digital manufacturing: an overview

8/9/2019 Digital Manufacturing: An Overview

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Digital Design and

ManufacturingDavid W. Rosen

Professor and Associate Chair for Graduate Studies

Rapid Prototyping & Manufacturing Institute

Woodruff School of Mechanical Engineering

Georgia Institute of TechnologyAtlanta, Georgia 30332-0405

404-894-9668 [email protected]
http://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photoshttp://www.gatech.edu/photos


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OverviewTechnologies

Direct Digital Manufacturing (DDM) 3D Computer-Aided Design (CAD)

Reverse Engineering

Manufacturing Custom Manufacturing

Local/Distributed Manufacturing Low Volume Manufacturing

Issues and Prognosis


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Takeaways

DDM, CAD, reverse engineering are

changing manufacturing industries:Customized, Personalized

manufacturingHigh value added products

Local vs. distributed manufacturing; on-

shoring vs. off-shoring

Enable innovative ideas


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Direct Digital Manufacturing

Layer-based additive manufacturing

Parts, tools, patterns, prototypesWide range of polymers and metals

Ex: Stereolithography (SL)


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StereoLithography (SL)

Process Characteristics

+ 3D Systems - inventor

+ UV laser solidifies liquidphotopolymer in layers using

a scanning system

+ Liquid is replenished and

leveled between layers+ Parts require support

structures

+ Completed parts require

cleaning and UV or Thermal

post curing

Related Technologies

+ DMEC/Sony, CMET, Denken,Meiko, EnvisionTec


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Process Characteristics+ C02 laser fuses thermoplastics

powders in layers using a

computer controller scanning

system

+ Powder is replenished and the

next layer is scanned

+ Powder temperature is

maintained near melting point to

aid fusion and minimize

distortions

+ Supports may be used

Related Technologies+ EOS GmbH

3D Systems purchased

DTM Corp. in late 2001.

Selective Laser Sintering (SLS)


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Process Characteristics+ A heated thermoplastic filament

is extruded from a capillary die

+ Thin layers are formed betweenthe die face and previous

layer(s)

+ Parts chamber is heated to

minimize stresses anddeformation

+ Required support structures

+ Cleanup required No post

processing Stratasys Corp.

Fused Deposition Modeling (FDM)

FDM 900mc


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Selective Laser Melting

MCP Realizer

0 5 10 1505

10

0

2

4

6

8

10

12

X

Z

Y

University of Liverpool


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Parts Gallery


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Overview of Commercially

Available RP Systems Stereolithography (SLA) - 3D Systems

Selective Laser Sintering (SLS) - 3D Systems, EOS

Fused Deposition Modeling (FDM) - Stratasys

3D Printing Technology (3DP) - Z Corp., Ex One

3D Printing & Deposition Mill ing (MM) - Solidscape Multi-Jet Modeling (TJM) - 3D Systems, Objet

Laser Engineered Net Shaping (LENS) Optomec

Direct Metal Deposition (DMD) POM Group

Solid Ground Curing (SGC) Cubital (out of business 2000)

Laminated Object Manufacturing (LOM) Helisys(out

of business 1999)


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3D Computer-Aided Design

3D solid modeling

Parametrics adjustable geometry

Assembly modeling

Interfaces to PDM,

PLM systemsKnowledge modeling and

capture

Computer-Aided Engineering

Computer-Aided Manufacturing


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Capabilities

Solids

Assembly Modeling

Surfaces

Parametrics

Knowledge-Based

Engineering


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CAD Systems

PTC: ProEngineer

Siemens Unigraphics: NX

SolidEdge

Dassault Systemes: CATIA

SolidWorks


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Crash Simulation

Roof crush during simulated roll-over.

Body-in-prime + doors# Elements = 127,000

20 design variables


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Reverse Engineering

Physical model to Point

Cloud to CAD modelScanners

Software


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Scanners

ATOS White Light scanners

Canon Laser scannersFaro hand-held/robot laser scanners


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Geomagic Software

Geomagic, Inc. www.geomagic.com


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Clothing

Body Scanner, Cyberware

Virtual Fitting:http://www.explore.cornell.edu/scene.cfm?scene=Th

e%203d%20body%20scanner


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Reverse Engineering

ManufacturingCustom Manufacturing




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The Key Elements

SCANObtain the Digital Model

CADDesign the Part Based on the Digital Model

CAM/RPAutomated Manufacture


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CynovadDental supply company.

Fabricate dental restorations (crowns,

bridges, etc.).Also markets systems for fabricating dental

restorations.

ThermoJet machines to fabricate patterns for

investment casting of

restorations.www.cynovad.com


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Align Technology

Introduction to Align Technology:

650 employees world wide 2 facilities outside of US

> 200,000 cases treated.

> 5 million aligners.

www.aligntech.com or

www.invisalign.com

Most of this content from Long Pham

at Align (Aug. 2002)


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Invisalign Manufacturing Process

Timeline

Receiving & Dent al Data Treat Align er Order Ent ry Laboratory Acquisition Operations Fabrication

SL A Mold

Fabrication

Prepare & Slice

SLA Build

Qu ali ty Control

Ship to Mexico

STL File Generat ion

Packing (orient & place)

Support Generat ion

Slice Data

Laser (Scanning)

Re-coat (dip in resin)

Sweep (remove excessresin)

Part Removal & Post-cure

Verify test parts

Conduct individual moldinspection

Kit in transportation box


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Manufacturing Floor25+ SLA 7000 machines running 24/5


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Automated UV Curing

2 minute UV post-cure


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Personalized Golf Grips


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Customized Radio Heads


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Direct Digital Manufacturing (DDM)

3D Computer-Aided Design (CAD)

Reverse Engineering




Align Technologies


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g ec o og es

DistributionNovel supply chain and business model.

Orthodontist

Data Manipulation

(Pakistan before2002)Molding(Mexico)

Align Tech

Data Manipulation

(Costa Rica)

f


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Distributed Manufacturing

Highly capable, integrated, inexpensive

manufacturing systems.

Put manufacturing capability where it is neededto best serve the customer:

Home Depot

Doctors or Dentists office

Home

Supply chains become very different

Manufacturing capability becomes a

commodity?


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Siemens Hearing Instruments

Partnership with Phonak (Germany) to produce hear

aids.

Producing in-the-ear hearing aid shell using AM since2002.

Siemens using mostly stereolithography now; started

with SLS.More than 100,000 hearing aid shells yearly.

Courtesy: Martin Masters

Siemens Hearin Instruments, Inc


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Digital Mechanical Processing

Create an impression of the ear.

Scan the impression

Modify the data through software

Fabricate the instrument shell

Create the desired surface finish

Close and ship the instrument

I i S i


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Minolta Vivid 900

Dual Head Configuration

Impression Scanning

S ft M d li


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Software Modeling

Create vent and wall

thickness from digital data.

H i Aid M f t i


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Hearing Aid Manufacturing

Local office:

Scan impressions

Ship data to central

location

Design hearing aid

Ship data back to local

office

Fabricate shell

Assemble from kit

Local Laboratory:

Ship impression from local

office to local laboratory

Scan impressions

Ship data to central location

Design hearing aid

Ship data back to local lab

Fabricate shell

Assemble from kit

Ship to local off ice

Kit h R d ti


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Kitchen Redecorating

Start with geometric layout of YOUR kitchen.

Select appliances, cabinets, sink, lighting

Configure (layout) items and appliances. Customize functionality of appliances (e.g., smart

refrigerator). Network appliances to ensure

everything interoperates. Customize appearance

of each item.

View in various lightingconditions.

.See: www.homedepot.com

S i B


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Service Bureaus

Companies that own machining and

DDM equipment.Contract prototype fabricators.

Mold making, molding.

Short-run production.

Contract design and engineering work.

Ex: ARRK, Compression Engineering,

Morris Technologies, FineLine

Prototyping, RedEye RPM, etc.

RP Markets


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RP Markets

Some companies act as market makers:

Xpress3D.com - central site for customers to

submit parts.

Solicits quotes from service bureaus.

QuickParts.com - Quotes directly oncustomers parts.

Finds service bureau.

Atlanta based.

Very nice web site.

Tough to make money.

Xpress3D com


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Xpress3D.com

QuickParts com


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QuickParts.com

QuickParts com (2)


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QuickParts.com (2)


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Overview

Technologies

Direct Digital Manufacturing (DDM)

3D Computer-Aided Design (CAD)

Reverse Engineering


Local/Distributed Manufacturing

Low Volume Manufacturing


Component Consolidation


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Component Consolidation(A) Conventional Duct fabricated

from Vac Formed plastic

Part Count = 16 (plus glue)

(B) Component modified and

consolidated for fabrication via Additive

Rapid Direct Manufacture

Part Count = 1

Courtesy: Patrick Dunne, 3D Systems

Example for Production


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ApplicationsPrevious (Kevlar/Rotomold)Configuration

New (SLS)

Configuration

Attach Straps

Eliminated

Part Count Reduct ion Quick & Easy Installation

Mult iple Ducts Combined to

Single-Piece Duct

Conformal Shapes Achieved and Internal Flow Features Added

Courtesy: Boeing PhantomWorks

Value of Direct Manufacturing


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Value of Direct Manufacturing

Engineering Design:

Direct from 3-D Model Base Definition

Design and Build Flexibility

Production: Eliminate non-recurring tooling costs

Lower recurring unit part costs

Faster part delivery times

Supplier flexibility

Direct Fabrication:

50% Cost Reduction

67% Cycle Time Reduction at

Minimum

Product: Reduced part count and weight

Lower inventory and transportation

costs

Improved Life Cycle Product CostsCourtesy: Boeing PhantomWorks

Stratasys FDM 900mc


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Stratasys FDM 900mc

32 parts for the FDM 900mc are built on

FDM machines.

RedEye RPM in-house rapid

manufacturing facility ~80 machines

FDM 900mc


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O i


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Overview

Technologies


Reverse Engineering

Manufacturing

Custom Manufacturing

Local/Distributed Manufacturing

Low Volume Manufacturing


Unique Capabilities


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Unique Capabilities

Shape Complexity

Material Complexity

Hierarchical Complexity

Functional Complexity

Customer-Driven Design


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Customer Driven Design

Bottlenecks in product development:

capture specifications and design

delivery to customer

New design tools, userinterfaces needed.

Automated design/engineering

for customized products.

Levers enabling RM


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Levers enabling RM

Unique Shapes: fabricate parts with customized

shapes.

Complex Shape: consolidate many parts into 1.

Lot Size of One: economical to fabricate

customized parts.

Fast Turnaround: save time, costs. Increase

customer satisfaction.

Digital Manufacturing: precisely duplicate CAD

model

correct shape.

Sustainability


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Sustainability

+ 90-100% of feedstock ends up in parts.

+ Few processes require hazardouschemicals.

+ Designed structures can be much

lighter, stiffer, and stronger, reducing

need for energy.

+ Multifunctional structures.

- Processes can be slow, consume lots of

energy.

Issues


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Issues

Rapid Prototyping industry

Prototyping is NOT productionMaterials need to be improved

Qualification of materials, processesCertification of users, suppliers, ...

Economics: costs, speeds, machinereliability, throughput

Supply Chains and Business Models


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Dental restorations and custom medicaldevices role for labs, large

manufacturing facilities?

Home Depot: products manufactured

world-wide, shipped to each store.

Custom designed, fabricated in-house.Supply chain?

Custom enhancements to cars,motorcycles, bikes.

Childrens toys design your own...

Business ModelsO t iti b d B t d kill


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Opportunities abound ... But need killer app

Custom manufactured World of Warcraft

figurines: www.figureprints.com (ZCorp

DDM machines).

What kinds of services and/or products canyou think of?

Prognosis


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g

Opportunities abound: auto, aero,

industry, medical, consumer...

New products. Spares. Enhancements.

Materials.

Economics.

Qualification, certification, standards.

Machine configurations, open architecture

Design and CAD Methods


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g

Medical Device Manufacturing


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g

LASER

Source

BeamExpander Lens

Mirror

DMD Chip

Collimator

lenses

Diffuser

High Viscosity Ink-Jet Printing


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g y g

Thank You!


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RPMI Industry Members: 3D Systems, 3M,DSM, Ford, Huntsman, Lockheed-Martin,

Pratt & Whitney, Siemens

National Science Foundation

Georgia Tech, colleagues, students

Dr. David RosenRapid Prototyping & Manufacturing Institute

Woodruff School of Mechanical Engineering

Georgia Institute of Technology

Atlanta, Georgia 30332-0405

[email protected] 404-894-9668

digital manufacturing: an overview

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