How to Utilize Additive Fabrication Machines for Direct Digital Manufacturing, 3D Printing and Rapid Prototyping.

1. How 3D Printers and Rapid Prototyping
Systems are Changing the Future of Product
Development and Manufacturing
MANUFACTURING THE FUTURE
Stratasys, Inc.
www.Stratasys.com/Future

2. Additive Manufacturing
Objectives
 Clear understanding of additive manufacturing market
Content
 Terminology
 Types of additive manufacturing approaches
 Application areas and benefits
Importance
 Foundation for identifying opportunities

3. Additive Manufacturing
Known by many names:
 3D Printing
 Rapid Prototyping
 Rapid Tooling
 Rapid Technologies
 Rapid Manufacturing
 Additive Fabrication
 Advanced Manufacturing
 Additive Layer Manufacturing
 Direct Digital Manufacturing
 Direct Manufacturing

4. Terminology
Additive Manufacturing
 Preferred term covering all 3D printing technologies/ applications
 Preferred replacement for rapid prototyping
Definition:
 Collection of technologies, directly driven by CAD data, to
produce 3-Dimensional physical models and parts through an
additive process.

5. Primary Applications for
Additive Manufacturing
Established / Traditional
(Design)
Direct Digital Manufacturing
(Manufacturing)
Additive Manufacturing
Conceptual
Modeling
End-Use
Parts

6. Technology Assessment
End-Use
Parts
3D Printers 3D Production
Systems
Performance Requirements Increase

7. Conceptual Models &
Functional Prototypes
Primary Benefits
• Reduce time to market
 Solidify design earlier
 Reduce late design changes
• Lower product development cost
 Make design changes earlier in process
 Make mistakes early and often
Secondary Benefits
• Facilitate communication between teams and
vendors
• Improve product design

8. Jay Leno’s Garage:
Concept Models
1907 White Steam Car
 D-Valve replacement needed
 Not available at local automotive center
Utilized multiple technologies
 3D Scanning
 Materialise - software
 3D Printing
From broken to fixed part - quickly
1. 3D scan broken D-Valve
2. Concept model produced
3. Validated design

9. Concept Models at Ducati
Design of Desmosedici Engine
 Saved over $1.5M in outsourcing costs
 Concept to final engine design in 8 months
vs. 28 months (71% time savings)
 Eliminated 83 design problems
Major piston design change
 Started with twin oval piston
 Final design a four round side-by-side
“To keep Ducati at the forefront of
engine design, we sought a
technology that could make
accurate, durable prototypes
quickly.”
Piero Giusti, Ducati

10. Functional Prototyping at Toro
Commercial & Residential Sprinklers
Prototyped in few hours for testing
 Validated form, fit and function
 Pressure testing at +100 psi
Working prototype made for each
new design
Over a 2 year period & many projects
 Reduced product development by 283 weeks
 Reduced tooling costs by $500,000

11. Functional Prototypes at
Logitech
Bluetooth Headset
• Headset failure
 Many iterations of functional prototypes
 Gave to focus groups for evaluation
• Found new, counterintuitive design fix
 273% stronger
• Faster response, lower cost
 More functional prototypes
 Better products, satisfied customers

12. Direct Digital Manufacturing
Applications
Primary benefits
 Lowering costs
 Increasing profits
 Decreasing time-to-market
 Decreasing cycle time
• Secondary advantages
 Design freedom
 Product redesign frequency
 Rapid response

13. Direct Digital Manufacturing
Applications
Best fit when:
• Relative low volumes
 Short run production and bridge to tooling
• High part complexity
 Eliminate expensive tooling
 Reduce long lead times
• Part acceptable
 Aesthetics not critical
 Finishing processes feasible
 Physical properties acceptable

14. Manufacturing Tools
Examples:
 Jigs
 Fixtures
 Check gauges
 Drill / rivet guides
 Go / no-go gauges
 Alignment tools & guides
 Tooling masters & patterns

15. Manufacturing Tools at BMW
Emblem Headlight Alignment
Cubing Device Gage Checker
Bumper Reach

16. Jigs & Fixtures at BMW
Manufacturing Jigs and Fixtures with FDM
• Automobile assembly & testing tools
 Over 400 jigs & fixtures / vehicle
 Many produced on Fortus system
• Benefits to workers and processes:
 Improved productivity
 Design optimized for worker comfort
 Increased process ease-of-use
 Greater process repeatability
AUTOMOTIVE

17. Manufacturing Tools at
Oreck
Repeatable & accurate assembly
• Custom vacuum assembly pallets
• Requirements
 40 – 50 / model
 5 – 10 models in production
• Benefits
 65% reduction in fixture costs
 $100,000 / fixture savings (up to)
 58% reduction in manufacturing defects
 Replacement fixtures in hours vs. weeks
 Nearly eliminated worker fatigue & injuries

18. End-Use Parts
• Primary Benefits
 Lower cost
 Shorter lead time
• Secondary
 Design freedom
• Few design for manufacturing constraints
 Change freedom
 Mass customization
 Supports lean initiatives
 True JIT (just-in-time) manufacturing
 Reduced warehouse space/inventory cost

19. End Use Parts at DST
Control
• Gimbal eye or camera
 For unmanned aerial and ground vehicles
 Stable images from unstable carriers
• Fortus machine produces 20 different parts
 Meet accuracy and quality standards
 Reduce delivery time for custom products
• FDM parts perform better
 Lower weight
 Better electrical insulation
• Time and cost savings
 Part cost reduced 66%
 Custom part production time reduced 63%
FDM reduces cost 66% & time 77%
Method Cost Time
Traditional
Manufacturing
€2,44
1
11
weeks
Direct Digital
Manufacturing
€830 4 weeks
Savings €1,61
1
(66%)
7 weeks
(63%)

20. • Custom bezels manufactured
 Accept only one vial size
 Easy customization
• Saving $25,000 on
 Engineering time
 Tooling / bezel
• Design flexibility
 New product design without tooling
 Able to support new vile sizes
 Unique competitive edge
Automated Pill Dispensing System
End Use Parts at
ScriptPro
Method Cost Time
Traditional $31,650 60
Days
Fortus $ 6,750 2
Days
Savings $24,900
(78%)
58
Days
(97%)

21. Summary
• Terminology
 AF
 DDM
 3D Printer
 3D Production system
• Business segments
 On Demand
 3D Printers
 3D Production Systems
• Applications
 Product design
• Concept models
• Functional prototype
 Manufacturing
• Manufacturing tools
• End-use parts

22. More Information
Test it, Prove it.
 Send 3D cad file and have Stratasys build it for you
 Application Engineer consultation
www.Stratasys.com/Future
 Download Application Guides and White Papers
 Fill out form to get benchmark built
 Get FDM sample part
 Request Consultation