3D-iExtrusion makes 3D production affordable & scaleable
Post on 14-Apr-2017
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Mark J Kragh
CEO Arsizio AB
+46-761042143
mark.jkragh@Arsizio.se
www.Arsizio.com
3D-iExtrusion®- a new, affordable, 3D serial production method :
3D-imprintExtrusion™
- Enabling 3D-intelligentExtrusion ™ solutions
Company & Technology Presentation
3D-iExtrusion:
3D-imprintExtrusion®-Next generation manufacturing
method
Arsizio license 3D-iExtrusion®, a globally patented production method that is used
by paying customers and enables:
→ 10-40% Savings of material, weight & energy
→ 10-20% Higher efficiency in heat-transfer & solar-energy.
→ 20-80% Lower production costs
→ Elimination of machining and investments
3D-extrusion is 100% compatible with all productionlines & materials
in the 75 billion Euro extrusion industry & can replace other production methods.
-Aluminium, magnesium, plastic, rubber, TPE, TPV, composites & ceramics.
That makes production with 3D-extrusion both scalable & cost efficient.
Mark J Kragh
CEO Arsizio AB
+46-761042143
mark.jkragh@Arsizio.se
www.Arsizio.com
2D-extrusion + machining (practice since 1797)
2Euro + 0,8 Euro + 0,15 Euro + 5 Euro + 0,2Euro = 8,15 Euro
2Euro + 1 Euro = 3 Euro : 60% saving
Reduction of process/maching cost : +80%
Comparison: 3D-iExtrusion® & 2D-extrusion + machining
3D-iExtrusion®
- Granted patents from USA in the West to Japan & S. Korea in
the East, Arsizio have a “grip” on the 75 Billion Euro Extrusion
Industry AND the + 70 Billion Euro Replacement Industry.
- All patents are method/principle based ( method & device )
Strong IP-position to back up business model :
Licensing & possibility for licensee to achieve higher margins
and possibility to exclusivity on market
3D-iExtruded profiles with exclusive satin finnish
-Directly out of the extrusion line
Design
Battery cooling
Anti-slipWeight saving
Product solutions
Ratio & aerodynamic
Solar Power &
energy
applications
Examples of customer segments & 3D-intelligentExtrusion™ applications
Energy efficiency
Higher efficiency
inSolar Power &
energy applications
3D-iExtrusion® enables:
10-40% Savings of Weight & Material
10-80% Savings of cost
Cost effective, efficient battery cooling
3D-iExtrusion® enable:
80% savings
Cost savings for THULE (XX million units delivered)
• 90% lower investments
• 80% lower production cost
• 50% lower total production cost incl. mtrl.
• 100% elimination of materialwaste
EV (battery-cooling), PV (Solar Energy Hybrid), Peltier (Waste heat regeneration)
Dynamically 3D-extruded profile with integrated 2mm deep & 2mm wide X-wise cooling channels
for applications with demands on cost efficient heat management and even temperature over
whole surface of component.
3D-extrusion in Energy generation & Storage Applications
Machining of cooling channels eliminated with 3D-extrusion = 90% costsaving
Alternative machining-cost in specialised fully automated dedicated line for
+100km profiles/year: over 30Euro/m. +investments.
(Profile developed for a PV-Hybrid solar panel)
3D-iExtrusion® enable: Rationalisation in energy applications
Osaka City University
Cluster gives Arsizio capabilities to deliver:•Profiles and/or Production
•Tools & Engineering
•Applictaion know-how
Virtual organisation –low cost & high capacity
Examples of function/feature – customer value generated with 3D-iExtrusion®
3D-intelligentExtrusion™ solutions enable higher performance & savings.
Different segments, applications and customer demands intersect.
1. Rationalisation (product / production optimization) 2. Weight/material savings 3. Design & Branding 4. Cooling/heat exchanging 5. New functions & integrations 6. Slip protection/security
1. VehiclesCar, truck, rail, air,
marine. Driving forces:
strong need to reduce
weight for increased
energy efficiency and a
need for rational
production. Desirable:
Improved LCA Major
demands and volumes.
2. Energy &
EnvironmentEnergy production/
storage, heating,
cooling. Driving forces:
Environmental, Cost,
Energy and Raw
materials prices. Need
for higher efficiency and
lower costs.
3. Construction Driving forces:
Operating costs,
construction costs,
Energy and Raw
materials prices.
4.
Design/consumer
products & decorDriving forces: costs,
greater opportunity,
need for brand identity,
new integrated
functionality, quality
impression
1.1 THULE Patterned integrated profile for reduced
sound levels & air resistance in the quietest and safest roof rack. Half the component cost compared to
injection molding.
1.6 Improved anti slip in/on
vehicles: boats, busses,
trains, cars, trucks.On: floors, ramps, sidesteps,
handles, steps etc.
2.41 PV: improved cooling of the solar
cells and increased electricity + heat
exchange in hybrid solar collector. Increased component lifetime.
2.3 Possibility to design products
for optimal performance and
lowest energy consumption during production and use. Ex. wise
apparatus housings with
integrated logo and efficient
cooling pattern in the casing,
which breaks laminar thermal
layering., or THULE's wingbar with extremely low air resistance
combined with record low noise,
2.2 Reduced materiause in Solar
panels : ca 0,6kg alu/m2.2.1 3D extruded profiles with optimal cooling channels
eliminated processing 30Euro/meter and increases
energy & efficiency 10-15% acc. customer.
3.1 . Rack of gear rod engines, eliminating material
waste and machining. Less than half the total
component cost, including materials also eliminated investment in processing equipment
3.21 Kåbe mat - 11% less material
consumption thanks to toothing
3.31 Patterned profiles and
profiles for window facade
furnishings, shelving systems etc
3.41 Optimized heat exchangers, heat
pumps, and radiators
3.51 Earthquake Protection with
integrated anti slip and logotype. (ref
Nippon Aluminum)
3.6 100% better slip resistance and
13.4% better scraping off (ref. Kåbe mat & SP Instituite)
1.3 3D-extruded sidesteps &
other components for exterior &
interior. Possibility to integrate logotypes & pattern in structural
4.11 Furniture, moldings, picture frames, floors, 4.2 3D extruded profiles with
weightsaving pattern. No material spills
(unlike injection molding / machining).
Examples of function/feature - customer value generated with dynamic 3D extrusion of aluminum, rubber, plastic, TPE, TPV, composites (eg either in production, or made prototype / calculation / study)Product/Application/Market
4.3 Mainsheet track with integrated
logo and slipping protection.
4.4 Electronics, amplifiers, TV etc
Improved design and heat dissipation.
Tactile feel, patterned surface etc.
1.5 Aerodynamic, sound dampening,
anti-slpi, text instrictions etc. Possibility
to integrate functions in a ttotally new way thanks to low cost and totally new
technological design possibilities.
Ex. THULE wind diffuser that
reduce wind drag and sound level at the
same time as it acts anti-slip for the load.
1,4 Battery cooling structure in EV s
& hybrids, heatsinks. Heat-
exchangers for fluids & gases. Low weight and good price/performance .
Combination of thermal & structural
optimization in batterypacks.
1,42 AVL, BSST, Scania mfl. Waste heat recovery/Peltier Termoelektrisk generator.
2.42 Heat exchangers and coolers
for electronics and heat recovery.
Increased power waste heat recovery (Peltier applications).
2.61 Improved anti-slip
means better / safer living
environment and working environment not just for humans
even animals such as livestock
affected.
Less need for the use of skid
protection products eg salt and
sand improves the environment and saves money and resources.
An integrated anti-skid weighs less
and makes vehicles lighter, safer
and more fuel efficient, good for
environment and wallet.
1.2 Topology optimized "structural
profiles". Saves 5 -40 % weight/material and optimize crash properties & safety .
2.43 Heat Sinks and heat exchangers
to a new design freedom = extremely
high efficiency and low cost thanks to manufacturing in existing extrusion
lines and eliminated the processing
needs (see examples 2.1 and 3.41).
2.51: Reduced heating and cooling
costs of buildings, with the help of
optimization opportunities.Also reduce construction cost through
saved material.
4.5 Decorative patterns and features of
interaction; locking functions, snap
modes, sound damping, traceability requirements. Increased heat dissipation,
tactile feel etc.
4.6 Better slip resistance & design
provides safer boat + positive build
identity & association for the brand.
Technical description & background
– 3D (Dynamic) Extrusion
- The 3D-extrusion technique was invented by Mark Jansson Kragh inspired when on his way to a climbing site. On
his way through the forest he noted tracks in the mud, made by forest machines. The almost perfect reliefs, printed
by the tyres of the machines, made him realise that most of the repetitive machining could be eliminated… A
couple of years later a first successful test was performed and 3D-extrusion was born.
- The concept is a further development of conventional extrusion technique. By the usage of integrated rotating
die(s)1 in the pressurized zone of the extrusion tool, an indent or "footprint“ is created on the extruded profile. The
technology thereby allows the creation of shapes and variations of thickness, that were impossible to previously
achieve. The shape is formed in a defined step under high pressure (and temperature) in a contained part of the
tool where static and rotating parts of the extrusion tool interact and pressurize the material, with surfaces that
define the cross-section and variation of the profile as well as the “patterns”, resulting in possibilities of eliminating
machining or replacing other expensive processes. The precision is higher than on ordinary profiles The genius
thing about the technology is that any material possible to extrude with conventional extrusion technique, such as
plastic, rubber, composites, aluminum etc., can be 3D-extruded. The technology is compatible with any existing
extrusion line. The only “add-on” is the specially developed tool with rotating dies (1).
- Arsizio has granted patents (from US in the west to Japan in the east) that cover 3D-extrusion of any plastically
deformable material, such as rubber, plastic, TPE, composites, metals, and combinations of different materials etc.
- See Movie: 3D-extrusion of rubber, plastic & TPE: http://www.youtube.com/watch?v=8v4wDUzMovs
1
3D-extrusion history:
3D-iExtrusion® die s/3D-iDies™
fit ordinary die holders:
No need for modification of die-
holders or extrusionline. No
investments are necessary and
existing industrial infrastructure
can be used.
Mounting of 3D-iDie™ for production of hollow aluminium 3D-intelligentExtrusion™
with pattern on two sides in standard die holder for 9-inch extruson line.
( Profilgruppen AB Sweden extrusionline: Press MAX, Åseda factory).
3D-imprintExtrusion™ dies are 100% compatible with existing extrusionlines:
This enable quick production ramp up of “machined” products in existing factories
without need of investments in machining equipment.
See Movie of installation of 3D-iDie™ and start of
3D-imprintExtrusion™ of 3D-intelligentExtrusion
rubber product for KåbeMattan:
http://www.youtube.com/watch?v=8v4wDUzMovs
3D-imprintExtrusion™100% compatible with all extrusion lines & materials
Also for rubber, plastics& composites
3D-imprintExtrusion is 100% compatible in all extrudable materials.
In Business:
Reference – Kåbe-Mattan | Original – Tandad (toothed)
Note:
The business with Kåbe (via production
partner Trelleborg), generating an income to
Arsizio in the form of licensing and royalty
revenues. According to projections made by
Kåbe, the volumes is increasing and the
product gets lots of attention.
See movie about the mat:
http://www.kabe-mattan.se/default.asp?ID=FILMER&sLang=en-gb
Text & texture on both sides & rip-off attenuation
AND ”hole” straight through profile.
Insertion of 3D-iExtruded profiles, means that You always have
access to the desired length with one article no.
Boat-ladder:
Anti-slip
&
Branding
Antislip, materialsaving, teethes, touch recognition
And rationalisation –in one step.
Visual and tactile recognition
Braille
Make your product recogniceable by touch
If instructions are integrated in product, avoid misstakes &
risks for getting sued.
2D-extrusion + machining (practice since 1797)
2Euro + 0,8 Euro + 0,15 Euro + 5 Euro + 0,2Euro = 8,15 Euro
2Euro + 1 Euro = 3 Euro : 60% saving
Reduction of process/maching cost : +80%
Comparison: 3D-iExtrusion® & 2D-extrusion + machining
3D-iExtrusion®
75 BEUR*extrusion global market
- segments and applications
AutomotiveAviation technology
Energy & Power
Building & Construction
Consumer products
Weight & material saving
X X X X X
Cooling X X X
Design & Branding
X X X
Ratio & Aerodynamics
X X X
Energy efficiency X X X X X
*Aggregated extrusion supply value for aluminium, magnesium, plastic, rubber, TPE, TPV & composites
+75 BEUR replacement** global market
- segments and applications
Replacing/eliminating
Automotive & transportation
Aviation technology
Energy & Power
Building & Construction
Consumer products
Injection molding X X X X X
Casting X X X
Machining X X X X X
Carbon fiber
CFRPX X X
Surface treatment X X X X X
**Aggregated global supply value injection molding, casting and machining of; aluminum, magnesium, plastic,
rubber, TPE, ceramics and composites
Comparision production methods for serial production
Productionmethod
Productivity Cost Infrastructure FinnishDesignfreedom
Environ
ment
Energy & Material efficiency
3D-imprint extrusion ++ ++ ++ ++ + ++ ++
Casting / moulding + + + + + + +
Machining - - + ++ ++ 0 0
Forging 0 0 + + + + +
3D-printing - - - - - - 0 ++ - -
(++)=very good (+)=good (0)=median/equal (-)=not good/quite expensive (- -)=poor/expensive
Max Size of 3D-iExtrusion depend on:1. Shape & area SA Flat Hollow Rect. Solid Rect.
2. Billet diameter (Inch or mm) BD f.ex 6inch 152mm 8inch 203mm
3. Die diameter of 3D-extr die/tool DD die diam.: std 200-220 special: 280-300
4. Type of 3D-pattern & depth in rel to WT 3D Higher % 3D/T & in mm increase difficulty
5. No of sides with 3D-pattern 1-sided 2-sided
6. Width of 3D-pattern (% of area & mm) 3W 50% 100%
Sizes of 3D-extruded profiles in 6-inch extrusion line Std. 3D-extr.die Special 3D-extr.die
Special dieholder increase max.tool & profilesize. Max profile size Max profile size
Flat 3D-pr. 1-sided 3D-pattern max profile W: W 70-90mm W 100-135mm
Flat 3D-pr. 2-sided 3D-pattern max profile W: W 50-60mm W 90-125 mm
Rect. (Hollow/solid) 3D-pr. 3D on 2 sides . W x H W 30-40 x H 20 mm W 50-80 x H 60 mm
Rect. (Hollow/solid) 3D-pr. 3D on 1 side .W x H W 40 x H 40 mm W 80-90 x H 80 mm
3D :Depth of 3D-imprint, & relation % Imprint depth in relation to wall thickness can reduce extrusion speeds compared to
ordinary extrusion. For extrusion-speeds see separate picture with examples of extrusions & speeds.
BDDDHT
W
3W
General rule for
ALU:
3D/T=max 0,9-1,0
H
3D
Max Size of 3D-iExtrusion depend on:1. Shape & area SA Flat Hollow Rect. Solid Rect.
2. Size % capacity of extrusionline Size limited only by size/capacity of extrusionline
3. Die diameter of 3D-extr die/tool DD die diam.: std 200-220 special: 280-300
4. Type of 3D-pattern & depth in rel to WT 3D (Can go through material) % 3D/T & in mm increase difficulty
5. No of sides with 3D-pattern 1-4sides 1-sided 2-sided
6. Width of 3D-pattern (% of area & mm) 3W 50% 100%
7. Choice of material & if reinforcement of fibres is used (fibres increase stability and improves tolerances)
3D :Depth of 3D-imprint, & relation % Imprint depth in relation to wall thickness can reduce extrusion speeds compared to
ordinary extrusion. However, replacement of injection-moulding give great savings (see example THULE): up to 80%
BDDDHT
3D
TPE/TPV/Rubber/softPVC:
3D/T=max 0,7-1,2
3d/T=max0,7-1,0 W
H
3W
3d
10-40% lower weight than with ordinary alu profiles:
Lower Weight + less material + lower cost
=higher value, good LCA & sensible alternative to carbon fiber?
• saving weight + material & tailoring properties
• closer to the strength/weight ratio of carbon fiber
• at a fraction of the cost of CFRP
• environmental friendly & recycleable material,
• using existing industrial infrastructure.
3D-iExtrusion enable:
10-40% Savings of weight + material
Arsizio AB - Lightweight Engineering –Strictly confidential
Classic vs. Dynamic-extrusion (Strength to weight ratio)
Ordinary extruded segment of beam: Max tension: 147,8 N/mm2
Dimensions: 275 x 32 x 3,1097 Vol.: 27365,4 mm3
Force: 250 N
3D-iExtrusion enable:
Weightsaving
Arsizio AB - Lightweight Engineering –Strictly confidential
Classic vs. Dynamic-extrusion (Strength to weight ratio)
3D-extruded xx-segment of beam: Max tension: 118 N/mm2
Dimensions: 275 x 32 x (2 to 4) Vol.: 27365,5 mm3
Force: 250 N
20% general saving of weight/material with XX-pattern that increase buckling resistance
(Calculation of beam-segment of roof-beam between B-pillars in Volvo V70)
3D-iExtrusion enable:
Weightsaving
Designexample: Branding, design & safety. Sailboat genoa track with logotype &
antislip. Negative pyramids in imprint of high quality.
3D-extruded result. ”CGI-extruded”.
0,8m/s
Extrusion speed 0,8m/s in std 6 inch extrusionline (SAPA P3 in Vetl.). Tool fit in std
dieholder. Butt-end 20-22mm Tolerances +-0,05mm (!)
3D-iExtrusion: High precision & new design possibilities.
Productivity, lightweight & design
3D-extruded examples and high productivity – aluminium
Thin, solid & hollow 3D-extrusions and typical
productionspeeds.
0,4m/s
0,15m/s
0,6-0,8m/s
0,9m/s
0,6m/s
3D-iExtrusion has superior productivity.
60 mm wide profile with leather imitation pattern, logotype &
countersink for screw.
3D-iExtrusion: Rationalisation, precision & new design possibilities.
Designexample: Branding, design & safety. Sidestep profile for SUV with integrated
logo & efficient, longlasting good looking antislip.
3D-iExtrusion: Rationalisation & new design possibilities.
Results of Antislip tests at SP Borås comparing 3D-extruded profiles
with; Alcoa diamondback and other machined & surface treated profiles
and surface treated solutions.
3D-iExtrusion: High safety & low cost.
3D-iExtruded profile for non-laminar flow in heat transfer
Enable low-cost compact cooling unit produced in one step.
Arsizio license 3D-iExtrusion®, a globally patented production method an solutions
that is used by paying customers and enables:
→ 10-40% Savings of material, weight & energy
→ 10-20% Higher efficiency in heat-transfer & solar-energy.
→ 20-80% Lower production costs
→ Elimination of machining and investments
3D-extrusion is 100% compatible with all productionlines & materials.
That makes production with 3D-extrusion both scalable & cost efficient.
Mark J Kragh
CEO Arsizio AB
+46-761042143
mark.jkragh@Arsizio.se
www.Arsizio.com
3D-iExtrusion®:3D-imprintExtrusion™:
making 3D-production affordable
3D-intelligentExtrusion™:
Rational & optimized 3D-solutions for future
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