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PLM and Additive Manufacturing

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by

Tim Pote

on 10 December 2014

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Transcript of PLM and Additive Manufacturing

Single Print 3D Motors
Progress
Printing with paste from 3D printer
PLM
New iterative loops in Manufacturing and Engineering creating faster iteration on design and manufacturing and lower distribution and overall life cycle cost
Future Application
Army research into 3D printing food for forward deployed soldiers
Additive Manufacturing

Quickly producing a physical object by adding material substrate, using a three dimensional CAD model as a blueprint.
PLM and Additive Manufacturing
Additive Manufacturing at Every Step
Unlike many technologies, implementing additive manufacturing into PLM has an impact on every step of the process
Custom Food
Remote production:
International Space Station
or the story of 3D printing
shiny things

Also known as: Rapid Prototyping, layered printing, 3D Printing
Common Forms
Photopolymerization -
light hardening liquid polymer
Fused Deposit Manufacturing (FDM) -
thermoplastics - wire filament or granular particles
Liquid extrusion -
pastes, food, plasters, ink
Laminate -
paper or other flat cut material
Granular binding -
lasers and electronic beams (titanium)
With Additive Manufacturing
Requirements
Analysis and Planning
Design and
Concept Engineering

Prototyping and
Product Engineering
Manufacturing and
Production
Sales and
Distribution
Recycling and
Disposal
Manufacturing
Engineering
New Iterative Loop
Reduces time between
prototype and design
iterative cycles based
on modifications
learned from prototype
creation
Recycled material can be reused during the manufacture of the next generation products or remanufactured into other 3D printable material and sold as a new product
Requirements for manufacturing using an additive method must be taken into account.
New processes may require a redesign of the part or process.
New designs are now possible using including:
Smaller scale
Part in part (pre-assembly)
Distributed manufacturing
Customization during manufacture
Prototypes can be made hours after the design process is complete and in distributed locations - like the design studio without waiting for costly and slow manufacturing processes
Retooling can be accomplished by using additive manufacturing to build new tool sets

Additive Manufacturing can cut down or eliminate the need to retool if an additive manufacturing step or steps are used
Producing components using additive manufacturing techniques can save energy, material, and the environment.
Distribution is simplified and expedited using a electronic methods to deliver CAD models to be printed at the source.
This reduced delivery time and transportation cost

Distribution to remote locations is also possible.
Completely customized products can be created for each individual.
Limited production runs are now economical as a result of nearly flat production cost for each part.
"[3D Printed Titanium parts] can be as strong as a machined part but use only 10% of the raw material..."
- The Economist , April 2012
"A Boeing F-18 fighter contains a number of printed parts such as air ducts..."
Open for Business: @NASA3DPrinter creates first object in space on @Space_Station:
http://www.nasa.gov/content/open-for-business-3-d-printer-creates-first-object-in-space-on-international-space-station/ …
- @NASA via Twitter
Audi 3D printed a prototype of their RSQ concept for the movie i-Robot
Sensors on the soldier would monitor nutrient levels in the body and report information to computers to customize food for the soldier
Remote updates to nutrition plan
Better Nutrition
More efficient calorie consumption
Healthier, more effective Soldiers
Every year the Army spends approximately
$5 Billion
on logistics including food transport
Custom Nutrition per Meal
- individualized for current need
Current Military Food
(MRE)
Expected deployment by 2025
Lower cost transportation
- generic ingredients and nutrients
Better tasting/textured
- on-demand food prep
New menu items
- remote updates
Quick feedback
-change what doesn't work
One print run - fully working motor directly from the printer: on centimeter scale
Liquid extrusion of Magnetic Polymer Paste using Fab@Home Model III 3D Printer
Next Step:
Two Material Inductor
$10,000/lb launch cost for Earth orbit
Manufacturing from recycled debris could reduce the amount spent on sending material into space by an order of magnitude
Rapid prototyping allows CAD files to be sent remotely, parts are manufactured on demand saving launch costs and storage space
Magnetic Paste
Printed Object
Extruder Tip
Resupply missions: Once a month
...and we're currently
dependent
on
for over
half
the logistics support...
What’s in an MRE (Meal Ready-to-Eat?

According to the United States Armed Forces, a MRE provides an average of 1,250 calories (13 percent protein, 36 percent fat, and 51 percent carbohydrates) and one-third of the Military Recommended Daily Allowance of vitamins and minerals.
-CNN
Generic Food
PLM With
Central
Database
Design and Requirements
ISS On Board
Manufacturing and recycling
Additive manufacturing of components in space

Models uploaded as needed
Recycling of in-orbit debris

PLM Disposal of previously manufactured items
Dual benefit: Cheaper material cost
Disposal of space debris
Resupply Management
Manufacturing is monitored

Materials that need to be replenished are be sent via resupply missions

Excess recycled materials are transported back to earth
Design Updates
Redesigns and live updates are pushed to the database and can be manufactured in hours after they go live

International collaboration by allowing access to files remotely
Parts need redesign to be compatible with additive manufacturing and materials found in space debris
“10-20-Militarylogisticssupport.pdf,” n.d.
account, NaSAVerified. “Open for Business: @NASA3DPrinter Creates First Object in Space on @Space_Station: Http://www.nasa.gov/content/open-for-Business-3-D-Printer-Creates-First-Object-in-Space-on-International-Space-Station/ … pic.twitter.com/eFWVL3V4JE.” Microblog, November 25, 2014. https://twitter.com/nasa.
“Army: Hot Breakfasts in Afghanistan Cut due to Logistics, Not Budget.” Accessed December 8, 2014. http://eatocracy.cnn.com/2013/01/30/army-hot-breakfasts-in-afghanistan-cut-due-to-logistics-not-budget/.
“Audi RSQ.” Wikipedia, the Free Encyclopedia, December 3, 2014. http://en.wikipedia.org/w/index.php?title=Audi_RSQ&oldid=605123320.
“Chow from a 3-D Printer? Natick Researchers Are Working on It | Article | The United States Army.” Accessed December 8, 2014. http://www.army.mil/article/130154/.
“NASA - Advanced Space Transportation Program Fact Sheet.” Accessed December 8, 2014. http://www.nasa.gov/centers/marshall/news/background/facts/astp.html_prt.htm.
Shahani, Aarti. “Army Eyes 3-D Printed Food For Soldiers.” NPR.org. Accessed December 8, 2014. http://www.npr.org/blogs/alltechconsidered/2014/11/04/361187352/army-eyes-3d-printed-food-for-soldiers.
“Solid Print.” The Economist, April 21, 2012. http://www.economist.com/node/21552892.
“We Need to Keep Printer Manufacturers Away from Filament.” 3D Genius - The Home of 3D Printing. Accessed December 8, 2014. http://www.3dgeni.us/we-need-to-keep-printer-manufacturers-away-from-filament/.
References
NASA and ISS
ESA
NASA
CNSA
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