Digital Design and

Manufacturing
David W. Rosen
Professor and Associate Chair for Graduate Studies
Rapid Prototyping & Manufacturing Institute
Woodruff School of Mechanical Engineering
Georgia Institute of Technology
Atlanta, Georgia 30332-0405
404-894-9668 david.rosen@me.gatech.edu

Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering

Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing

Issues and Prognosis

2

Takeaways
DDM, CAD, reverse engineering are
changing manufacturing industries:
Customized, Personalized
manufacturing
High value added products
Local vs. distributed manufacturing; onshoring vs. off-shoring
Enable innovative ideas
3

Direct Digital Manufacturing

Layer-based additive manufacturing
Parts, tools, patterns, prototypes
Wide range of polymers and metals
Ex: Stereolithography (SL)

StereoLithography (SL)
Process

Characteristics

+ 3D Systems - inventor
+ UV laser solidifies liquid
photopolymer in layers using
a scanning system
+ Liquid is replenished and
leveled between layers
+ Parts require support
structures
+ Completed parts require
cleaning and UV or Thermal
post curing

Related Technologies
+ DMEC/Sony, CMET, Denken,
Meiko, EnvisionTec

Selective Laser Sintering (SLS)

Process Characteristics
+ C02 laser fuses thermoplastics
powders in layers using a
computer controller scanning
system
+ Powder is replenished and the
next layer is scanned
+ Powder temperature is
maintained near melting point to
aid fusion and minimize
distortions
+ Supports may be used

Related Technologies
+ EOS GmbH

3D Systems purchased
DTM Corp. in late 2001.

Fused Deposition Modeling (FDM)

Process

Characteristics

+ A heated thermoplastic filament

is extruded from a capillary die
+ Thin layers are formed between
the die face and previous
layer(s)
+ Parts chamber is heated to
minimize stresses and
deformation
+ Required support structures
+ Cleanup required No post
processing
Stratasys

Corp.
FDM 900mc

Selective Laser Melting

MCP Realizer

12

10

10
5
Y

5
X

10

15

University of Liverpool

Parts Gallery

Overview of Commercially
Available RP Systems

Stereolithography (SLA) - 3D Systems

Selective Laser Sintering (SLS) - 3D Systems, EOS
Fused Deposition Modeling (FDM) - Stratasys
3D Printing Technology (3DP) - Z Corp., Ex One
3D Printing & Deposition Milling (MM) - Solidscape
Multi-Jet Modeling (TJM) - 3D Systems, Objet
Laser Engineered Net Shaping (LENS) Optomec
Direct Metal Deposition (DMD) POM Group
Solid Ground Curing (SGC) Cubital (out of business 2000)
Laminated Object Manufacturing (LOM) Helisys (out
of business 1999)
10

Users of DDM
Wohlers and Associates, 2006
Government and
Military
5%
Academic Institutions
11%

Medical
14%

Other
11%

Motor Vehicles
17%
Aerospace
8%
Industrial Machinery
9%
Consumer Products
25%

11

3D Computer-Aided Design
3D solid modeling
Parametrics adjustable geometry
Assembly modeling
Interfaces to PDM,
PLM systems
Knowledge modeling and
capture
Computer-Aided Engineering
Computer-Aided Manufacturing
12

Capabilities
Surfaces
Parametrics

Knowledge-Based
Engineering

Solids
Assembly Modeling

13

CAD Systems
PTC: ProEngineer
Siemens Unigraphics:
NX
SolidEdge

Dassault Systemes:
CATIA
SolidWorks

14

Crash Simulation
Roof crush during simulated roll-over.
Body-in-prime + doors
# Elements = 127,000
20 design variables

15

Reverse Engineering
Physical model to Point
Cloud to CAD model
Scanners
Software

16

Scanners
ATOS White Light scanners
Canon Laser scanners
Faro hand-held/robot laser scanners

17


Geomagic

Software

Geomagic, Inc. www.geomagic.com

18

Clothing
Body Scanner, Cyberware
Virtual Fitting:
http://www.explore.cornell.edu/scene.cfm?scene=Th
e%203d%20body%20scanner

19

Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering

Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing

Issues and Prognosis

20

The Key Elements

SCAN
Obtain the Digital Model

CAD
Design the Part Based on the Digital Model

CAM/RP
Automated Manufacture

21

Cynovad
Dental supply company.
Fabricate dental restorations (crowns,
bridges, etc.).
Also markets systems for fabricating dental
restorations.
ThermoJet machines to fabricate patterns for
investment casting of
restorations.
www.cynovad.com

22

Interpore Cross
Manufacturer of spinal implants
Facility with >30 MJM machines from SolidScape
Fabricate patterns for investment casting of
implants in titanium
Data from CT, MRI scans. Easy to send data
anywhere
www.interporecross.com

23

Align Technology
Introduction to Align Technology:
650 employees world wide
2 facilities outside of US
> 200,000 cases treated.
> 5 million aligners.
www.aligntech.com or
www.invisalign.com
Most of this content from Long Pham
at Align (Aug. 2002)

24

Invisalign Manufacturing Process

Timeline

Receiving &
Order Entry

Dental
Laboratory

Data
Acquisition

Treat
Operations

SLA Mold
Fabrication

Prepare & Slice

SLA Build

Aligner
Fabrication

S TL File Generation
P acking (orient & place)
Support Generat ion
Slice Dat a

Laser (Scanning)
Re-coat (dip in resin)
Sweep (remove excess
resin)
Part Removal & Postcure

Quality Control

Verify test parts

Conduct individual mold
inspect ion

Ship to Mexico

Kit in transportation box

25

Manufacturing Floor
25+ SLA 7000 machines running 24/5

26

Automated UV Curing
2 minute UV post-cure

27

Personalized Golf Grips

28

Customized Radio Heads

29

Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering

Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing

Issues and Prognosis

30

Align Technologies
Novel supply Distribution
chain and business model.

Align Tech

Molding
(Mexico)

Orthodontist

Data Manipulation
(Costa Rica)

Data Manipulation
(Pakistan before
2002)

31

Distributed Manufacturing
Highly capable, integrated, inexpensive
manufacturing systems.
Put manufacturing capability where it is needed
to best serve the customer:
Home Depot
Doctors or Dentists office
Home

Supply chains become very different

Manufacturing capability becomes a
commodity?
32

Dental Restorations:

CEREC

Example System: CEREC-3

Chairside workstation
with interaoral 3D camera

CEREC-3D
CAD Environment

Benchtop Milling Station

33

Siemens Hearing Instruments

Partnership with Phonak (Germany) to produce hear
aids.
Producing in-the-ear hearing aid shell using AM since
2002.
Siemens using mostly stereolithography now; started
with SLS.
More than 100,000 hearing aid shells yearly.
Courtesy: Martin Masters
Siemens Hearing Instruments, Inc

34

Digital Mechanical Processing

Create an impression of the ear.
Scan the impression
Modify the data through software
Fabricate the instrument shell
Create the desired surface finish
Close and ship the instrument
35

Impression Scanning
Minolta Vivid 900
Dual Head Configuration

36

Software Modeling
Create vent and wall
thickness from digital data.

37

Hearing Aid Manufacturing

Local Laboratory:
Local office:
Scan impressions
Ship data to central
location

Ship impression from local

office to local laboratory
Scan impressions
Ship data to central location

Design hearing aid

Design hearing aid

Ship data back to local

office

Ship data back to local lab

Fabricate shell
Assemble from kit

Fabricate shell
Assemble from kit
Ship to local office
38

Kitchen Redecorating
Start with geometric layout of YOUR kitchen.
Select appliances, cabinets, sink, lighting
Configure (layout) items and appliances.
Customize functionality of appliances (e.g., smart
refrigerator). Network appliances to ensure
everything interoperates.
Customize appearance
of each item.
View in various lighting
conditions.
.
See: www.homedepot.com

39

Service Bureaus
Companies that own machining and
DDM equipment.
Contract prototype fabricators.
Mold making, molding.
Short-run production.
Contract design and engineering work.
Ex: ARRK, Compression Engineering,
Morris Technologies, FineLine
Prototyping, RedEye RPM, etc.
40

RP Markets
Some companies act as market makers:
Xpress3D.com - central site for customers to
submit parts.
Solicits quotes from service bureaus.

QuickParts.com - Quotes directly on

customers parts.
Finds service bureau.
Atlanta based.
Very nice web site.

Tough to make money.

41

Xpress3D.com

42

QuickParts.com

43

QuickParts.com (2)

44

Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering

Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing

Issues and Prognosis

45

Component Consolidation
(A) Conventional Duct fabricated
from Vac Formed plastic
Part Count = 16 (plus glue)

(B) Component modified and

consolidated for fabrication via Additive
Rapid Direct Manufacture
Part Count = 1

Courtesy: Patrick Dunne, 3D Systems

46

Example for Production

Applications
New (SLS)
Configuration

Previous (Kevlar/Rotomold)
Configuration

Attach Straps
Eliminated
Part Count Reduction
Quick & Easy Installation

Multiple Ducts Combined to

Single-Piece Duct

Conformal Shapes Achieved and Internal Flow Features Added

Courtesy: Boeing PhantomWorks

47

Value of Direct Manufacturing

Engineering Design:
Direct from 3-D Model Base Definition
Design and Build Flexibility
Production:
Eliminate non-recurring tooling costs
Lower recurring unit part costs
Faster part delivery times
Supplier flexibility
Direct Fabrication:
50% Cost Reduction
67% Cycle Time Reduction at
Minimum
Product:
Reduced part count and weight
Lower inventory and transportation
costs
Improved Life Cycle Product Costs
Courtesy: Boeing PhantomWorks

48

Stratasys FDM 900mc

32 parts for the FDM 900mc are built on
FDM machines.
RedEye RPM in-house rapid
manufacturing facility ~80 machines

FDM 900mc
49

Freedom Of Creation

50

Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering

Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing

Issues and Prognosis

51

Unique Capabilities
Shape Complexity
Material Complexity
Hierarchical Complexity
Functional Complexity
52

Customer-Driven Design
Bottlenecks in product development:
capture specifications and design
delivery to customer

New design tools, user

interfaces needed.
Automated design/engineering
for customized products.
53

Levers enabling RM
Unique Shapes: fabricate parts with customized
shapes.
Complex Shape: consolidate many parts into 1.
Lot Size of One: economical to fabricate
customized parts.
Fast Turnaround: save time, costs. Increase
customer satisfaction.
Digital Manufacturing: precisely duplicate CAD
model correct shape.
54

Sustainability
+ 90-100% of feedstock ends up in parts.
+ Few processes require hazardous
chemicals.
+ Designed structures can be much
lighter, stiffer, and stronger, reducing
need for energy.
+ Multifunctional structures.
- Processes can be slow, consume lots of
energy.

55

Issues
Rapid Prototyping industry
Prototyping is NOT production
Materials need to be improved
Qualification of materials, processes
Certification of users, suppliers, ...
Economics: costs, speeds, machine
reliability, throughput
56

Supply Chains and Business Models

Dental restorations and custom medical
devices role for labs, large
manufacturing facilities?
Home Depot: products manufactured
world-wide, shipped to each store.
Custom designed, fabricated in-house.
Supply chain?
Custom enhancements to cars,
motorcycles, bikes.
Childrens toys design your own...
57

Business Models
Opportunities abound ... But need killer app
Custom manufactured World of Warcraft
figurines: www.figureprints.com (ZCorp
DDM machines).
What kinds of services and/or products can
you think of?

58

Prognosis
Opportunities abound: auto, aero,
industry, medical, consumer...
New products. Spares. Enhancements.
Materials.
Economics.
Qualification, certification, standards.
Machine configurations, open architecture
59

Design and CAD Methods

60

Medical Device Manufacturing

LASER
Source

Beam
Expander

Collimator
lenses
Lens
Mirror

Diffuser

DMD Chip

61

High Viscosity Ink-Jet Printing

62

Thank You!
RPMI Industry Members: 3D Systems, 3M,
DSM, Ford, Huntsman, Lockheed-Martin,
Pratt & Whitney, Siemens
National Science Foundation
Georgia Tech, colleagues, students
Dr. David Rosen
Rapid Prototyping & Manufacturing Institute
Woodruff School of Mechanical Engineering
Georgia Institute of Technology
Atlanta, Georgia 30332-0405
david.rosen@me.gatech.edu 404-894-9668

63