Eric Wooldridge, PE, RASomerset Community College

AMEFA, NSF ATE: 1600081USDA Rural Development

CONNECTING THE MONEY DOTS

THE BIG QUESTIONSWHAT IS KENTUCKY’S LARGEST

EXPORT INDUSTRY?

WHAT IS THE DIFFERENCE BETWEEN A MANUFACTURER

AND AN ASSEMBLER?

THE FACTSKY CED, 2016 exports:

$29.2BAerospace = $10.9B

Automotive = $5.5B

How does AM work?

What is at stake?1. Jobs

2. Production contracts3. New manufacturing plant locations

4. Innovative business startups

Why does AM matter?

Enterprise Level Companies (ELC):

Additive Manufacturing = $$$?

For an ELC, it starts with a simple research question.

Is there an advantage (cost or end product)

of additive over conventional?

Courtesy of GE at SME Design for Additive Manufacturing Conference, April 2017

Courtesy of GE at SME Design for Additive Manufacturing Conference, April 2017

Courtesy of GE at SME Design for Additive Manufacturing Conference, April 2017

Courtesy of GE at SME Design for Additive Manufacturing Conference, April 2017

OLD CONVENTIONAL APPROACH

MULTI PART-ASSEMBLY

NEW ADDITIVE APPROACH

SINGLE PART

MORE EXTERNALLY & INTERNALLY COMPLEX = BETTER PERFORMANCE

Courtesy of Caterpillar at SME Design for Additive Manufacturing Conference, April 2017

SO, ELC’S ARE SEEING $$$ in AM.

BUT WHAT IS THEIR RESPONSE?

GE: Spent nearly $2B investment in metal printing, new Blackhawk engine has 161% increase in range

Project A.T.L.A.S., large format, fast AM

AirBus: Buy-to-fly ratio has flipped, so print as

much as possible

Brexit: UK 7 year strategy focus on AM, become the global leader, potential for 175,000 new jobs & generate $600 Billion

Airbus installs first visible 3D printed part in passenger cabin

Now in the A320, a new printed spacer panel in full view of passengers

Honeywell approves Sintavia to provide AM aerospace components

After rigorous qualification process, Sintavia finances new $15M AM facility in FL

Parts for Honeywell airline, general aviation, spacecraft, and defense apps.

BMW’S NEW i8 ROADSTER

BMW to open new $12M AM CampusBMW’s existing Munich center already produces 100,000 AM parts annually

New facility will be a major milestone.

Providing a process chain for individual components, small run, and large-scale manufacturing

GM turning to AM to fabricate lightweight parts for new cars

Producing tens of thousands of lightweight parts for mass production

40% lighter 20% stronger 8 to 1

Starting integration with high-end motorsport vehicles next year

HP: Producing metal 3D Printers in 2019, change the entire market

Swiss Oerlikon : $55M 3D Printing plant in Charlotte

Makes a 5 year deal with Boeing

To define the path in producing airworthy AM components for mass production

CARBON and ADIDAS make a $200M deal

Honeycomb geometries, previously impossible to make via injection-molding, are perfect for shock absorption and durability

Millions of insoles in 2018

Sweden’s Sandvik invests $25M to build new plant to make metal powders for AM

Alcoa invests $60M to build new plant to make metal powders for AM in Pittsburgh in 2015

Volkswagen: we use 90 metal 3D Printers for exclusive car series and replacement parts. Plant saved $177k the first year, nearly $390k the second.

Volvo 3D prints spare parts for construction equipment

Announced it will be using AM to create aftermarket parts for customers

“Producing new parts by 3D printing cuts down time and costs, so it’s an efficient way of helping customers”

Bugatti Reveals World’s First AM Titanium Brake Caliper

Bugatti already employs the most power brakes in the world on the new Chiron, made from aluminum

The new Titanium version would be 3 to 4x stronger and decrease the weight by 40%

THE US HEARING AID INDUSTRY

The industry converted to 100% additive manufacturing production in less than 500 days

No company that stayed with conventional manufacturing processes has survived.

Harvard Business Review:

NAVY AWARDS GE $9M TO SPEED UPDEVELOPMENT OF AM PARTS & DIGITAL TWINS

Accelerate production of AM replacement parts and digital inventories

Digital twins can also be updated in real time with new data & engineering knowledge

NAVY WILL RELY ON 1,000 3D PRINTED PARTS BY END OF 2018

Mission critical parts, such as valves for flight masks

Goal is not to 3D print all flight critical components, but those that can be improved by the process.

THE AIRFORCE, $2.9M RECHARGE PROGRAM

Will fund Ohio based company to 3D print molds for legacy aircraft parts

What would have been a $50k cost and one year lead time, can be a fraction of that and one week

Orbital AK successfully tests partially 3D printed warhead for hypersonic weapons

Makes complicated hypersonic geometries, cuts down on waste

New warhead can survive high speeds and high temperatures.

Primarily built using AM, drastically cut down production time. Concept to test in 60 days.

NASA & Aerojet RocketdyneCompleted final testing of AM parts

“This test demonstrates the viability of using additive manufacturing to produce even the most complex components in one of the world’s most reliable rocket engines,” said Eileen Drake, CEO and president of Aerojet Rocketdyne. “We expect this technology to dramatically lower the cost of access to space.”

Skyrora: Scotland joins space race with 3D printed suborbital launch vehicle

South African defense company using 3D printing to build surveillance & attack aircraft

“All Ahrlac parts are manufactured at the new Wonderboom production facility, with very little

outsourcing to other suppliers”

“Without being burdened by a lagging supply chain”

New facility is designed to produce 2 aircraft each month

THE SHIPBUILDING INDUSTRYFirst 3D printed propeller

(WAAMpeller) produced and tested

WATCH THE AM AQUISTIONS

AM AQUISITIONS

Ford Motor Company leads additional $65M to Desktop Metal in fund raising

(total of $277M to date)

German automation company Seimensopening a $38M 3D printing facility in Worcester, England

$17M to Metalysis, make metal AM powders less expensive

Cheshire 3D Printing Hub, over $8Mfacility, 40,000 sf being built to expand

the practical use of the technology

NAVY awards $6.4M to CTC to bring up metal AM to production readiness

Mark Cuban invests $10M (Series B of $35M) in Relativity Space, 3D print its rocket engines

AM AQUISITIONS

Carpenter Tech Corp: $35M acquisition of Puris, for titanium powder market entry

Coherent acquires Lumera Laser (flexible laser AM system) for $52M

Warren Buffett’s largest acquisition ever, $37.2B for Precision Castparts ($1.5B aerospace market position) and Atlantic Precision (metal AM technology)

AM AQUISITIONS

NUMBERS

-75% of aircraft will use 3D printed parts

-20% of the world’s top 100 consumer goods companies will use 3D printing to create custom products

By 2021:

INTERNATIONAL DATA CORPORATION

FORECASTS GLOBAL AM SPENDING TO INCREASE 20% IN

2018 TO $12 BILLION

FYI: FORECASTS FOUR YEARS AGO WERE $4 BILLION BY 2020

PRINT FARM: A GAME CHANGING MANUFACTURING ADVANTAGE

Prusa using up to 500 low cost 3D printers (FDM)

System runs 24/7 & managed by only 15 employees

Why not injection molding?

– Because AM has a huge advantage

Allows for constant upgrading

Make much more complex parts than injection molding

Workflow is always simpler

Allows for the ultimate satisfied customer oriented business model

STANLEY BLACK & DECKER: Cut lead times by 98%, cut costs by 92%

Printed in metal

3 parts to 1

After thousands of test cycles, printed part just as good & 53% lighter

Parts for a high stress, post driving system

STANLEY BLACK & DECKER:2nd Evaluation, Profile Grinder

Cut lead times by 48%

Printed version 20% lighter

25 times cheaper

Previously a machined part with 90% stock waste

Goal is for volume production switch to AM, capital investment is minimum

NUMBERS

CONFORMAL COOLING: THE MARRIAGE OF CONVENTIONAL & 3D PRINTING

“Industry game changer”

Significantly reduced cycle time, unlimited design flexibility, control over cooling cycle, decreased cavitation

55% reduction

THE POINTS

AM adoption is a copycat exponential model, with small

entry barriers and comparatively small lead times

-It is not about just prototyping

-It’s about end use production

-Constant Beta, constant updating to products

-Complexity and designs previously impossible

-The speed that the transition is occurring and its impact on Kentucky manufacturing

Remember

How to prepare?-Low cost AM integration

-Partner with us, use our resources

-Research, learn what your tiers are doing

-Seek out training

Our Partners

GE’s statement to the World:

“You are either going to be a leader in this technology or a victim.”

Joshua MookEngineering LeaderGE Additive

QUESTIONS & PLAUSIBLE ANSWERS

eric.wooldridge@kctcs.eduFacebook: CADD.LAB

606.451.6878

Google search: SCC 3d printing (14 days)

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