3H15-012-20 AM Engagement Strategy V1,0

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Additive Manufacturing Engagement Strategy

John E. SteckBUSINESS AND REVENUE DEVELOPMENT SERVICES+ Product Design, Engineering, Manufacturing, QA/QC

+ Next Generation Strategy & Road Mapping

+ Structured Problem Solving & Lean Optimization

+ Systems Integration Engineering

+ Applied Research and Development

+ Additive Manufacturing Technologies

Lancaster PA - www.JohnSteck.com - (717) 417-8325

”Quality is Never an Accident”

Presentation and Content Copyleft (c)2015 Tetrahelix Inc. Slide No. 11 July 2015

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Additive Manufacturing Scope

Additive manufacturing is a catch-all phrase that encompasses many digitally driven on-demand

production processes across a wide variety of materials and applications.

Materials and Applications:

A) Plastic fabrications; parts, fixtures, assemblies

B) Metal fabrications; parts, tooling

C) 3D integrated circuitry; payloads, interconnects, antennas

D) Conductive material deposition; ink, plasma, polymer

E) Consumables; packaging, one-time-use, proofs

Correct Business Unit engagement requires clear understanding and definition of business goals and

how various additive manufacturing technologies may be leveraged to achieve them.


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Additive Manufacturing Utilization Plan

A key element of successful Business Unit engagement is to have a clear definition of intended

utilization and to properly set expectations accordingly with respect to cycle time, costs, and

performance.

Fundamental Areas of Business Focus:

A) Pre-Sale Customer Engagement

B) Concept and Product Development

C) Manufacturing and Production Support

D) Disposables and Packaging

E) Production On-Demand

Each area of business focus has different objectives, different Return On Investment, different resource

requirements, and dissimilar considerations with respect to design, process, material, and product

performance. Correct Business Unit engagement requires clear definition of intended utilization.


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Additive Manufacturing Design Strategy

Intended utilization drives material and process selection, which ultimately drives design strategy.

Design for manufacturability with additive manufacturing must be individually focused on each

processing technology and material selection.

There are critical business considerations behind each area of design strategy that are typically keyed

to Operation Income goals. It should be understood that there will be a notable performance

equivalence delta without product tailoring to AM and there are no known Finite Element Analysis

tools available to evaluate Additive Manufacturing designs at this time. Correct Business Unit

engagement requires clear definition of design strategy and a fundamental understanding of a given

additive process.

Fundamental Areas of Design Strategy:

A) Unaltered replacement of existing production design

B) Hybrid design of existing design optimized for AM

C) Additive manufacturing only design


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Additive Manufacturing Material Selection

Correct material selection requires clear definition of mechanical, thermal, electrical, and chemical

requirements. Material and process are typically conjoined with additive manufacturing as they

typically exist as a purpose built system.

Performance requirements are the primary driving factor for additive material and process selection.

Each Business Unit will have very specific and historically defined driving requirements for their

product lines. Correct engagement will requires those needs individually taken into consideration and

addressed with material and additive process matching.

Considerations of Mechanical:

A) Structural loading

B) Wear

C) Cosmetics

Considerations of Thermal:

A) Working environment

B) Reflow soldering

C) Flammability

Considerations of Electrical:

A) Dielectric constant

B) Conductivity

C) Signal resonance

Considerations of Chemical:

A) Environmental stability

B) Plating and secondary processing

C) Polymer degradation


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Additive Manufacturing Process Selection

Material and process are typically conjoined with additive manufacturing as they typically exist as a

purpose built system. New additive manufacturing processes are being developed all the time.

It should be clearly understood that there exist distinct trade-offs with respect to each technology with

regard to cost, speed, and material compatibility. In most cases, these technologies are not

interchangeable or direct replacements for traditional manufacturing because of product performance

requirements. Correct Business Unit engagement requires clear definition of design strategy and a

fundamental understanding a given additive process.

Current Additive Manufacturing Technologies:

A) Liquid based thermoset photopolymer

B) Powder based laser sintered metal and plastic

C) Extrusion based thermoplastic polymers

D) Laser structuring

E) Conductive materials deposition

F) Chemical and electrical metal deposition


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Additive Manufacturing Engagement Plan

Key Elements:

A) Understanding of Business Unit business goals and needs

B) Matching intended use and setting expectations

C) Determining critical product performance requirements

D) Accurately matching material and process to needs

E) Expertly navigating design considerations and trade-offs

F) Developing a resource plan to implement strategy

G) Meeting defined Business Unit financial objectives


D efine - I dentify - D esign - O ptimize - V erify

3H15-012-20 AM Engagement Strategy V1,0

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