Event Information: Direct Metal Printing – How Additive Manufacturing Drives New Levels of Efficiencies Through Part Count Reduction

Learn about transformational productivity through metal additive manufacturing and Part Count Reduction (PCR). Change the way you think about designing parts and understand the potential for revolutionary new designs in aerospace, automotive, energy and manufacturing industries.

Experience how the integration of Design for Additive Manufacturing (DfAM) software, advanced metal additive manufacturing, and thoroughly developed metal materials are revolutionizing metal parts design and production.

Learn how to improve production efficiency: (examples)

– Part Count reduction of 155:1 and production time reduction by 75%
– Assembly errors, checks and time reduced to zero
– 50% reduction in material volume and 60% increase in cost-effectiveness
– Reduced part weight of 20% with 20% improvement in performance

See customer use cases from the Center for Environmental Engineering, Univ. of Maryland, the European Space Agency, Havells Sylvania, and Airbus Defense and Space.

Learn from an expert: Patrick Dunne, VP, Advanced Application Development, 3D Systems
– Over 15 years of experience in additive manufacturing and advanced applications development and engineering with 3D Systems, Brontes Technologies, and BMW.

Register now and get a complimentary eBook! The Definitive Guide to Direct Metal Printing

Register here

3-D and the Global Supply Chain

Over the last 5 years, 3-D printing, also known as additive manufacturing, has had a tremendous influence in our industry. It is considered the current and future of almost any conceivable form of fabrication.  Though this technology has been embraced by enthusiasts from small-time makers to international aerospace ventures, questions about its cost effectiveness are paramount to widespread adoption. Here’s why.

Costs of production for additive manufacturing fall into two categories: “well-structured” costs, such as labor, material, and machine costs, and “ill-structured” costs, which can include machine setup, inventory, and build failure.  Right now, most cost studies focus on well-structured costs, which comprise a significant portion of 3-D printing production and are cited by detractors as evidence of cost ineffectiveness. Unfortunately, these studies focus on the production of single parts and tend to overlook supply chain effects, thus failing to account for the significant cost benefits which are often concealed within inventory and supply chain considerations.

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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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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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Carbon fiber bikes may become a whole lot cheaper with 3D-printed frames

A company backed by the CIA that calls itself Arevo is hoping to lead a revolution in manufacturing that uses 3D printing to build products in a more efficient and cost-effective manner. The Silicon Valley, California startup recently picked up $12.5 million in funding to help pursue this goal and has revealed an impressive proof-of-concept product to help demonstrate its capabilities. That product is a carbon fiber bike frame that could give us a glimpse of the future for the cycling industry.

Arevo 3D printed bike

According to Arevo, its bike frame is the first to be 3D printed using carbon fiber. The company uses 3D printer technology, paired with a custom-built robotic arm and web-based software, to create products made from proprietary raw materials. The robot arm is able to print out shapes in a single pass using a thermoplastic material that is melted into strands of carbon fiber that helps bind everything together. The end result is a bike frame that costs about $300 to make, which is considerably less than what most bike manufacturers pay.

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Six ways to cut costs with 3D Printing

3D printing can cut costs by accelerating production and reducing tooling costs, work-in-process, and waste. Here are some design considerations for making this happen.

3D printing3D printing (aka additive manufacturing) has gone far beyond making prototypes quickly. It is now entrenched in manufacturing, and examples abound:

  • The Juno spacecraft, built by Lockheed Martin and NASA and currently completing its mission in orbit around Jupiter, carries a dozen 3D-printed waveguide support brackets.
  • Activated Research Co. used 3D Printing to develop a new design for its Polyarc gas chromatography catalytic microreactor, bringing it to market in just 15 months.
  • Raytheon uses 3D printing for rocket engines, fins, and control components for guided missiles, creating parts in hours rather than days.
  • Boeing set a world record in 2016 by building the largest 3D-printed item ever made, a fixture used in building 777 airplanes, reportedly cutting weeks off its manufacturing time.
  • Brunswick Corp. relied on 3D printing for air conditioning grills on its Sea Ray yachts, eliminating the need for disposable tooling and speeding product development.
  • This air-conditioning grill for Sea Ray yachts was 3D printed.

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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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What 3D Printing means for your supply chain

3D printing is going beyond prototyping to help transform the customer experience.

When you think of innovations that 3D printing has brought to the supply chain, dentistry might not be the first industry to spring to mind. But 3D printing is revolutionizing the manufacturing of custom transparent orthodontic braces and transforming the customer experience.

Courtesy of Align Technology

Stereolithography (SLA) 3D printers are used to create Align Technologies’ patient-specific Invisalign aligners. Every day, 3D printing is used to produce 150,000 custom molds based on a 3D digital model of a patient’s teeth, around which their braces are formed. These digital methods bring speed and agility to the process, which is made even more efficient by printing multiple molds simultaneously.

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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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