Industrial Engineering Applications of Rapid Prototyping

Transcription

1 Industrial Engineering Applications of Rapid Prototyping Dr. Denis Cormier Rochester Institute of Technology Department of Industrial and Systems Engineering

2 Introductions North Carolina State University 2009-present Rochester Institute of Technology Involved in RP industry since 1996 Rapid Prototyping Journal editorial advisory board ASTM F-42 standards group founding member Contributor to NSF, Navy, Air Force additive manufacturing roadmap efforts

3 What Is Rapid Prototyping? a.k.a. additive manufacturing, 3D printing, solid freeform fabrication, digital printing, rapid manufacturing, etc. A family of fabrication processes that use layer additive manufacturing Key is that parts of any complexity are made without molds or dies RP allows a part to be made in hours or days

4 Quick Overview of Selected AM Processes

5 AM Processes for Polymer Parts Stereolithography (3D Systems) Laser sweeps over liquid polymer vat to selectively harden one layer of resin at a time 96SxDnXA Fused Deposition Modeling (Stratasys, MakerBot, Bits-from- Bytes, etc) Molten thermoplastic is extruded through a moving nozzle =ykhmmkqdi68 Skull and implant model Printed on FDM machine

6 AM Processes for Polymer Parts Selective Laser Sintering (3D Systems, EOSint) Scan a laser over selected regions of a layer of powder to melt the powder Inkjet Printed Photopolymers (Objet, 3D Systems) Inkjet print photopolymer where you want it, and then cure it with UV light Nylon lattice structure printed via SLS Multimaterial ink jetted photopolymer component

7 AM Processes for Metal Parts Selective Laser Melting (EOS, Concept Laser, etc) Laser is selectively scanned over layer of metal powder tch?v=afdjy-4uhse Electron Beam Melting (Arcam) E-beam is selectively scanned over layer of metal powder Bronze infiltrated steel chess piece Titanium components produced via EBM

8 AM of COLOR Parts 3D Printing (ZCorp) Inkjet print color binder onto thin layers of plaster atch?v=21rluhsni6q

9 Summary: What Makes AM Processes Different? Geometry is free DFM rules effectively go away Functionally graded materials (someday) Ability to produce parts having enhanced material properties Titanium auxetic lattice structures produced via EBM (Credit: Li Yang)

10 Industrial Engineering Applications of RP/AM Some obvious and some not so obvious

11 Production Economics Fixed vs. variable costs Conventional processes include fixed tooling costs as well as variable per-part costs (material, labor, etc) Tooling costs are amortized over the total quantity of parts produced AM processes eliminate fixed tooling costs At low production quantities, the elimination of tooling costs is significant Source: Hopkinson and Dickens, Proc. Instn Mech. Engrs Vol. 217 Part C: J. Mechanical Engineering Science

12 Ergonomics Form, fit, feel, and function Prototype parts in user focus groups EU CustomFIT Project Running shoes Motorcycle seat Customized consumer goods Eyeglasses (nose bridge) Swimming goggles Helmets Office seating etc. proceedingsarchive/pubs/ Manuscripts/2009/ Jones.pdf

13 Assembly Jigs and Fixtures Assembly fixtures are typically produced in lots of one AM process may be faster/cheaper than machining AM process can produce nonmachinable geometries Error proofing Color and text Arrows or other 3D annotations printed right into the fixtures to reduce assembly errors

14 Objective: Improve quality and reduce cost of orthopedic health care Improved fit vs. mass produced bone implants Impact on cost of health care? Reduce surgical time Custom Implants and Surgical Drilling/Cutting Guides Pre-fabricated plates/guides vs. forming bone plates during surgery Locate drill holes at optimal locations Reduce surgical complications Credit: Mr. Ketan Jajal

15 Presurgical Planning Create 3D models from CT/MRI scan data Fabricate physical models Models used for: Presurgical planning Communication with patient

16 Component Unitization DFA guidelines Separate parts needed for relative motion, different materials, etc. Multiple parts are often used due to DFM guidelines DFM essentially doesn t apply when we make parts via additive manufacturing Component unitization Merge parts that would have been produced separately due to DFM guidelines Advantages Fewer parts and assembly steps Enhanced reliability in some cases Challenge mechanical designers will need to reconsider how parts are made to take advantage of the possibilities Titanium EBM parts

17 Concurrent engineering Short runs of parts for assembly line design Design and refine assembly line and assembly stations while production tooling is being produced Pilot production runs Time and motion studies Line balancing Ergonomics Work station design Assembly training Assembly Line Applications

18 Short Run Tooling Direct tooling Molds/dies Vacuum thermoforming tools InVisalign Braces

19 Short Run Tooling Indirect tooling Sand casting patterns Wax investment casting patterns Examples: Jewelry and minimally invasive surgical instruments Custom investment cast bronze drawer pull Investment cast aluminum suturing device

20 Rapid Manufacturing of Functional Parts Small production quantities Mass Customization Medical parts High dollar value parts Aerospace components, exotic materials that need to be near net shape, etc. Example: Custom hearing aids made using FDA-approved polymers Electroless nickel plated stereolithography air pump housing Steel turbine produced via SLM process

21 Impact of AM On Logistics (someday) Distributed vs. centralized manufacturing Centralized manufacturing high tooling costs dictate that parts are made in high volumes at 1-2 central locations and then shipped to finished goods warehouses Distributed manufacturing elimination of tooling allows parts to be produced close to the point of use on demand

22 Impact of AM On Logistics Reduce or eliminate finished goods warehouses for discontinued products Reduce inventory carrying costs Dollar investment in finished goods Land, electricity, HVAC, maintenance, etc. Product damage Product obsolescence Reinvest inventory funds in modernization and efficiency upgrades Potential environmental impacts Material utilization Tooling Transportation

23 Rapid Manufacturing of the Future? Digital libraries of spare/replacement parts Go online and select make/model/year/part Customize the part (optional) Enter payment info Click Print Part prints out at your local 3D copy shop, or even in your own home Concerns Much discussion about digital rights management for 3D models

24 Questions and/or Discussion? Feel free to contact me if you have questions/comments on this topic: Denis Cormier at