Benefits and Implementation of Additive Manufacturing Werner Stapela, Global Head Additive Design & Manufacturing 27 Feb, 2017 Werner.stapela@danfoss.com Twitter: @PITVtweets #PIBerlin
Agenda -Brief Introduction to Danfoss -Overview ADM/3D market & technologies -Major Application areas & examples -Implementing ADM/3D in Manufacturing Companies (beyond Aerospace & Automotive) -ADM/3D @ Danfoss -Conclusions -Q & A
Introduction to Danfoss, group facts (2015) Employees 23,400 Worldwide sales Factories Top three markets Ownership Headquarters more than 100 countries 61 in 20 countries USA, China and Germany Privately held Nordborg, Denmark 3 Additive Design & Manufacturing, Feb. 2017
Key financials (2015) Net sales 38.0 bn DKK 5.1 bn EUR EBIT 4.1 bn DKK 549 m EUR Free cash flow 3.4 bn DKK 456 m EUR Net sales bn DKK the last five years EBIT bn DKK the last five years Gains from divestments 4 Additive Design & Manufacturing, Feb. 2017
Our global markets & employees Share of net sales per region 2015 and FTE s North America 24% (3,410 FTE s) Western Europe 39% (9,540 FTE s) Eastern Europe 9% (3,910 FTE s) Latin America 5% (1,200 FTE s) Africa/Middle East 3% (195 FTE s) Asia-Pacific 20% (5,170 FTE s) Total 100% (23,425 FTE s) 5 Additive Design & Manufacturing, Feb. 2017
Our history and Segments Founded in 1933 by Mads Clausen in Nordborg, Denmark Grown from a solo enterprise into a world-leader Made possible by clear focus on innovative engineering and early entry to emerging markets Cooling Heating Power Solutions Drives First product was an expansion valve for refrigeration systems (1933) Danfoss invented one of the first radiator thermostats in the world (1943) Entered hydraulics business with orbit motor for agricultural and construction machines (1964) First company to massproduce variable speed drives for controlling motors (1968) Later the hermetic compressor for refrigerators and freezers followed (1952) Today, we are one of the world s leading producers of these and many other products 6 Additive Design & Manufacturing, Feb. 2017
Current state of market & industry Legend SL=Stereolithography SJ=Polyjet BJ=Binder Jetting LM=Laser Melting (metal) EBM=Electronbeam melting (metal) FDM=Fused Deposition Moulding LS= Laser Sinter MJ=Multijet (new HP) Compliments of additively.com Market Size: ~$ 5,5 Billion in 2015 26,5 % CAGR growth over 2 decades ++ 7 Additive Design & Manufacturing, Feb. 2017
Major Application Areas & Complication Degree Quick gains, NPD process speed-up Easy gains in productivity Hard stuff, BIG gains R. Prototyping (R & D) Examples: Display new & novel design features Early design exploration Evaluate functional characteristics Use in concept selection process Multiple Iteration examples R. Tooling (Production Aids) Examples: Fixtures for product assembly Assembly tools Field Test Units Molds (for low volume, ramp-up) End Component Manufacturing Examples: Multiple part assemply into one Part strengthening Weight reduction Surface optimization Conformal Cooling/Heating 8 Additive Design & Manufacturing, Feb. 2017
End component manufacture, a prime example: GE Aerospace CFM Leap Engine Fuel Nozzle https://www.youtube.com/watch?v=rmzvsbnebcg Compared to previous Nozzles: 5 x stronger 5 x fewer brazes/welds Parts consolidation: 20 parts >> 1 part Environment: 50% lower NOX levels than regulatory limit Fuel Savings: $ 1,6 Million per Airplane per year Source: GE Aeropsace (with thanks) Nozzle cost: Does it matter?? 9 DBS, Additive Design & Manufacturing
Example Applications Gripper Device, conventional 1/2 Source: Kuhn-Stoff GmbH & Co KG, with thanks 10 DBS, Additive Design & Manufacturing
Example Applications Gripper Device, re-designed for AM 2/2 Downstream advantages: -Downtime after crash radically reduced (21-4 days) -Lighter weight, smaller robot (~ 4,000 saving), less energy used (?? Saving) -Faster cycle times (critical in Injection Molding) -principle can be used for many gripper applications, including retro-fitting Source: Kuhn-Stoff GmbH & Co KG 11 DBS, Additive Design & Manufacturing
Implementing ADM/3D in Manufacturing Companies, HOW? Senior Management must recognize the value of ADM/3D for the company (part of digitalization, one of the first bricks in the wall of digital manufacturing) Senior Management needs to commit financial and human resources (internal, if available, otherwise external) to developing ADM/3D in the company A development strategy needs to be defined by major application area (r. prototyping, r. tooling, end component manufacture). NOTE: development strategy in major application areas call for different skills and investment levels. Different companies strategies will differ, depending on the starting point (which needs to be analyzed at the outset) 12 Additive Design & Manufacturing, Feb. 2017
Major Application Areas & Who is involved R. Prototyping (R & D) Who is involved: NPD project leaders & teams Product designers Customers Sales & Marketing Production staff Management Suppliers ADM/3D leaders R. Tooling (Production Aids) Who is involved: All in production Managers Field Test Engineers External suppliers (e.g. molded product suppliers) ADM/3D leaders End Component Manufacturing Who is involved: Product designers Product engineers Sales & Marketing ADM/3D leaders 13 Additive Design & Manufacturing, Feb. 2017
Major Application Areas & What is to do R. Prototyping (R & D) Map existing NPD s Map ADM/3D vs. NPD Develop specific use cases Determine advisability in NPDs, implement R. Tooling (Production Aids) Identify production ADM/3D opp. Seek opportunities in set-up + re-vamping new prod. Lines Establish whether indirect usage relevant (internal & external) End Component Manufacturing Train product designers and engineers in Design for ADM Incorporate ADM as a standard methodology for design or re-design of products Document Measure benefits Encourage Molds in use at suppliers? Integrate ADM/3D as a standard process at all above junctures 14 Additive Design & Manufacturing, Feb. 2017
NOW, decisions to build or buy (or both) can be taken Buy only equipment which will be extensively utilized, remember peripheral equipment R. Prototyping (R & D) Early decisions to buy desk top printers for familiarization? Alternately/plus buy best for purpose printers based on above outcomes Likely FDM, SLA, SLS, Jetting techn. Buy AND build may apply in many cases R. Tooling (Production Aids) Buy best for purpose printers based on above outcomes Likely FDM, SLA, SLS, Jetting and MJ technologies End Component Manufacturing First and foremost is knowledge building If worth while and feasable, likely technologies FDM (+fiber enhanced), MJ, and in metals LM, EBM and two phase process 15 Additive Design & Manufacturing, Feb. 2017
t Current Danfoss Situation, complication degree Low investment, low skills High investment, high skills R. Prototyping R. Tooling Component Manufacturing Danfoss use now Danfoss use now Danfoss use now This includes redesigned existing parts, new parts and spare parts Danfoss potential: 100% Danfoss potential: 100% Danfoss potential: 100% R & D Manufacturing Operations (SC) End Parts (Design & Manufacture) 16 Additive Design & Manufacturing, Feb. 2017
Conclusions Ensure senior management (C-Suite) is fully committed Ensure the resources are made available Do a thorough analysis across all application areas before making (wise) buy or build decisions Incorporate ADM/3D as standard procedure across all the major application areas. ADM/3D has huge potential, to shorten the NPD cycle considerably (earlier to market, savings), optimize production processes (savings), AND Can be critical in the creation of newly designed products and entire business models (it has already made some business models obsolete) 17 Additive Design & Manufacturing, Feb. 2017
ADM is one of the first bricks in the wall of digital manufacturing Q & A? Thank You Contact details: Werner Stapela, werner.stapela@danfoss.com Twitter: @PITVtweets #PIBerlin 18 Additive Design & Manufacturing, Feb. 2017
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