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Additive Manufacturing

Product development
Additive manufacturing

Highly competitive & shorter lead time


Mass market demand to individual niche markets
Product push to market-pull
Improved quality & lower cost
Tremendous internal flexibility
Move from mass production
of high volume small range of products
to small volume and wide range of products

Factors affecting the


marketplace

Globalization
Brutal competition from new industrial low
cost companies in located internationally
Requires new innovation to rapidly adapt
and deliver to the new markets
To overcome adverse competition
Everyone must be involved and cooperate
Effective, clear communication is essential

Lean load leveling solves the problem of


Customized market
Individualized selection

Toyota: install a grey console

Lean does not address the problem


of design time to market lead time
Product development time
Process development time

Product development process


Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Product development process


Five stages
1. Information
phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Information phase
Market research
Analysis of patents
Competing
products
Competing price
points
Demographics

Product development process


Five stages
1. Information
phase
2. Concept phase
3. Engineering
phase
4. Tooling phase
5. Production phase

Concept phase
Design modeling step
Virtual model generated
Hand/craftsman
Subtractive
manufacturing
Material removal
Cutting, milling,
shaping, turning
Computer model
Virtual or soft
prototyping

Product development process


Five stages
1. Information phase
2. Concept phase
3. Engineering
phase
4. Tooling phase
5. Production phase

Engineering phase
Find the best and
most
simple
technological
solution
Implement the
initial concept
Prototype of the
product is made

Product development process


Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production
phase

Tooling phase &


Production
phase
Conventional
subtractive
manufacturing

Conventional
formative methods

Product development
process
Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Conventional
subtractive
manufacturing
Material
removal
Cutting, milling,
shaping, turning

Product development
process
Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Conventional
formative
methods
Casting,
injection
molding,
compressive
molding, forging

With inconsistencies
the probability of
errors
increases dramatically
Failure cost
of an
aircraft
engine
component

Product development process


Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Phases are
preformed
sequentially

Product development
process
Five stages
1. Information phase
2. Concept phase
3. Engineering phase
4. Tooling phase
5. Production phase

Phases are preformed


sequentially
Any serious error implies
a new concept phase and
repetition of the sequence
Majority of the
development time is
spent in the concept and
engineering validation
phases ( approx 50%)
Important to identify
inconsistencies early on

Additive Manufacturing
and Lean
Layered manufacturing
Rapid prototyping
Reverse prototyping

Additive manufacturing
steps

CAD file
Stereo lithography convent file
2D slices
Print 2 slide
Repeat Print 2D slice
Remove, post treat.

http://www.wimp.com/functionaltools/

Tessellation
A tessellation is created when a shape is
repeated over and over again covering a
plane without any gaps or overlaps. i.e.
triangles

Gel part

Monome
r

Sol
part

Cross
linked
polymer

Medical applications
Surgical and diagnostic aids
Prosthetic developments
Manufacturing of medically related
products
Tissue engineering

Wind tunnel final model (1:8 scale)


for prototype
tilt motor plane
Build time days instead of months

Marketing forces impacting lean


Application of Additive
manufacturing
Reduction of design lead time from
conventional methods of weeks and
month to days