Company & Technology Overview David Stevenson Product Manager
Agenda Company Introduction and Global locations ExOne 3D printing Technology (incl. short video) Equipment Overview Production Service Center Industries, Applications and Customers Case Studies
Company Introduction and Global locations 3
The ExOne company ExOne Digital Part Materialization History / Ownership ExOne founded by Lawrence Rhoades in 2005 when the finishing technologies of Extrude Hone were sold to Kennametal, Inc. and the remaining advanced manufacturing processes were formed into a new company. S. Kent Rockwell of Rockwell Venture Capital (formerly of Rockwell International) acquired ExOne in 2008. Over $80 million in investment in global research & development over the last decade.
The ExOne company Digital Part Materialization (Additive Manufacturing) Sand Printing for Patternless Production of Sand Molds & Cores Metal Printing for Functional Metal Parts Glass Printing for Glass Components Micromachining with Short-Pulse Laser Technology Short-pulse laser micromachining for small, complex holes Services and Equipment Provided for all Technologies
Global Facility Locations 160 employees
7 3D Printing Technology
Industry-Proven Technology CAD data Digital Part Materialization Digital cores CAD data to Digital Part Materialization layer by layer Cost saving: eliminate tooling Improve product quality: design freedom Short lead time: Rapid casting process
Binder systems
10 Equipment Overview
Overview out of production S-Print S-15 S-Max S-Print 2012 750x380x400 mm 1500x750x700 mm 1800x1000x700 mm 800x500x400 mm Max 10 liters/hours Max 29 liters/hours Max 108 liters/hours Max 28 liters/hours Rapid Prototyping Small production Medium production Medium production High flexibility
S-Max (Furan) Build size: 1800x1000x700mm Speed: up to 108 Liters/hours Branch: medium production batches Features: Sand recycling; Fluidmatic central fluid supply; Jobmatic automatic job starter; Joblist feature; Larger printhead; Multisand: silica sand, aluminoxyd, zircon, synthetic sand; Post-processing: None
S-Print (Furan Phenol Silicate) Build size: 800x500x400mm Speed: up to 28 Liters/hours Features: Sand recycling; Joblist feature; Larger printhead; Multisand: silica sand, aluminoxyd, zircon, synthetic sand; Post processing (Phenolic and Silicate versions): Load jobbox into oven using the roller coveyer: Cure in Microwave oven Cooling down of jobbox Extraction and Cleaning of parts
Industry Machine Sales S15 S-Max S-Print S-Print 2012 Industry Machine Count S15 S-Max S-Print Grand Total Aerospace 6 4 1 11 Automotive 8 3 3 14 Engineering 2 1 3 Foundry 3 8 2 13 Marine 1 1 R&D 1 1 2 4 PSC 12 7 5 24 Grand Total 33 24 13 70
Machine Locations UK: 4 Germany: 24 Russia: 9 China: 1 Canada: 1 USA: 14 France: 2 Italy: 1 Switzerland: 1 Kazakhstan: 1 Japan: 10 India: 1 Thailand: 1 University/Research Installations Commercial Use Installations
Remote Machine Assist
Production Service Center 17
Production Service Center (PSC) CAD Core Cast PSC facilities print digital cores and molds for foundries, manufactures and engineering companies ExOne has PSC facilities in Germany, Japan, Russia, America and Britian It is planned to open up new PCS facilities in Scandinavia, Italy, Spain & Portugal, Brazil, China and India Cores are printed with a high resolution directly from the CAD data files Ideal for complex geometries where conventional methods are difficult Reverse Engineering of obsolete parts is also possible
Production Service Center (PSC)
Production Service Center (PSC)
Production Service Center (PSC) Typical S-Max layout
PSC - Digital Core Example
PSC - References Customers
Industries, Applications and Customers 24
Industries - Market Capabilities Aerospace Energy/Oil/Gas/Pump Automotive Reverse Engineering Hydraulic systems Faucets industries Marine Institute Foundries
Applications - Aerospace Magnesium castings Gear housing Decrease lead time by more than 10 weeks High complexity of cores (reduced number of core) 40% cost saving Excellent material properties
Applications - Energy/Oil/Gas/Pump Housing and impeller castings Pump impeller prototype Reduce Impeller Prototypes Costs up to 90% Decrease lead time by more than 4 weeks
Applications - Automotive Powertrain castings FORD 4-cylinder engine block Aluminium engine block with cast-in liners 30 blocks casted in 3 months Decrease lead time by more than 6 weeks
Applications - Reverse Engineering Examples Submarine replacement parts Reverse Engineer Compressor Pump Castings with 43 weeks reduction in lead time 40% cost saving
Customers - Installations
Case Studies 31
Case Study Automotive Industry
Engineering and CAD Design Digital Core Production at Danielson Benefit Easier design of mold package (no tool needed) excellent design freedom
ExOne Technology 3D Sand Printing Benefit Molds and Cores with complex geometry available without tooling cost saving due continous product design modifications
Assembly Digital Molds and Cores ready for Casting Benefit Faster assembly and high precision of the cores Reduce number of cores as freedom in core design
Foundry Casting with Digital Molds and Cores Benefits Molds and cores are ready in hours Industrial proven casting materials (aluminium, magnesium, cast-iron )
Case study of MCE-5 VCRi Benefits Short lead time in product development Complex parts feasible: Innovative product design Cost saving with design changes (no tooling)
Case Study Aerospace Industry
Why Digital Core Production at Fonderie Messier? Put the foundry in the 21 st Century Implement digital core production technology Create a new economic model Attract new market and customers Develop a process using digital tools Propose innovative design with the introduction of new materials
Digital Core Production Advantages at Fonderie Messier? Using sand molds and cores without tooling High cost reduction Reduction of casting development cycle Reduce lead time for prototypes with digital molds and cores Systematic usage of digital core for serial production Substitute old core box tooling with digital core production Print directly from CAD data
ExOneTechnology 3D Sand Printing Benefit Molds and cores with complex geometry available without tooling Economic and optimised product design modifications
Assembly Digital Molds and Cores ready for Casting Benefit Molds and cores are ready in hours Faster assembly and high precision of the cores Reduced number of cores through freedom in core design
Case study of Door hinge Benefits Short lead time in product development Complex parts feasible: innovative product design Cost saving with design changes (no tooling)
Thank you for your attention david.stevenson@exone.com ExOne The Americas MID-ATLANTIC 127 Industry Boulevard Irwin, PA 15642 USA +1 877 773 9663 MIDWEST 2341 Alger Drive Troy, MI 48083 USA +1 248 740 1580 SOUTH 7409 Railhead Lane Houston, TX 77086 USA +1 281 931 0011 ExOne Europe ExOne GmbH Am Mittleren Moos 41 86167 Augsburg Germany +49 (0) 821 7476 0 ExOne Asia 161-5 Haneo Odawara-shi, Kanagawa Japan 256-0804 +81 465 44 1303 www.exone.com Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.