Transcript
AM and 3D print – From prototyping to manufacturing • • • • • •
Company presentation 3D printing - the first years 3D printing for production 3D printing to support development process New 3D printer 2016 Round-off conclusion and questions
Teledyne confidential and proprietary
Teledyne Marine Global Centers of Excellence
High Pressure Connectors
Cable/Seismic Assemblies
Vehicles Acoustics
Vehicles Instruments Dry Mate Connectors
Sub Sea Connectors
Instruments
Teledyne confidential and proprietary
3D printing - the first years • • • •
Purchase of Stratasys printer 2009 Printing tools and prototypes the first years Printer running 20-30% of available hours Printing for production begins late 2010
Feasibility model
Coil former prototype Fitting prototype
”Feel and touch model”
3D printing for production Cost reduction exercise •
From machining to printing
•
From COTS to printing
From machining to printing SeaBat 7125
Board support example Small component used for production and service
Machined delrin (until 2010) Cost machined: 130DKK/pc
ABS (from 2010) Cost printed: 27DKK/pc
Yearly cost saving: approx. 30,000DKK
From COTS to printing SeaBat 7150
Protection cap Using approx. 150pcs/year
Cost from manufacturer: 300DKK/pc
Cost printed: 50DKK/pc
Yearly cost saving: approx. 18,000DKK
3D printing to support development process
Challenges: Compact, Elegant, Marine Suitable • • • •
Re-arrange existing proven components High power handling thermal issues with heat transfer Small portable Rugged design suitable for use on small open survey boats
Heat transfer via cooling ribs and forced airflow
3D printed pump housing (largest that would fit)
Possible location of a compact, IP54 (at least) rated fan. Centrifugal fans move a lot of air, but aren’t suitable where pressure builds up and directional flow is required. COTS fans were way too big to fit desired cabinet shape. Turn a small compact COTS fan into a “pump” and verify concept.
The solution: To include printed part in assembly 3D printed air guide
Flexibility and cost reduction • Low stock level requirements • Easy re-prioritization between printed parts • Quick and easy revision changes
Revision 001
…002….003…
Revision 004
3D printer usage 2010-2015
Problem: Printer breaking down regularly due to wear Solution: New printer
Cost savings
Cost saving in one year: 233,270DKK on a printer costing 120,000DKK Questions that should be asked: • Would all tools have been made without a printer? • Is all cost for alternative production correct? • Is the cost for running the printer the same as ordering externally? • Is this a ”standard/normal” year?
New 3D printer 2016
• • • • • •
Higher speed Material options Higher precision Larger build area Larger material canisters RELIABILITY FOR PRODUCTION
New products 2016/2017
Rack-mounted Sonar Processor Parts developed for 3D printing
New products 2016/2017 ODOM MB2 Sonar head
BlueView M900-2250 Sonar head Parts developed for 3D printing
New printer 80,000
Sum of Material (cm³)
70,000
60,000 2010 50,000
2011
40,000
2012
30,000
2013
20,000
2014
10,000
2015 2016/2017
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2016/2017 – First year (11 months) with industrial grade printer (marked green)
And all the rest…. • • • • • • •
Fixtures Mold forms Prototypes Cutting tools Connector boxes One-off brackets Etc. Etc.…..
Headset is for size reference
Summary • • • •
Conclusions Using AM for production makes good sense in certain cases Getting to know the possibilities and challenges takes years Getting management convinced to invest in 3D printer requires business case Flexibility and direct cost savings are driving factors for using AM for production
• • • •
Wish list for 3D printer Less manual work Higher speed (not too fast for our purpose) Dense/impenetrable materials – being watertight is an advantage in our business Reduced material cost
Future of 3D printing in Teledyne RESON • More products will certainly contain AM parts • AM Group is forming under Teledyne Marine • Metal printing capabilities in the future…. Who knows?
Questions, comments, thoughts?
