Professional Documents
Culture Documents
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
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
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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
Related Technologies
+ EOS GmbH
3D Systems purchased
DTM Corp. in late 2001.
Characteristics
Corp.
FDM 900mc
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10
10
5
Y
5
X
10
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University of Liverpool
Parts Gallery
Overview of Commercially
Available RP Systems
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%
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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
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Capabilities
Surfaces
Parametrics
Knowledge-Based
Engineering
Solids
Assembly Modeling
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CAD Systems
PTC: ProEngineer
Siemens Unigraphics:
NX
SolidEdge
Dassault Systemes:
CATIA
SolidWorks
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Crash Simulation
Roof crush during simulated roll-over.
Body-in-prime + doors
# Elements = 127,000
20 design variables
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Reverse Engineering
Physical model to Point
Cloud to CAD model
Scanners
Software
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Scanners
ATOS White Light scanners
Canon Laser scanners
Faro hand-held/robot laser scanners
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Geomagic
Software
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Clothing
Body Scanner, Cyberware
Virtual Fitting:
http://www.explore.cornell.edu/scene.cfm?scene=Th
e%203d%20body%20scanner
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Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
CAD
Design the Part Based on the Digital Model
CAM/RP
Automated Manufacture
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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
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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
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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)
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Receiving &
Order Entry
Dental
Laboratory
Data
Acquisition
Treat
Operations
SLA Mold
Fabrication
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
Ship to Mexico
25
Manufacturing Floor
25+ SLA 7000 machines running 24/5
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Automated UV Curing
2 minute UV post-cure
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Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
Align Technologies
Novel supply Distribution
chain and business model.
Align Tech
Molding
(Mexico)
Orthodontist
Data Manipulation
(Costa Rica)
Data Manipulation
(Pakistan before
2002)
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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
Dental Restorations:
CEREC
CEREC-3D
CAD Environment
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Impression Scanning
Minolta Vivid 900
Dual Head Configuration
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Software Modeling
Create vent and wall
thickness from digital data.
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Fabricate shell
Assemble from kit
Fabricate shell
Assemble from kit
Ship to local office
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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
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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.
Xpress3D.com
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QuickParts.com
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QuickParts.com (2)
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Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
Component Consolidation
(A) Conventional Duct fabricated
from Vac Formed plastic
Part Count = 16 (plus glue)
46
Previous (Kevlar/Rotomold)
Configuration
Attach Straps
Eliminated
Part Count Reduction
Quick & Easy Installation
47
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FDM 900mc
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Freedom Of Creation
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Overview
Technologies
Direct Digital Manufacturing (DDM)
3D Computer-Aided Design (CAD)
Reverse Engineering
Manufacturing
Custom Manufacturing
Local/Distributed Manufacturing
Low Volume Manufacturing
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
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.
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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.
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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
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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?
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Prognosis
Opportunities abound: auto, aero,
industry, medical, consumer...
New products. Spares. Enhancements.
Materials.
Economics.
Qualification, certification, standards.
Machine configurations, open architecture
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60
LASER
Source
Beam
Expander
Collimator
lenses
Lens
Mirror
Diffuser
DMD Chip
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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
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