2016-11-25 1 Nader Asnafi Nader Asnafi 2016-11-25 1 3D Printing/Additive Manufacturing from Product Creator & Tool Maker Perspectives in the Automotive Industry Professor Nader Asnafi Tel: 070 ‐ 311 00 74 E‐post: [email protected]Nader Asnafi Nader Asnafi Contents Introduction: Brief status report related to 3D printing Current 3D printing examples and applications Future applications and required development 2 Nader Asnafi Nader Asnafi 3 0% 10% 20% 30% 40% 50% 60% Criterion ranked first in Decision‐Making‐Process A/B C/D E/F MPV C:VW Golf,Ford Focus D: Volvo S60,BMW3 series E: Mercedes Eclass, Audi A6 F: BMW 7‐series, Mercedes S Class A:Citroën C1 B:VW Polo,Ford Fiesta MPV: Renault Escpace, Ford C‐max, VW Touran Decision Criteria in Car Purchase Source: Peters & deHaan, 2012
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Final3DPNaderAsnafi23Nov2016 · 2016-11-25 5 Nader Asnafi 13 Nader Asnafi The new Koenigsegg Agera One:1 has a 3d printedturbo housing, printed in one piece, with no further assembly
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2016-11-25
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Nader AsnafiNader Asnafi2016-11-25 1
3D Printing/Additive Manufacturing from
Product Creator & Tool Maker Perspectives in the Automotive Industry
Introduction:Brief status report related to 3D printing
Current 3D printing examples and applications
Future applications and required development
2
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0%
10%
20%
30%
40%
50%
60%
Criterionrankedfirstin
Decision‐Making‐Process
A/B
C/D
E/F
MPV
C: VW Golf , Ford FocusD: Volvo S60, BMW 3 series
E: Mercedes E class, Audi A6F: BMW 7 ‐series, Mercedes S Class
A: Citroën C1B: VW Polo, Ford Fiesta
MPV: Renault Escpace,Ford C‐max, VW Touran
Decision Criteria in Car Purchase
Source: Peters & de Haan, 2012
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Product Creation/Development &
Production/Manufacturing
2 0 1 6 ‐1 1 ‐2 5 2 9
Time
Product Development Production/Manufacturing
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Product Development: Duration and Cost
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Competitive Factors
from Product Creation Process Perspective
Investment Costs for Production
Product creation Lead Time (Time‐To‐Market/Time‐To‐Production)
Hit rate: product targets such as emissions, fuel efficiency, weight,
production/manufacturing costs, …
…
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Lead Time (or Time to Market) Reduction
Volvo Cars Target
Courtsey of Volvo Cars
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Competitive Factors – the product perspective
• Safety
• Driving experience
• Styling/design
• Quality (both functional and perceived)
• Delivery precision
• Environmental friendliness
• Fuel efficiency
• Price
• …
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The Importance of Different Criteria in
Car Buyers’ Purchasing Process*
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* According to the global automotive executives
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Quality
DeliveryCapacity
Cost Efficiency
Flexibility
Competitive factors from a
Product and Manufacturing Perspective
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Car Production
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Car bodycomponents
BodyShop
PaintingFinal
Assembly
Powertrain
Interior
Customer
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Supply and Distribution
2 0 1 6 ‐1 1 ‐2 5 2 9
Suppliers’ suppliers
Suppliers Producer(OEM)
Retailers Customers
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www.va-automotive.com13
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The new Koenig segg Ag era One:1 has a 3d pr inte d t urbo hou sing, pr inte d in
one p iece, with no furt her a ssem bly r equ ire d. stra ight fr om the pr inter tothe engine.
The new Koenig segg Ag era One:1 has a 3d pr inte d4 00 grams ti tanium exhau st
pipe end.
The first production car that offers a 1:1 power to weight ratio — it weighs 1340kg and produces 1322bhp(1340 metric horsepower).
Five (5) units of the One:1 have been produced, retailing for around $2 million (€1.45 million).
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
Product Development/Creation
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Source: Divergent3D, www.divergent3d.com
Product Development/Creation
Nader AsnafiNader Asnafi
Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Source: Divergent3D, www.divergent3d.com
Product Development/Creation
Nader AsnafiNader Asnafi
Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Source: Divergent3D, www.divergent3d.com
Source: 3D Printing Industries, 3dprintingindustry.com
Product Development/Creation
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Source: Divergent3D, www.divergent3d.com
Source: 3D Printing Industries, 3dprintingindustry.com
Product Development/Creation
Nader AsnafiNader Asnafi
Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Source: Local Motors, www.localmotors.com/3d‐printed‐car
Product Development/Creation
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Local Motors LM3D Swim
• Electric car• Made up of 80% plastic and 20% Carbon Fiber. • It’s light yet strong as a traditional car. Being tested right now.• Big Area Additive Manufacturing printers at a variety of locations around
the world.• To pump out 250 highly customized cars a year. • Price = $53,000/car.
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Local Motors 3D Swim
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It took Local Motors 44 hours to print this car body (including the seats) in carbon fiber reinforced thermoplastic or ABS.
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
23 Source: Local Motors, www.localmotors.com/3d‐printed‐car
Product Development/Creation
Nader AsnafiNader Asnafi
Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Product Development/Creation
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
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Product Development/Creation
http://3digiprints.b logspot.se/2 014 /11 /the‐t op‐best‐ sls‐3d‐p rin ted‐object s.html
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
Unsplit and split styling respectively
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Product Development/Creation
Nader AsnafiNader Asnafi
Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout Production
Citroën Hypnos
Functional testing
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Product Development/Creation
https://www.wired.com/201 1/0 2/t he‐secre t‐world‐ of‐pr int ing‐conce pt‐cars‐in‐3d /
Source:Nader Asnaf i: ”Tooling and Technologies for Processing of Ultra High Strength Sheet Steels”, Conf. Proc. of Tools and Technologies for Processing Ultra High Strength Materials, Sept 19 ‐21, 2011, Graz, Austria, At Graz, Austria
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Concept/
Styling
Product
Design
Production
Planning
Process
Engineering
Tool Design &
ManufacturingTryout
Part
Production
A two‐out automotive side member progressive stamping die in the build process
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Product Development
Source: Tooling Systems Group, http://www.tooling syst emsg roup.com/compa nie s/a ts
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3D metal printing
(& metal related printing) ‐ current possibilities & limitations
The current maximum size of the metal piece to 3Dprint?
The metallic materials that can be printed?
Tool/die weight/design: Solid structure vs hollow honeycomb structure?
The strength of the printed metallic material?
Surface roughness of the printed metal piece?
Hardness of the printed metal piece?
Can the printed metal piece be machined, polished, hardened and surface‐coated?
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The current maximum size of
the metal piece to 3D‐print?
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500
500
500
100
10080
140
140100
250
250
300
275
275
420
Current maximum build
volume
Source: 3D Systems, http://www.3dsystems.com/
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500
500
500
100
10080
140
140100
250
250
300
275
275
420
Current maximum build
volume
CoCrMo
1.2709
17‐4PH
Full
CoCrMo
1.2709
17‐4PH
AlSi12
CoCrMo
1.2709
17‐4PH
AlSi12 AlSi12
CoCrMo
1.2709
17‐4PH
AISI 316
Inconel 718
Ti Gr. 1
Ti Gr. 23
Ti Gr. 5
PdAg
Ti6Al4V/
Ti6Al4V ELITi6Al4V/Ti6Al4 V ELI Inconel 718 Hastelloy X AISI 316 CuSn6 AL2O3/AL2O3+Al