3D Printing - GPCA PLASTICON printing has come a long way from printing toy rabbits in the late...

3D PrintingA Remarkable yet Disruptive Technology

Roberto Ribeiro

• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda

GCC Polymer Value Chain: Creating Future Leverage

Introduction

How many times have you heard (or said), “that product is so simple, why didn’t I think of that?”

IDEA ≠ EXECUTION

Product Development Lifecycle Management

Idea/

Innovation

Refinement/

PrototypingProduction

Sales/

Service/

Marketing

Where each step

requires significant

capital and labor


Introduction


Introduction

3D Printing or Additive Manufacturing is a process that makes a physical object from digital manufacturing or

design software.

3D printing has come a long way from printing toy rabbits in the late 1980’s. Now 3D printers have the technology

to print working parts for machines, injection molds, biological implants, apparel, and even functional buildings.

3D printed Art by Fdecomite via Flicker


Introduction: 3D Printing Patent Timeline

The number of 3D

printing related

patents issued

annually started to

grow with

significance after the

four basic 3D

printing process

patents had been

granted, and grew

with aggression as

patents for

specialized

processes were

granted.

Source: Townsend Solutions


Global Market

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0

Ap

pro

xim

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Va

lue

(in

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ion

s o

f U

SD

)

Total Global 3D Market Value• The total global 3DP market,

including products, materials,

and services, is projected to

reach $20 billion USD by 2020.

• The total global market value in

2015 was over $5 billion

• The CAGR from 2010 to 2015 is

31.35%

• If the CAGR of 31.35% remains

steady over the next three

years, the total global market

value is projected to hit over $20

Billion (USD) by 2020.

* Future Projections



Global Market: Countries

• United States continues to

lead the 3D Printing Market

with 38%

• Japan ranked 2nd with 10%

• Germany and China tied for 3rd

with 9%

• UK and Italy tied for 4th with 4%

• France has 3%

• Korea has 2%

• Other various countries shared

a collective 21% with individual

shares of less than 2%

• AP is the fastest growing region

United States38%

Others21%

Japan10%

China9%

Germany9%

United Kingdom

4%

Italy4%

France3%

Korea2%

3D Printing Total Market Shares in 2016:By Country


• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda


Technology: Light Polymerization

Stereolithography (SLA)

A laser or conventional light source traces a pattern

on the surface of a vat of photopolymer.

Highlights Fast process that uses liquid

photopolymer, and produces a detailed smooth

product for the dental, healthcare, electronics, and

consumer goods sectors.

Poly-jet (PJ)

A stationary laser or conventional light source cures

photopolymer that is traced in a pattern.

Highlights Fast process that uses liquid

photopolymer, and produces a detailed, accurate,

multi-material prototype for the automotive, healthcare,

dental, and consumer goods sectors.

Carbon

introduced

Continuous Liquid

Interface

Production (CLIP),

derived from

Stereolithography,

in 2015; the

fastest 3D printing

technology to

date.

3D printing

produces an

Injection mold

prototype in hours

instead of days.

Courtesy of EngatechCourtesy of Carbon 3D


Technology: Powder Bed

Selective Laser Sintering (SLS)

Powdered material is rolled out to make an even bed,

and a laser fuses together each subsequent layer.

Highlights This process uses thermoplastic, metal,

and ceramic, and produces strong, complex products

for the aerospace, healthcare, automotive, electronics,

and consumer product sectors.

Binder Jetting (BJ)

Layers of material powder are rolled out into an even

bed, and a binding agent traces and binds each

subsequent layer.

Highlights Fast process uses metal, ceramic and

plastic powders, and produces multicolor products for

Aerospace, automotive, education, and art.

In 2013 Nike

developed

the Vapor

Laser Talon,

the first

football cleat

to use 3D

printing

technology.

A featured

1200 dpi

CMYK full-

colored

sculpture.

Courtesy of 3Ders.org Courtesy of 3Ders.org


Technology: Extrusion

Fused Deposition Modeling

Filaments are heated, extruded, and each

layer solidifies and binds to subsequent layer

Industries Automotive, aerospace,

electronics, consumer products, healthcare,

education, architecture, construction,

recreational

Highlights This process is common,

simple, reliable, accurate, low cost, and

fitting for both industrial and home

environments. Materials include

thermoplastics, but the extrusion concept

lends to rubber, modeling clay, eutectic

metal, cement, etc.

Achievements May 2016 Dubai completed the worlds first functional 3D printed office building. It measures

2,690 sq. ft., took only 17 days to build, and cost only $140,000 for construction and labor; 50% cheaper than

traditional methods.

Courtesy of The Huffington Post


Technology: Lamination

Basic process Thin layered sheets of material are

traced with adhesive, glued together, and cut layer by

layer

Printer Manufacturers Mcor, Envisiontec, Impossible

Objects

Industries Office, education, architecture, fine arts,

recreational

Highlights This process creates a full color, safe and eco-

friendly product. Materials used are paper, metal foil, and

plastic film bound by adhesive. It’s limited by complex

geometries and size, but post-processing is not necessary.

Achievements In 2015 Mcor launched the world’s first

full-color desktop 3D printer; the Mcor ARKe. In

addition, it provides consumers with creative 3D

technology that is reliable and low cost.

Courtesy of Mcor

Courtesy of Mcor


Technology: Specialized

Bioprinting (patent issued 2006)

Assembles living cells in a pattern to create tissue like structures for

the healthcare and research fields. In 2015, the bioprinter manufacturer,

Organovo, announced that it had bioprinted kidney tissue that is now

used for drug testing and disease research.

Selective Silicon Etching (patent issued 2012)

Used for manufacturing micro- and nanoscale components in silicon for the electronics sector. A focused ion beam

implants ions in a pattern followed by silicon deposition.

Parabon Essemblix™ Drug Development

(patent issued 2012)

This 3D printed drug development process has the ability to create

compounds by rapidly and accurately placing each atom and molecule.

Zero Gravity (patent issued 2014)

In-space additive manufacturing 3D prints in zero gravity environment.

Courtesy of Popular Science

Courtesy of Space Angels Network

• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda


3D Printing

Printer Manufacturers

Printers

Materials

Software

Services


3DP: Printer Manufacturers

3D Systems, Stratasys, and Materialise are key 3D printer manufacturers in the world that cover all three areas

in the 3D printing market in printer capability, industry, and materials. 3D Systems was founded on SLA, and

Stratasys was founded on FDM, though both make printers that use SLA, FDM, and SLS technology; and

Materialise is based fairly equally on all three technologies. Even Hewlett-Packard, now HP Inc, has significantly

invested in manufacturing their own brand of 3D printers. Some 3D printer manufacturers, like Formlabs,

Ultimaker, XYZPrinting, and Airwolf 3D focus mainly on the non-industrial areas.



3DP: Printers

The Q3D One

Up is a

recreational

desktop 3D

printer that uses

FDM technology,

and costs $199.

The Form Labs

Form 2 is a

professional

desktop 3D

printer that uses

SLA technology,

and costs

$3,500.

The Stratasys

Fortus is a series

of industrial 3D

printers that uses

FDM technology,

and costs

upwards of

$250k.

The basic recreational desktop printer

prices range in the hundreds to

thousands of dollars; the

Professional/Design printer prices range

in the thousands to tens of thousands

of dollars; and the industrial printer prices

range in the hundreds of thousands of

dollars.

Courtesy of 3D Printing IndustryCourtesy of Form Labs

Courtesy of Stratasys


Global Market: Printers

Over 275,000 desktop 3D printers (worth under

$5,000) were sold worldwide in 2015. This is a 70%

increase from 2014, a 340% increase from 2013,

and a 915% increase from 2012.

1,000 5,00020,000 30,000

80,000

160,000

275,000

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

450,000

2009 2010 2011 2012 2013 2014 2015

Num

be

r S

old

(A

pp

roxim

ate

)

Number of Desktop Printers (< $5,000) Sold Worldwide

0

10

20

30

40

50

60

70

2011 2014 2015

Num

be

r S

old

(A

pp

roxim

ate

)

Number of Manufacturers that Sold Industrial Grade 3D Systems (> $5,000)

Over 60 manufacturers sold industrial grade 3D

printers in 2015; double the number from 2011.Source: Townsend Solutions



Global Market: 3D Printers

In 2015, over 275,000 desktop 3D printers were sold worldwide, and over 12,500 Industrial 3D printers were sold,

but 81% of the sales value was from industrial 3D printers.



3DP: Materials

The 3D Printing materials market consists mainly of plastics, metals, and ceramic. Plastic is the single most used

material in 3D printing, but the demand for metals has increased over the past several years.

Key Plastics

Photopolymers, ABS, polyamide, PMMA, PVC, HIPS,

PC, PP, PET, PVA, PLA, and others (powder, filament,

resin)

Key Metals

Titanium, Nickel, Stainless Steel, Aluminum, copper,

alloys, precious meals, Others (powder)

Other

Ceramic, gypsum, concrete, laywood, food, biomaterial,

composites, and various others

Courtesy of 3DPrint.com



Global Market: Materials

• The global market value for 3D Printed

materials was over $575 million in

2015

• Plastic materials held over $220

million of the share

• Metal materials held about $160

million of the share

• Ceramic and other various materials

held the rest of the share with $195



Global Market: Material Suppliers

Companies are investing heavily in the development of new 3DP materials. Key players include:

BASF, Solvay, LG Chem, SABIC, Evonik Industries, Eastman, Dutch Filaments, DuPont,

Lyondellbasell, and Nature Works LLC.


Global Market: Materials

• Plastic materials held almost

40% of the material market

value

• Of the plastics, photopolymer

accounts for 70% of that share

• Photopolymers are proprietary

liquid mixtures of oligomer,

monomer, and polymer base

with a photoinitiator



3DP: Software

Some 3D printer manufacturers provide their own

software that is brand or even printer specific, but for

general recreational and semi-professional printers

software can be found online, and some tools are free,

like Cura, Netfabb Basic, and Slic3r.

3D Printer ManufacturersSoftware/

Services

3D Systems CorpGeomagic/ CimatronE/ GibbsCAM/

On Demand

Stratasys Ltd.Objet/ Insight/ Polyjet/ CatalystEX/

GrabCAD/ On Demand

Materialise NV Materialise Brand software/ On Demand

MobileFusion is a developing Microsoft App that turns any

smartphone into a 3DP scanner.




3DP: Services

3D printing service-specific companies, like Proto

Labs, and Shapeways provide on demand 3D

printed parts and prototypes to small businesses,

entrepreneurs, and consumers. Other companies

like 3D HUBS and Amazon provide a community

platform for consumers that aligns designers,

manufacturers, and sellers.

UPS currently has 63 3D printing US locations, and

one in Singapore, where customers place orders

online with Fast Radius, formerly CloudDDM, and

can pick up their product within 4 to 24 hours.

Staples has even partnered with MakerBot to provide

in store services in select stores, and Staples, Best

Buy, and Home Depot offer 3D printers, materials, and

supplies.

Courtesy of UPS

Courtesy of Staples

• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda


Global Market: Industries

Approximate 3DP industry market

share:

• Aerospace & Defense

• Healthcare

• Consumer Goods

• Automotive

• Dental

• Recreational, Education, Art, and

Other

Aerospace & Defence

20%

Healthcare20%

Automotive

15%

Recreational, Education, Art, Other

10%Dental15%

Consumer Goods

20%

Key 3DP Industries



Applications: Aerospace and Defense

The main applications of 3DP in aerospace and defense focus on prototyping, the manufacture of complex

geometrical parts not possible with traditional manufacturing, niche low volume parts, and replacing parts for

weight reduction.

Boeing has used 3D printing for over a decade, and plans

to build 3D printed Modular satellites to save on costs.

General Electric Aviation has printed over 114,000

fuel nozzles for use in 6000 jet engines. They

were made out of metal using SLS technology.

Courtesy of EngadgetCourtesy of General Electric


Applications: Healthcare

The main applications of 3DP in healthcare focus on prototyping, prosthetics, custom orthodontic implants,

medical instruments, training, models to guide surgery and other potentially problematic or novel procedures,

pharmaceutical testing and production, tissue used in testing and transplants.

Cranio-Maxillofacial Implant.e-NABLE's printed hand prosthetic cost less than $50

to produce for volunteers with access to 3D printers.

Courtesy of Materialise Courtesy of Medical Daily


Applications: Dental

The main applications of 3DP in dentistry focus on prototyping, dentures, caps, bridges, custom implants, dental

instruments, training, teeth straightening products, and models.

Align Technology created Invisalign with 3D Systems in 1998 to straighten teeth with a polyurethane aligner

instead of metal braces. By 2012 the 3D printed Invisalign product had generated over $500 million in revenue

globally; last year global revenue reached over $958 million.

Courtesy of Align Technology


Applications: Consumer Goods

The main applications of 3DP in consumer goods focus on prototyping, jewelry, high performance sporting goods,

household & office goods, toys, electronics, apparel, décor, tools, and many other types of general retail goods.

Adidas designed a shoe with 3D printed soles

that can be customized to the wearer’s feet. Mattel uses 3D printing in their production

process to make Hot Wheels toy cars.

Courtesy of 3D Printing Industry Courtesy of 3DPrint.com


Applications: Automotive

The main applications of 3DP in the

automotive sector focus on prototyping,

engine components, design, aftermarket

customization, vehicle restoration,

consolidation of many components into

one complex part, production tooling,

spare parts and components, form and

fit testing, and the goal of chassis in the

future.

This 3D printed car was built part by part

by the US Department of Energy’s

Manufacturing Demonstration Facility.

Courtesy of All3DP

• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda


Benefits: 3DP vs Traditional Manufacturing

Volume Cost Per Unit Time to Market Cost of

Complexity

3D Printing Small batch,

Highly

Customized

High variable

costs,

No fixed costs

Very fast

(< 1 day)

No higher than

simple parts

Traditional Large batch,

Not customized

Low variable

costs,

high fixed costs

Very slow to

moderately

slow

Much higher

than simple

parts

3D Printing specializes in low volume,

highly customized batches, has no fixed costs, short

lead time, and there is no difference in cost between

simple and complex parts.

Traditional manufacturingis more beneficial with simple high volume parts,

has high fixed costs, longer lead times, and

complex parts cost more.



Benefits: 3DP vs Traditional ManufacturingC

os

t P

er

Un

it

Production Volume

Costs Per Unit vs Production VolumesThe figure shows

that with 3DP, a

low number of

goods can be

produced at an

inexpensive cost,

and that traditional

manufacturing

requires higher

volumes to reach

a lower cost per

unit.

3D

Printing

Traditional

Manufacturing



Benefits: Medium Scale

Medium scale

production benefits

bridge manufacturing is

the use of 3D printing in

the early stages of

product manufacturing in

order to make up for the

slow lead time, and to

cut the early costs of

traditional

manufacturing. Once the

breakeven point is

reached traditional

manufacturing then

becomes more

beneficial.


• Introduction

• Technology

• Process

• Applications

• Benefits

• Conclusions

Agenda


Trends & Drivers: Regional

NA

The US Department of Energy plans to invest $1M to 3D print wind-turbine blades

Europe

In 2016, Germany’s electrical engineering company, Siemens, invested $23.1M in 3DP by opening the first manufacturing facility

for the mass production of metal 3D printed components in Sweden

Japan

At the end of 2015, Toshiba announced a high quality industrial-grade laser metal deposition 3D printer that will manufacture

parts ten times as quickly as powder bed fusion 3D printers

China

Shanghai company Winsun currently uses one of the biggest 3D printers in the world to print furniture, houses, and even six-

story buildings using FDM technology. New China TV news clip on 3D printed buildings:

https://www.youtube.com/watch?v=WZ0Inu8YDfk

UAE

The Dubai 3D Printing Strategy initiative plans to focus on the medical, consumer products, and construction industries. A

specific construction focused goal is to have at least 25% of Dubai's buildings to be built using 3D printing technology by 2030.

Vice President and Prime Minister of the UAE and Ruler of Dubai, His Highness Sheikh Mohammed Bin Rashid Al Maktoum

stated, “We believe that this technology is capable of transforming the construction sector by lowering costs and reducing the

time it takes to implement projects.”

https://www.youtube.com/watch?v=WZ0Inu8YDfk


Trends & Drivers: Supply Chain Impact



Trends & Drivers: Supply Chain Scenario

Customer uses

smartphone 3D scanner

app to scan desired

product

An online database app

detects and matches product

(brand, model), and a

customization app allows the

customer to tailor the product to

their specifications (size, color,

pattern, materials)

A local 3DP facility

prints the product, and

the customer picks it

up on the way home

3DP Shopping in the Future


Conclusion

3DP is not a disruptive

technology only, it can be

an platform enabler,

assisting other business

models!


Idea/

Innovation

Refinement/


Sales/

Service/

Marketing

Artificial Intelligence to conceive

and improve products. Virtual

Reality to foster collaboration and

improve the user experience.

3DP to prototype, refine,

manufacture and personalize the

resulting products

Each technology is disruptive by

itself, combined, they can

optimize product performance

and improve speed to market,

reducing the overall costs of

research and development


Conclusion

3DP is not a disruptive

technology only, it can be

an platform enabler,

assisting other business

models!


Idea/

Innovation

Refinement/


Sales/

Service/

Marketing

Artificial Intelligence to conceive

and improve products. Virtual

Reality to foster collaboration and

improve the user experience.

3DP to prototype, refine,

manufacture and personalize the

resulting products

Each technology is disruptive by

itself, combined, they can

optimize product performance

and improve speed to market,

reducing the overall costs of

research and development

IDEA = EXECUTION

Thank youwww.gpca.org.ae

3D Printing - GPCA PLASTICON printing has come a long way from printing toy rabbits in the late...

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