customer requirements
-World market with emphasis in the east
-Complex processes with project character & high reliability requirements
-Pressure, time & costs - 9What are the AM requirements of the Aerospace industry?Short term: prototypes & design aids, qualification for long-term series production, series production
Long term: lightweight design of structural airplane components, new engine concepts, enhanced components (e.g. multi-materials, digital metals) - 10What did the first AM manufactured turboprop engine by GE Aviation achieve?-Parts reduction from 855 to 12
-20% lower emission fuel burn (complex fuel nozzles)
-5% weight reduction - 11Besides weight reduction: how much CO2 saving is possible with the consistent application of AM throughout the entire aircraft body?300,000 tons
- 12How does the scenario for aircraft manufacturing in 2030 look like?-Small parts in 3D processes at airports
-Digital simulation of prototypes
-Airplanes & airplane parts in 3D process
-Smart production - 13What are the two motivating factors for Airbus to apply AM?-Agile manufacturing
-High volume -> optimised parts, integrated architecture - 14What are AM fields applied today at Airbus?-New product: functional prototyping, long lead time items, ease of design evolution
-Serial production: mitigate supply disruption, optimised parts, integrated structures
-In-Service: repair, spare parts, supplier obsolescence - 15What are the three focus areas of Boeing's 20 worldwide sites with 3D printing facilities?-Tooling
-Fly away parts
-Interiors
(60,000+ 3D-printed parts) - 16Which AM technologies does Boeing apply? What are the advantages?-Powder bed fusion (metals) -> tooling cost, reduced detail counts for expensive materials
-Wire fed directed energy deposition (Ti wire) -> improved material yield
-Material extrusion (FFF) and SLS -> time & cost of tooling - 17What is the main factor for the complexity in Boeing's processes?65% of airplane cost come through the supply chain
- 18What are automotive customers' needs regarding AM on a short term?-Racing & super cars: lightweight, high-performance alloys, new functionalities, reduced part count
-Mass market: fast prototyping & delivery, part selection tool - 19What are automotive customers' needs regarding AM on a long term?-Custom motorsport services with further lead time reduction
-Exploit full strength & potential of AM
-Process industrialization - 20What were the phases of the AM "hype cycle" in the automotive industry?2012: Innovation trigger
2014: Peak of inflates expectations
2017: -Disillusion (high volume series, small series parts)
-Enlightenment (exclusive series, tooling)
-Productivity (motorsport, prototypes) - 21What are the challenges of AM in today's automotive industry?-Economics limited to low-volume production
-Manufacturing large parts
-Intellectual property concers - 22What are the opportunities of AM in today's automotive industry?-Game changer in design & production
-More materials available
-Improved product quality & reduced post-processing - 23What are the circumstances in the healthcare industry?-Implants: complex geometries, safe, biocompatible, sterilizable
-3D imaging data
-Individualized protheses and support constructions
-Precision in surgical procedures - 24What is the advantage for AM in the healthcare industry?Cost becomes a secondary concern to a successful outcome
- 25What are medical markets AM is applied in?-Complex surgical instruments
-Cardio thoracic (e.g. pacemakers)
-Prosthetics
-Pediatrics (e.g. trauma)
-Neurology (e.g. neuro stimulators)
-Cranio Maxillo Facial (e.g. reconstruction) - 26What does the interconnected value of AM medical solutions consist of?1) Precise patient data capture from imaging
2) Digital solution planning (specialized medical software)
3) Realization of physical production (3D printing) - 27What are the disadvantages of not using AM for healthcare?-Bigger cost increases with complexity
-Small tooling for better access sacrifices tool stiffness & accuracy
-Challenges when milling thin sections - 28What are the three main pillars of AM application for industrial gas turbines (IGT) and what are the respective statuses?-Rapid prototyping (part of standard process)
-Rapid repair (in commercial application)
-Rapid manufacturing (in comm. appl.) - 29What are the advantages of AM regarding the gas turbine burner?1) Repair time: 85% faster manufacturing of complete burner set
2) Upgrades: optimized burner tip for lower fuel use & reduced emissions - 30On which AM areas does GE put its focus?-Powder producer & distributor (346 metal powder patents)
-Software producer (in part; Predix)
-Systems (acq. of leading equipment manufacturers: Concept Laser + Arcam)
-AM production (full fabrication process chain, in-house products) - 31What does GE's AM business model consist of?-Lead in equipment (vertical)
-Leverage GE store (horizontal)
-Add. recurring revenue: services, material, design, product, software (digital)
-Predix as a base for creating productivity for customers (content) - 32On which AM areas does Siemens put its focus?-Software developers (key player in CAD, PLM etc.)
-AM production
-> service & maintanance (spare parts on demand, rapid repair, rapid manufacturing) - 33Which value does AM bring to Siemens?-30% less greenhouse gas emissions
-65% less resources in production processes
-75% less development time
-Design flexibility
-60% faster repairs
-50% less lead time
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- Industry Technologies (Oerlikon) Fichas sobre Lecture 2, creado por Timo Bierwirth el 06/02/2019.
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- Timo Bierwirth
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