With additive manufacturing in oil and gas, the future starts now

For the oil and gas industry, digitalisation is much more than automation, artificial intelligence and cybersecurity.

For the oil and gas industry, digitalisation is much more than automation, artificial intelligence and cybersecurity. It’s the opportunity to reimagine the design, manufacturing and operation of the assets and technology, leading to expansive breakthroughs in safety, efficiency and performance.

Nowhere is this promise more evident than in additive manufacturing (AM). More commonly known as 3D printing, AM will provide oil and gas companies with the power to transform how parts are created and optimised. The ability to fabricate parts on-demand stands to upend established and often inefficient supply chain models, reducing costs and opening the door for innovation.

Radical change is coming. The successes of early adopters, coupled with the wealth of expertise and resources now available, gives little reason for companies to press pause on starting their AM journeys. The barriers to entry have never been lower – and the rewards so high.

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3D Printing Case Example: On the highway to the comfort zone

Case Study: 3D Printing is on the Highway to the Comfort Zone-1The history of the Oberle shoe company began more than 150 years ago. In 1859, the great-great grandfather of Oberle’s current General Manager, Achim Oberle, opened a cobbler’s shop in Ettenheim that made shoes for customers in town and the surrounding areas. In 2006, the company began specializing in “Healthy Shoes.” And today, it’s recognized as a leader in the orthopedic footwear technology space. The company saves a lot of time and money by using the German RepRap X350pro 3D printer.

Oberle – Gesunde Schuhe is a specialty manufacturer that develops products for everything associated with legs, feet, and/or extremities. Behind its products is a highly technical process. The so-called 3D posture analysis (which involves 3D measurements of whole body posture), as well as the 3D walking analysis (which measures gait, body angles, and forces), have long been standard procedures for this company. To stay on the cutting edge of the industry, Oberle – Gesunde Schuhe must continuously employ state-of-the-art technologies as they become available.

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3D printing moves into manufacturing with gusto

Trade shows often come with an unstated theme. The second LiveWorx conference in 2015 came with the theme: “IoT can be deployed from product development through manufacturing and customer use.” A couple years ago, Siemen’s PLM World users’ conference was all about digital twins. At Advanced Design and Manufacturing in Cleveland last year, presenters and attendees were talking about how small- to mid-size companies were ready for smart manufacturing technology.

Jabil, Stratysis, 3D printing, additive manufacturing, serial production, trade shows

At the Rapid TCT 3D printing show last month, the unstated theme on the trade show floor was: 3D printing is ready for product manufacturing. Not just small runs, not just custom production, but honest-to-goodness manufacturing across multiple industries. The buzzword on the show floor was “serial production”—code for “manufacturing.”

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Chanel to produce up to 1 million 3D printed mascara brushes a month

Chanel Parfums Beauté, the cosmetics unit of the famous French design house, has turned to 3D printing for the production of an unlikely item: a mascara brush. In partnership with France-based Erpro 3D Factory, Chanel says it will begin manufacturing mascara brushes on an industrial scale using 3D printing.

When applying mascara, one might not think twice about the wand they unscrew from the bottle and lightly drag across their eyelashes. The truth is, however, that a ton of engineering and testing has gone into that seemingly simple object before it was put into production, marketed, and ultimately purchased.

From being eye-friendly, safe, effective, and even aesthetically pleasing, a lot goes in to making a mascara brush, which is why Chanel became interested in exploring 3D printing technologies for their production.

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Oracle and the impact of 3D printing on supply chains

Oracle’s Supply Chain expert, Dominic Regan, discusses the impact 3D printing is having on the supply chain

Oracle’s Supply Chain expert, Dominic Regan, discusses the impact 3D printing is having on the supply chain and how the multinational database giant is supporting the dynamic additive manufacturing market by helping to increase business agility, lower costs, and reduce IT complexity

Oracle is best known for its database services, offered to business since the company started over 40 years ago. This technology background was the platform to expand into applications in the ERP space and several other disciplines including supply chain.

Oracle supports the classic approach to designing products, planning and forecasting supply and demand, focusing on procurement and the sourcing of products in the manufacturing space then providing the logistics of fulfilment via transport and global trade warehouse management before closing that cycle with service, so once a product has been delivered it can manage the repair and maintenance process.

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How distributed and agile manufacturing power new business models

3D printing, aka Additive Manufacturing, is changing the way things are made; and not just on a small scale or prototyping sense, but changing the way global scale production gets done.

Gartner believes that in 2018, 3D printing will accelerate new business model innovation. Here are some of the 3D printing predictions by Gartner:

  • By 2021, 75 percent of new commercial and military aircraft will fly with 3D-printed engine, airframe and other components.
  • By 2021, 25 percent of surgeons will practice on 3D-printed models of the patient prior to surgery.
  • By 2021, 20 percent of the world’s top 100 consumer goods companies will use 3D printing to create custom products.
  • By 2021, 20 percent of enterprises will establish internal startups to develop new 3D print-based products and services.
  • By 2021, 40 percent of manufacturing enterprises will establish 3D printing centers of excellence (COE). “The long-term goal of a 3DP COE is to become a seamless part of the design and manufacturing process. When successful, the COE has broad implications on use of 3DP in the design, manufacturing and maintenance of products,” – Gartner

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How local manufacturing is redefining humanitarian aid

Local manufacturing is not a new concept, but advancements in technology and design mean that now more than ever, it is a viable option – especially when it comes to disaster recovery and helping war and weather-torn areas. Field Ready’s Eric James talks about how creating supplies-in-the-field can make all the difference when responding to humanitarian crises.

In regions where something as simple as an umbilical cord clamp or a plastic u-bend can help save lives, local manufacturing can have a hugely positive impact. Hard to reach areas stricken by disaster, conflict and extreme poverty can be slow to receive emergency aid and broken or non-existent supply chains often mean that people in these areas don’t have the equipment they need when or where they need it.

local manufacturing

Access to the right technology can circumvent these supply chain problems and can mean the difference between waiting weeks and sometimes months for medical equipment, power or clean water to having systems up and running in a day or even less. But local manufacturing isn’t just about the technology. It’s about putting the people – the communities – first, focusing on the actual support they need on the ground. We can then apply design thinking and other methods to map the technology best suited to meeting their needs and alleviating their suffering as quickly as possible – not the other way around.

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3D printing: from the automotive design studio to the factory floor

The automotive industry is in a state of flux. Significant swings in gas prices, as well as environmental and political pressures, challenge the industry to balance between the economics of gas guzzling SUVs and lightweight electric vehicles. Ride-sharing and shared ownership business models are gaining momentum, and leaps in technology have put autonomous vehicles on the road, changing the way we view our use of cars. Automotive manufacturers must adapt to all that change, whilst also facing the age-old challenge of minimizing p roduction costs. Scott Sevcik, VP Manufacturing Solutions at Stratasys, considers 3D printing – the definition of disruptive technology – and its role supporting the automotive industry as it adjusts to a new reality.

Using additive manufacturing in the automotive industry

The automotive industry was one of the first to really grasp the benefits of 3D printing. Long used as a tool for rapid prototyping, it was this industry that led high-end 3D printer and material sales in recent years, but this was often kept under wraps as cagey design studios withheld their secret weapon. By slashing design costs and timescales, even contributing to better design by enabling adaptations on the fly with multiple iterations in a matter of hours, 3D printing has made a significant contribution to the automotive design process. As the technology and materials continue to advance even further, it’s a trend set to stay for the foreseeable future.

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US Navy will rely on 1,000 3D printed parts by the end of 2018

The U.S. Naval Air System Command (NAVAIR) is ramping up production of 3D printed parts.

System Command estimates that it will have approximately 1,000 3D printed parts approved for use across the fleet before the end of 2018. Currently only 135 3D printed parts are authorised for use.

3D printing helmets to flight-critical parts

3D printed parts will be used in a range of Naval applications, from modifications to helmets to critical parts for aircraft: NAVAIR categorizes parts depending on their air-worthiness. Parts not requiring airworthiness can be fabricated more quickly.

Fabricating a MV-22B nacelle link inside a directed energy deposition 3D printer. Photo via NAVAIR.

In 2016 NAVAIR proved that 3D printing could be used to produce safety-critical parts with the successful flight of an MV-22B Osprey, fitted with a 3D printed titanium engine nacelle link and attachment. Last spring, a 3D printed flip-top valve was added to the T-45 Goshawk breathing mask, allowing pilots in training to breathe cabin air up to a certain altitude. 300 valves were printed within a month without which training would have been impossible.

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The difference between: 3D printing and CNC machining

With today’s increase in complexity for engineered products and the need for faster production of these products, manufacturers are having to choose between technologies. This paper will discuss and compare two of the methods used to produce parts, while recognizing that each has its place, and can complement each other in the design and manufacturing workflow. Download this paper to learn about the differences between 3D Printing and CNC Machining and when to choose each technique.

The Difference Between: 3D Printing and CNC Machining

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