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Dr Philip Reeves
Rapid Manufacturing Eco-innovation in the context of recession
TITLEInnov_ex09
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Dr Philip Reeves
Rapid Manufacturing Innovation in the outdoor
industries in the context of recession and the
environment
ALTERNATIVE & TRUTHFUL TITLEInnov_ex09
www.econolyst.co.uk
econolyst.co.uk
Dr Philip Reeves
Rapid Manufacturing Innovation & sustainability in the outdoor industries irrespective of recession
ALTERNATIVE & TRUTHFUL TITLEInnov_ex09
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
• Environment – how can RM contribute
• Innovation – how does RM enable
• Outdoor Industries – where does RM fit
• Outdoor Industries – where could RM fit
•Questions
Agenda
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
•Environment– how can it help
• Innovation – how does it support it
• Outdoor Industries – where does it fit
• Outdoor Industries – where could it fit
•Questions
Agenda
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Rapid Manufacturing is the manufacture of ‘end-use’ component
parts using Additive Layer Manufacturing processes
WHAT IS RAPID MANUFACTURING?AGREEING TERMS
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There are Four fundamental manufacturing principles:
• Subtractive
– Material is successively removed from a solid block until the desired shape is
reached (2.5M BC – Hominids)
• Fabricative
– Elements or physical material are combined and joined (6,000 BC – Western
Asia)
• Formative
– Mechanical forces and, or heat are applied to material to form it into the
desired shape such as bending, casting and molding (3,000 BC – Egyptians)
• Additive
– Material is manipulated so that successive pieces of it combine to make the
desired object (1985 – Californians)
How does ALM differ from traditional manufacturing
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ALM processes are automated
systems that take 2-dimensional
layers of computer data and rebuild
them into 3D solid objects
WHAT IS AN ALM PROCESSAGREEING TERMS
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ALM MATERIAL OPTIONSMATERIALS
Waxes
Polyamide (nylon)
Organic materials Polymeric materials Metallic materials Ceramic materials
ABS
Glass filed Polyamide
Composite loaded PA
Thermosetting epoxies
Ceramic (nano) loaded epoxies
PMMA
Polycarbonate
Polyphenylsulfone
Tool Steel
Aluminium
Titanium
Inconel
Cobalt Chrome
Copper
Stainless steel
Mullite
Alumina
Zirconia
Gold / platinum
Silicon Carbide
Hastelloy
Aluminium loaded polyamide
Beta-Tri calcium Phosphate
Silica (sand)
Plaster
Graphite
ULTEM
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Prototypes (Rapid Prototyping)
Casting Patterns (Rapid Casting)
Tool cavities (Rapid Tooling)
Direct Parts (Rapid Manufacturing)
ALM IS THE ENABLER – RM IS THE APPLICATIONAGREEING TERMS
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
•Environment– how can it help
• Innovation – how does it support it
• Outdoor Industries – where does it fit
• Outdoor Industries – where could it fit
•Questions
Agenda
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THE PRIMARY BUSINESS DRIVERS
RM reduced the need for tooling (moulds / jigs)
Risk mitigation
Enables the manufacture of low volume production (no fixed asset amortizations)
Simplifies the supply chain & reduces capital investment
Enables complicated assemblies to be built in one piece
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Enabling low volume complex part manufacture?CASE STUDIES
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
• Environment (sustainability) – how can RM
help
• Innovation – how does it support it
• Outdoor Industries – where does it fit
• Outdoor Industries – where could it fit
•Questions
Agenda
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Increased process & supply chain efficienciesLess raw material usage
Less waste production & recycling
Less energy used in processing
Less transportation in the supply chain
Lighter weight more efficient products
SUSTAINABILITY DRIVERS?
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A holistic approachSOLUTION
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TITANIUM ICE SCREWSSUSTAINABILITY
15,000 KWh per ton to extract160 KWh per ton to CNC machine8:1 – waste ratio
Don’t machine from solid – sinter from powder!
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
•Environment– how can it help
• Innovation – how does RM enable it
• Outdoor Industries – where does it fit
• Outdoor Industries – where could it fit
•Questions
Agenda
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THE PRIMARY BUSINESS BENEFITS OF RM
RM enables complex geometries manufacture
RM enabled added functionality
RM enables optimised geometries
RM enables personalised products
RM enables distributed manufacture
Enables true just-in-time
Lean & agile = Legile
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2 3 4
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(1) Images courtesy of Phonak www.phonak.com
Design freedoms & personalized part manufacture?CASE STUDIES
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OBSERVATION
“Most current successful RM applications and business models are people-centric
and driven by societal wants and needs ”
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
•Environment– how can it help
• Innovation – how does it support it
• Outdoor Industries – where does RM fit
• Outdoor Industries – where could it fit
•Questions
Agenda
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• Low volume
• High value
• Customised
• Personalised
• Niche
OUTDOORS
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PETZL TECHNICAL ICE AXEEXAMPLE
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ECONOMICS & SUSTAINABILITY
EXAMPLE PETZL TECHNICAL ICE AXE
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ERGONOMICS &PERSONALISATION
EXAMPLE PETZL TECHNICAL ICE AXE
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BURTON SNOWBOARD BINDINGEXAMPLE
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BURTON SNOWBOARD BINDINGEXAMPLE
ERGONOMICS,PERSONALISATION
& MARKET DIFFERENCIATION
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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE
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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE
ERGONOMICS,PERSONALISATION& PERFORMANCE
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PERSONAL PROTECTIVE EQUIPMENT (PPE)EXAMPLE
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(1) Images courtesy of Liverpool University www.liv.ac.uk
IMPACT ABSORBANCYEXAMPLE
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CUSTOM FOOTWAREEXAMPLE
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CUSTOM FOOTWAREEXAMPLE
ORTHOTICS& PERFORMANCE
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CUSTOM ORTHESISEXAMPLE
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CUSTOM ORTHESISEXAMPLE
PERFORMANCE, COMFORT& INCLUSIVITY
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• Rapid Manufacturing – what is it
• Recession – what are the business
driver
•Environment– how can it help
• Innovation – how does it support it
• Outdoor Industries – where does it fit
• Outdoor Industries – where could RM fit
•Questions
Agenda
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Agenda OPPORTUNITIES
+ =
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Agenda OPPORTUNITIES
+ =
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Agenda OPPORTUNITIES
+ =
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• Many successful applications of RM exist today• The best applications are people centric• Supporting consumers wants and needs• High value, low volume, Niche• Customize & Personalise • Product differentiation & competitive advantage• Sustainability & resource efficiency• Not so many current applications in the Outdoor Industries• I am sure the opportunities exist – talk to me if you have
ideas!
SUMMARY
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QUESTIONS, OBSERVATIONS, DISCUSSIONEND
Dr Philip ReevesEconolyst Ltd
The SilversmithsCrown YardWirksworth
Derbyshire, UKDE4 4ET
+44 (0) 1629 [email protected]
www.econolyst.co.uk
www.rm-masterclass.com
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