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Additive Manufacturing e Stampa 3D:La visione di Dedagroup
Renato Bocchi – Head of Industry 4.0, Dedagroup
What is 3D Printing/Additive Manufacturing ?Definition
A process of joining materials to make physical objects from 3D CAD model, usually layer upon layer, as opposed to subtractive manufacturing or molding/casting technologies
Additive Manufacturing allows for building metallic parts with very complex geometries (actually impossible with conventional methods) without tooling, fixtures and without producing any waste material
This is a revolution in the world of manufacturing …
… but to date, existing CAD systems was not able to address the challenges of this new technology
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http://youtu.be/OhYvDS7q_V8?list=PLF992841F1A4677FASource:
What is 3D Printing/Additive Manufacturing ?Two main Additive Manufacturing processes
Bed-based Materials(powder, liquid) Powder bed processes consolidate
thin layers of powder or liquid to solidify scans of the sliced Computer Aided Design (CAD) data
Feeder-based Materials(powder, wire, liquid) Focused selective material
deposition (wire, powder, liquid) and solidification by fusion, polymerization or cooling depending on the process
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Additive Manufacturing processesBed-based Materials (powder, liquid)
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ADDITIVE MANUFACTURING CATEGORIE
PROCESS TYPE
MATERIAL TYPE
Notes
POWDER BED FUSION
Thermoplasticselastomers
Ferrous & non ferrous alloys
Non ferrous alloys
BINDER JETTING in Powder VAT
Composite materials
VAT LIQUID POLYMERIZATION
Polymers
MATERIAL JETTING
Digital Materials, Wax
MATERIAL EXTRUSION
ABS, Nylon
Selective Laser Sintering(SLS)
Selective LaserMelting(SLM)
Electron BeamMelting(EBM)
Full color printingStereolithography
(SLA)PolyJet (PJ),
MultiJet Printing (MJP),
Wax DepositionModeling (WDM)
Fused DepositionModeling (FDM),Fused Filament
Fabrication (FFF)https://www.youtube.com/watch?v=9E5MfBAV_tA
https://www.youtube.com/watch?v=Mjf6oaMVWr8
https://www.youtube.com/watch?v=BxxIVLnAbLw&index=14&list=PLUMSQMrg3EMuAk6fQAkxnGsR49nrb_tho
https://www.youtube.com/watch?v=VBK_4ruKC8s
https://www.youtube.com/watch?v=oNpAnBhgIIs
https://www.youtube.com/watch?v=Som3CddHfZE
https://www.youtube.com/watch?v=MX0HPjc-3aw
https://www.youtube.com/watch?v=9RuJ_Ejc4WQ
https://www.youtube.com/watch?v=SPtkOmP_HoA
https://www.youtube.com/watch?v=GxLjDNrQBgs&index=3&list=PLwpDxJ0jrz6jpFFp4xLP9e2B1aaRdBC3K
POWDER BED FUSION: thermal energy selectively fuses regions of a powder bed
VAT POLYMERIZATION: liquid polymer in a vat is selectively cured by light-activated polymerization
MATERIAL JETTING: droplets of build material are selectively deposited onto a build bed to develop a three-dimensional object
MATERIAL EXTRUSION: extruding of thermoplastic materials
BINDER JETTING: a liquid bonding agent is selectively deposited to join powder materials
Source:
Main benefits of Additive Manufacturing technology 6
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[1/3]
Main benefits of Additive Manufacturing technology 7
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[2/3]
Design freedom Leverage topological optimizations Hollow parts with internal lattices
become possible Function integration
Weight reduction Topological optimizations Hollow parts with an internal lattice to
keep/improve mechanical strength
Costs reduction No more need of expensive tooling Manufacturing/assembly cost reduction
with parts integration (1 single part instead of 20)
Function integration
Speed up manufacturing process No lead time for tooling Shorten assembly process with “parts
integration”
High material utilization No waste of material - less than 10% Buy-to-Fly ratio reduction
Ability to manufacture on-site, reducing logistics complexity Inventory Shipments
Main benefits of Additive Manufacturing technology 8
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[3/3]
Proof Points3D Print Technology – industry metrics
3D printing market is expected to grow 500% over the next 5 years
Survey of over 1,000 Stratasys 3D printer owners Almost 1/3 reported a 25% or higher improvement in product launch times
O (NASCAR team) uses AM to accelerate new part designs
O estimates: 3D printing helped reduce development time by as much as 75%
O "Within 6 months we were able to go through 12 rounds of prototype iterations that we fully tested”
9
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Main industries interested by Additive Manufacturing 10
Aerospace & Defense industry Weight reduction Function integration Buy-to-Fly reduction Spare parts management
Automotive Weight Function integration
Medical industries Weight reduction Shape customization, etc.
Car racing (ex.: F1) Weight reduction Optimization
…
Source:
AM: a big impact on the design itself New, impossible before, geometries for
manufacturing Old design constraints for designers vs. too
much design freedom … Current design decisions based on known
limits of traditional manufacturing processes Machining, casting, plastic injection, etc.
3D modeling issues: Impossible to create specific CAD models for
AM – optimized with internal lattices No specific features, large models,
performance issues, etc. Impossible to simulate parts with internal
lattices Lattices created with external manufacturing
applications CAD reconstruction after external topological
optimization very painful and complex No printability check
Design rules, supporting structure, etc.
CAD models (exact representation)converted into tessellated models (approximation. E.g. STL format) to be manipulated for 3D printing
Often an intermediary software needed to prepare the files to be printed
Ensure watertightness Correct normals Assign colors …
One or several software applications for each 3D printer/printer manufacturer …
…
CAD/CAM and Additive ManufacturingTwo separated domains …
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CAD/CAMDomain
Source:
[1/2]
AM: a big impact on the design itself New, impossible before, geometries for
manufacturing Too much freedom vs. new design constraints
for designers … Current design decisions based on known
limits of traditional manufacturing processes Machining, casting, plastic injection, etc.
3D modeling issues: Impossible to create specific CAD models for
AM – optimized with internal lattices No specific features, large models,
performance issues, etc. Impossible to simulate parts with internal
lattices Lattices created with external manufacturing
applications CAD reconstruction after external topological
optimization very painful and complex No printability check
Design rules, supporting structure, etc.
AdditiveManufacturing
Domain
CAD models (exact representation)converted into tessellated models (approximation. E.g. STL format) to be manipulated for 3D printing
Often an intermediary software needed to prepare the files to be printed
Ensure watertightness Correct normals Assign colors …
One or several software applications for each 3D printer/printer manufacturer …
…
CAD/CAM and Additive ManufacturingTwo separated domains …
12
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[2/2]
Additive Manufacturing benefits:Still under-realized/under-achieved
13
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3rd Party ToolsLatticecreation
Latticeanalysis Print
validation OriginalDesign
A.2
Latticeoptimization
A.2.1RevisedDesign
[1/2]
Additive Manufacturing benefits:Still under-realized/under-achieved
14
Source:
3rd Party ToolsLatticecreation
Latticeanalysis Print
validation OriginalDesign
A.2
Latticeoptimization
A.2.1RevisedDesign
[2/2]
Lattice creation/optimization exploits the value of AMWithout specialized tools, designs are over-engineered and rarely optimized to take advantage of Additive Manufacturing
Reliance on 3rd party solutions and manual effort will not support long-term goals
Manual lattice creation and optimization: too tedious and costlyCAD + 3rd party solutions: manual, disconnected, cumbersome, expensive process that cannot be automated or optimized
Create/analyze lattice, validate geometry, recreate final B-rep geometry …
Additive Manufacturing can reallyrevolutionize engineering and design
Engineers want to… Create innovative products not
limited by the constraints of traditional manufacturing
Use a single solution for: 3D print design, analysis and geometry optimization
Eliminate 3rd party solutions and avoid time-consuming rework
Companies want to… Apply next-generation manufacturing
techniques to overcome barriers to manufacturing
Deliver products exceeding quality, performance and durability standards
Achieve competitive differentiation
15
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Lattice featureKey:
Creo Additive Manufacturing Extension (AMX)Lattice feature: creation, analysis and optimization
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Automated creation of 2 ½ D , 3D and Conformal Lattices Single feature with parametric control over all aspect of the lattice structure Full B-rep geometry (NOT an approximation using facet geometry)
Seamless analysis and optimization of lattice structure Lattices are optimized using Creo Simulate Idealized elements for faster analysis
Source:
Creo Additive Manufacturing Extension (AMX)Lattice feature: creation, analysis and optimization
17
Automated creation of 2 ½ D , 3D and Conformal Lattices Single feature with parametric control over all aspect of the lattice structure Full B-rep geometry (NOT an approximation using facet geometry)
Seamless analysis and optimization of lattice structure Lattices are optimized using Creo Simulate Idealized elements for faster analysis
ORIGINAL DESIGN
– Material: Titanium
– Tensile Yield Stress: 139.96 MPa
– Tensile Ultimate Stress: 219.94 MPa
– Mass: 6.09 kg
SIMULATION RESULTS
– Max Stress (Von Mises): 36.23 MPa
– Max Displacement: 0.044 mm
OPTIMIZED DESIGN
– Material: Titanium
– Tensile Yield Stress: 139.96 MPa
– Tensile Ultimate Stress: 219.94 MPa
– Mass: 3.28 kg ( – 46.21 %)
SIMULATION RESULTS
– Max Stress (Von Mises): 104.22 MPa
– Max Displacement: 0.086 mm
A.2
A.2.1*
A.2.1M
OPTIMIZEVALIDATE
A.2.1
A.2.1
A.2.1
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Creo Additive Manufacturing Extension (AMX)Other capabilities
3D Printers connectivity Broadening the ecosystem Bi-directional exchange of
information between Creo and 3D Printers
Tray assembly A repository for parts/assemblies
to be printed, assign material and store other attributes/parameters
Nesting A method for optimizing the tray
…
18
Source: [1/4]
Creo Additive Manufacturing Extension (AMX)Other capabilities
3D Printers connectivity Broadening the ecosystem Bi-directional exchange of
information between Creo and 3D Printers
Tray assembly A repository for parts/assemblies
to be printed, assign material and store other attributes/parameters
Nesting A method for optimizing the tray
…
19
Source: [2/4]
Creo Additive Manufacturing Extension (AMX)Other capabilities
3D Printers connectivity Broadening the ecosystem Bi-directional exchange of
information between Creo and 3D Printers
Tray assembly A repository for parts/assemblies
to be printed, assign material and store other attributes/parameters
Nesting A method for optimizing the tray
…
20
Source: [3/4]
Creo Additive Manufacturing Extension (AMX)Other capabilities
21
Source: [4/4]
❶ ❷ ❸
❹ ❺ ❻
❼
Creo Additive Manufacturing Extension (AMX)Beyond Creo 4.0
FUTURE
Tray Assembly
Analysis-driven lattices
+Topology
Optimization (Partners)
Printability Checking
(Parts + Assemblies)
ADDITIVE MFG
High-Order Facets
(Only Output)
3D Printer Connectivity(Stratasys and
others)
NC/ INSPECTION/
MOLD
2 ½ D & 3D Lattices
Split large parts
Support Structures
Optimization
ADDITIVE MFG
Multi & Graded
Materials
3D nesting
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PROFILO AZIENDALEFebbraio 2017
Dedagroup24
Siamo uno dei più importanti attori dell'Information Technology “Made in Italy”.
Supportiamo Aziende, Enti Pubblici e Istituti Finanziari nelle loro strategie IT con competenze applicative, tecnologiche e di systemintegration.
L’headquarter si trova a Trento – terra d’eccellenza per esperienze d’innovazione –ma il nostro Gruppo, con filiali in Italia e all’estero, supporta oltre 3.600 clienti in tutto il mondo.
Chi siamo NumeriMission
Accompagniamo aziende ed enti nella trasformazione digitale, aiutandoli a progettare il cambiamento.Con i nostri clienti e per i nostri clienti individuiamo strategie, architetture, soluzioni e competenze perché possano crescere e rimanere innovativi nel tempo. Partendo dall’Italia, terra d’eccellenza, portiamo le nostre soluzioni in tutto il mondo.
1.600+PERSONE
230 M€FATTURATO
10ANNI CONSECUTIVI DI CRESCITA
40PAESI IN CUI ABBIAMO CLIENTI
CAPACITÀ NEL SETTORE INDUSTRIALEFebbraio 2017
DISCRETE
MANUFACTURING
Segmenti26
AUTOMOTIVEMACHINERYAEROSPACEELECTRONICSMEDICAL DEVICESRAILWAYS
PROCESS
MANUFACTURING
BIOTECHNOLOGYFOOD & BEVERAGEOIL & GASCHEMICAL
DIVERSIFIED
MARKETS
GROCERYDISTRIBUTED FACILITIESWAREHOUSING
Punti di forza27
DISCRETE
MANUFACTURING
PROCESS
MANUFACTURINGDIVERSIFIED
MARKETS
KNOW-HOW SULLE PRATICHE INDUSTRIALI
GRANDE CAPACITÁ DI DELIVERY
ABILITÁ NELL’INTEGRAZIONE DI SOLUZIONI E PIATTAFORME
FORNITURA DI SERVIZI SPECIALIZZATI
"CROSS FERTILIZATION"
COPERTURA TERRITORIALE ESTESA IN ITALIA E ALL’ESTERO
PARTNERSHIPS QUALIFICATE
1.000+ CLIENTI
Discrete Manufacturing – Expertises28
SALES & MARKETING SUPPLY CHAINRESEARCH &
DEVELOPMENT MANUFACTURING AFTERMARKET SERVICES
OPERATIONS & COMPLIANCE
Design for MFG
CRM
Sentiment Analysis
Digital Marketing
Demand & Supply Planning
WarehouseManagement
TransportationManagement
Inventory Optimization
Finite CapacityScheduling
Performance-Based Monitoring/OEE
Process & Shop Floorcontrol systems
MES/SCADA
FinancialPlanning & Analysis
Treasury & Financial Risk Managemnt
Reach & CO2Omni Channel
MBSE/Systems Engineering
Conformity/Homologation
Prototyping & Testing Material Handling
Health & SafetyAdditive MFG Supplier/CustomerCollab.portals
Enterprise Resource Planning (ERP)
Quality
Product Data Management (PDM) – Product Lifecycle Management (PLM)
Change Management
Internet of Things (IoT)
Augmented Reality
Product Costing
Business Analytics/Big Data/Machine Learning
Requirements Management/ALM
CAD/CAM/CAEECAD
ServicePart Management
Predictive/ProactiveMaintenance
Repair & Tracking
SLM
Asset management
Additive MFG
TechnicalDocumentation
Health & Safety
Industrial IT – Capacità29
IT STRATEGY
Project & Program Management
Application management
Service management & Governance
Infrastructuresmanagement
Transition & transformation
Validation
Application integration
Cloud (SaaS, IaaS, BaaS)
Connectivity
Cybersecurity
HW & SW selection
Telecommunic.
HW & SW provisioning
EDI
Qualification & Auditing
Help Desk
Application development
IT Outsourcing
Business Process Outsourcing
Conoscenze tecnologiche e certificazioni Tecnologie CAD/CAM/CAE, PDM, ALM, PLM & IoT
PTC, Siemens, Dassault, AutoDesk, Mentor, etc.
VAR PTC dal 2001 Certificazione "PTC Windchill Authorized Partner" (PLM) Certificazione "PTC Integrity Configuration and Customization" (ALM) Certificazione "PTC's Authorized Training Partner" (CAD) Certificazioni "ThingWorx Implementer" (IoT)
Best practices/Metodologie
Conoscenza dei settori industriali Industria automobilistica Aerospaziale e Difesa Meccanica Elettronica e High Tech Scienze naturali
Esperienza nel processo di sviluppo prodotto Idea → Progettazione → Industrializzazione → Produzione → Servizi
Consulenza, integrazione e infrastruttura Qualificazione, auditing e pratiche di validazione tecnica
CO
NSU
LEN
ZA
INTE
GR
AZI
ON
EIN
FRA
STR
UT
TUR
A
Fornitura e supporto workstations e server
Hosting per applicazioni aziendali, virtualizzazione workstations e server
Manutenzione applicazioni, support tecnico, SPOC
Sviluppo e configurazione applicazioniCAD, PLM, IoT, integrazione di sistemi
Generazione della “visione” PLM/SLM/IoT, valutazioni AS-IS, business cases, business process reenginering
Servizi di supporto per l’ingegneria
Clo
ud
Fornitura di soluzioni software CAD, PLM, IoT
Sviluppo Prodotto → Servizi7
Partnerships31
