3d printing vs cnc machining - stratasys · additive manufacturing consulting and communications....
TRANSCRIPT
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COMPARING TWO RAPID PROTOTYPING ALTERNATIVES
3D PRINTING VS CNC MACHINING
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CNC vs 3DP, Similar but Different
Workflow: Design, Prepare, Set Up, Manufacture, Post Process
Time and Cost Comparison
Guidelines: When to 3D Print
Quality Considerations
Rethink the ‘Givens’
TODAY’S TOPIC
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OUR SPEAKER
TODD GRIMM | President
T.A. Grimm & Associates,
Additive Manufacturing
Consulting and Communications
3D Printing vs CNC MachiningComparing Two Rapid Prototyping Alternatives
Todd Grimm
Terms
Rapid Prototyping
3D Printing
Additive Manufacturing
ScopeProduct development3D printers3-axis CNC milling machines
Source: Fairchild Air Force Base
Out of ScopeManufacturing/production workManual milling machines4-axis (or more) milling machines
3D Printing | CNC Milling
Similar, but different
Design sensitivity
Automation
Batch processing
Setup
Operations
Workflow
Workflow
Workflow
Design
Prepare
Set Up
Manufacture
Post Process
Time →
DesignAssumed equivalency
Considerations
Design modification likelihood
Need for engineering drawings
DesignAssumed equivalency
Considerations
Design modification likelihood
Need for engineering drawings
3DP
Design: # hr
CNC
Design: # hr
PrepareDifference
Skill level
Decision making
Automation
Source: Flickr, Siemens PLM Software
3D printing
CNC milling
PrepareDifference
Skill level
Decision making
Automation
Source: Flickr, Siemens PLM Software
3DP
Prepare: 5-30 min
CNC
Prepare: 0.5-8 hr
3D printing
CNC milling
SetupDifference
Skill level
# of tasks
# of occurrences
3D printing
CNC milling
SetupDifference
Skill level
# of tasks
# of occurrences
3DP
Setup: 5-15 min
CNC
Setup: 15 min+
3D printing
CNC milling
ManufactureDifference
Skill level
Automation
# of setups
Time factors
3DP: Size & volume
CNC: feature count/type, % material removed
3D printing
CNC milling
3DP
Mfg: part dependent
CNC
Mfg: part dependent
3D printing
CNC milling
ManufactureDifference
Skill level
Automation
# of setups
Time factors
3DP: Size & volume
CNC: feature count/type, % material removed
Post ProcessingDifference
Optional vs. required
Post ProcessingDifference
Optional vs. required
3DP
Post 5 min – 4 hr
CNC
Post: 0 min
Time/Cost Comparison
Assumptions
Labor: $37/hr.
Machine time: $1/hr.
Materials:
3DP: $1/in3
CNC: $0.5/in3
Time/Cost Comparison
Labor Manufacturing Total
3D printing 0.3 hr. 2.0 hr. 2.3 hr.
CNC milling 1.0 hr. 0.3 hr. 1.3 hr.
Labor Manufacturing Material Total
3D printing $11.10 $2.00 $17.50 $30.60
CNC milling $37.00 $0.30 $8.75 $46.05
Complexity
Source:Sudir Singh Gill
Complexity
Source:Sudir Singh Gill
Complexity
High feature count
Difficult features
Multiple feature axes
Multi-part assemblies
Hollow parts/encapsulated chambers
Time Drivers
◦ 3D Printing
◦ Volume and height
◦ Support structures
◦ CNC
◦ Volume of material removed
◦ Removal rate
◦ Specified tolerance
◦ Size/depth of holes/pockets
◦ Wall thickness
◦ Material
◦ Setups
◦ Both
◦ Resource availability
OperationsInhouse or outsource
Centralized or distributed
OperationsSelf-serve
Managed lab
PrepSet
UpManufacture
Post
Proc.
PrepSet
UpManufacture
Time/Cost Considerations
2.3
hr
1.3
hr
3D Printing: $30.60
CNC Milling: $46.05
PrepSet
UpManufacture
Post
Proc.
PrepSet
UpManufacture
Time/Cost Considerations
16 hr
18
hr
4:30
p.m.
start
Delay
3D Printing: $30.60
CNC Milling: $46.05
PrepSet
UpManufacture
Post
Proc.
PrepSet
UpManufacture
Time/Cost Considerations
8 hr
Days
Delay
3D Printing: $30.60
CNC Milling: $46.05
Queue
filled
Schedule
firm
PrepSet
UpManufacture
Post
Proc.
PrepSet
UpManufacture
Time/Cost Considerations
4.3 hr
5hr
3D Printing: $75.00
CNC Milling: $140.00
Set
UpManufacture
Set
UpManufacture
Qty=3
PrepSet
UpManufacture
Post
Proc.
PrepSet
UpManufacture
Time/Cost Considerations
4.5 hr
5.4hr
3D Printing: $128
CNC Milling: $218
Set
UpManufacture
PrepSet
UpManufacture
Prep
3
Design
Revs
Time/Cost Considerations
Features: all faces
Challenging
Features
3DP CNC
Complex
Design
Time/Cost Considerations
3D printing Time Cost
1 day $120
CNC milling Time Cost
7 days $300
Worst/Best
Case
Guidelines: When to 3D Print
Design
◦ Part size : Order quantity
◦ Part size : Design complexity
◦ Part surface area : Bounding box
Drivers
◦ Fast, efficient delivery
◦ Multiple design iterations
◦ Design subject to change
Quality Considerations
Materials
Material properties
Tolerance
Surface finish
Rethink the “Givens”The trap:
Assuming need what have always gotten
For best alternative:
Honest assessment of goals & requirements
I Need
Rethink the “Givens”The trap:
Assuming need what have always gotten
For best alternative:
Honest assessment of goals & requirements
I Want
Wrap Up
Rethink demands
Understand both options
An alternative, not a replacement
Leverage the differences
Todd Grimm | [email protected]
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QUESTIONS?
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KEEP THE CONVERSATION GOING
Read the white paper
http://www.stratasys.com/campaign/whitepaper/3d-vs-cnc
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COMPARING TWO RAPID PROTOTYPING ALTERNATIVES
3D PRINTING VS CNC MACHINING