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RAPDASA and Formnext

November 17, 2018

Filed under: 3D printing,additive manufacturing,education,event — Terry Wohlers @ 17:11

I attended last week’s 19th annual conference and exhibition of the Rapid Product Development Association of South Africa (RAPDASA) in Johannesburg. About 220 people attended from several countries. The RAPDASA organization does a fantastic job with the event year after year, and this year was no exception. (I’ve attended all 19 of them.) Thanks to the fine people at Resolution Circle and the University of Johannesburg for hosting the event, and many others who worked hard to make it a success. Pictured in the following image are Ian van Zyl and Deon de Beer, both of Central University of Technology (CUT), and Amelia Du Toit of Lonmin, and me. CUT and Lonmin are a part of an interesting project named PlatForum, which involves the development and 3D printing of parts in platinum.

This week was Formnext, a trade fair in Frankfurt, Germany, which included much of the best in additive manufacturing products and services worldwide. An estimated 26,919 people and 632 exhibitors filled two large exhibition halls at Messe Frankfurt. AM machines and parts dominated, but design software products for AM and post-processing machinery were also in abundance at this year’s fourth annual event. The development of end-to-end process chains has never been more important and it was evident. The following image shows the XJet exhibit—one of the many impressive displays at Formnext.

On November 14 at Formnext, a half-day Additive Manufacturing Standards Forum was held. It was initiated by America Makes and the American National Standards Institute (ANSI) with support from the U.S. Department of Commerce’s U.S. Commercial Service in Düsseldorf. The purpose of the half-day session was to bring together key stakeholders and others to provide an update, answer questions, and discuss AM standards development worldwide. I had the privilege of moderating the session. The following shows the organizations that supported the event.

An important part of this session was the presentation of the America Makes and ANSI Standardization Roadmap for Additive Manufacturing (Version 2.0) and the Additive Manufacturing Standardization Collaborative (AMSC). Both could have a long-term impact on the adoption of AM around the world.

After 14 days on four continents, it was nice to return to Colorado. I like to meet with friends and make new ones, but it’s also good to be home with family and friends, especially over the holidays. (Thanksgiving is next week in the U.S.) The ski season is underway, so it’s time to visit the high country to take part in a sport that is relaxing and exhilarating. It’s a great compliment to a full and rewarding year of travel and work.

AM in Africa

October 21, 2018

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education,event — Terry Wohlers @ 07:29

Yesterday, I recently returned from my 22nd visit to Africa. Twenty of them have been to South Africa where additive manufacturing activity is the strongest. In fact, I estimate that 99% of AM work on the continent has occurred in the country. Some limited activity is underway in Botswana, Egypt, Namibia, and Nigeria. Adoption has been especially strong at Central University of Technology, Vaal University of Technology, Stellenbosch University, and North-West University—all in South Africa.

The Government of South Africa has been supportive of AM, with the Council for Scientific and Industrial Research (CSIR) doing the most in a hands-on way. Among the companies that are leading the way is Aerosud, an 800-person supplier of parts and assemblies to Airbus and Boeing. Many other companies are benefiting from AM parts, but they do not own high-end equipment. A reseller network of companies for AM products has been in place for many years.

Central University of Technology (CUT) in Bloemfontein was the first to install multiple high-end industrial machines in South Africa. Its world-class Centre for Rapid Prototyping and Manufacturing (CRPM), shown in the following two images, continues to have the largest commercial impact in the country. Last year, the CRPM completed 580 projects consisting of ~13,500 AM parts. Twenty-five percent of the projects were medical cases, most of high complexity. The centre received ISO 13485 quality certification for medical devices in 2016, which has contributed to its capabilities.

CUT and its impressive CRPM served as host to last week’s three-day course on design for additive manufacturing (DfAM) conducted by Wohlers Associates. Twenty-five engineers and others participated, and many were advanced in their knowledge and experience in AM and DfAM when they arrived. Wohlers Associates has conducted many of these courses, the first in August 2015 for NASA Marshall Space Flight Center. One exercise involved the redesign of a manifold by the participants on the first day. Five of them were manufactured in titanium and delivered for inspection by the third day. Thanks to our good friends at the CRPM for helping to make this happen.

The previous images show the conventional manifold design (left) and five versions of the manifold produced by AM. One of the primary objectives of this hands-on, DfAM exercise was to reduce weight and substantially reduce or eliminate the need for support material, which can add substantial time and cost to a part. We are thankful to those who participated, for how engaging they were, and for their favorable feedback. It was one of our very best three-day DfAM courses. Thanks also to CUT and its CRPM for organizing the event and serving as such great hosts.

The Impact of DfAM

June 16, 2018

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education,manufacturing — Terry Wohlers @ 11:22

Note: Associate consultant and DfAM expert Olaf Diegel authored the following.

Over the past three decades, the bulk of research in additive manufacturing has largely focused on AM processes and materials. In the last three years, organizations have begun to appreciate the importance of design for additive manufacturing (DfAM). Funding agencies are increasingly supporting DfAM, and companies are asking for courses on the subject. Over the past 12 months, I have given more than 20 DfAM courses for companies wanting to deepen their knowledge and understanding.

When a part is designed for conventional manufacturing, it is usually more expensive to produce by AM in typical production quantities. This is largely because AM processes are relatively slow compared to conventional methods of manufacturing. However, when a part is redesigned for AM, costs can be competitive or even lower, depending on quantities. Research for Wohlers Report 2018 revealed that 46% of the cost of a metal part is tied to pre- and post-processing. A large part of this cost often involves the production and removal of the support structures, also referred to as anchors. A well-designed part can greatly reduce the need for this support material, which dramatically reduces cost.

Good methods of DfAM can add value to products by making them substantially lighter in weight and enhancing performance using topology optimization, generative design, and lattice structures. Conventionally manufactured products made up of many simple parts can be redesigned to consolidate the assembly into a single part. This reduces part numbers, inventory, and assembly costs. Using methods of mass-customization, products can conform to the individual needs of customers without substantially increasing cost. Knowing how and when to use these techniques require designers and engineers to learn how to design for AM.

One of the biggest barriers to the widespread adoption of AM is the lack of knowledge and skills among the design and engineering workforce. Only through DfAM education, training, and best practices will we see significant progress toward the use of AM for production applications. Some organizations are beginning to understand its importance, but a vast amount of work is ahead.

Editor’s note: Wohlers Associates is conducting a three-day course on DfAM in the Rocky Mountains of Colorado, with Olaf Diegel as lead instructor. Click here to learn more.

Design for AM in Montreal

May 20, 2018

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education — Terry Wohlers @ 13:28

Design for additive manufacturing (DfAM) is a key to unlocking the power of AM. Neglecting to understand its importance may present a problem for companies hoping to tap into the technology’s potential. It is quite possibly the most challenging piece of the AM puzzle and requires far more than what meets the eye.

To justify the use of AM for production applications, a well-advised company will perform an analysis on the cost to manufacture the design, both conventionally and by AM. Doing so can determine the “breakeven” point of AM versus a conventional method of manufacturing. The effort seeks to determine the volume at which it costs the same to make the part using either method. If you are producing parts up to the breakeven point, AM may be a candidate for production. The higher the breakeven point, the more attractive AM usually becomes.

If a design is not modified for AM, the breakeven point may be too low, meaning that AM is probably not suitable. If a part or assembly is redesigned to take advantage of AM, the breakeven point may be higher, and in some cases, dramatically higher. Consider, for example, the possible economic impact of consolidating many individual parts into one, as shown in the following relatively simple example.

DfAM is the subject of a hands-on course being offered June 12-14, 2018 in Montreal, Canada. Up to 20 practicing professionals will gather to learn the latest tools and methods of part consolidation, topology optimization, lattice structures, and biomimicry. The course will uncover important design rules and guidelines (e.g., thinnest walls and smallest holes possible, depending on the process and material), part orientation, and support material. These elements of design can impact build time, cost, and trial ‘n error. They can result in a reduction in the number of suppliers, manufacturing processes, tooling, inventory, assembly, labor, maintenance, and certification paperwork. Good DfAM tools and methods result in parts that use less material and are lighter in weight, with scrap reduced to a minimum.

Wohlers Associates and the Québec Industrial Research Centre (CRIQ) have partnered to offer this important DfAM course. If you want to benefit from what AM has to offer for production applications, contact Martin Lavoie at dfammtl2018@gmail.com to register for the course.

Important Events in AM

April 22, 2018

Last week, I attended the 20th Annual FIRPA Conference in Espoo, Finland, which is about 20 km (12 miles) from Helsinki. The event included some excellent presentations, including one from Jonas Eriksson of Siemens Industrial Turbomachinery AB. Eriksson discussed the production of parts by additive manufacturing for land-based gas turbine engines. To date, the company has redesigned many parts for metal AM and used the technology to produce more than 1,000 burner tips. The use of AM has resulted in a time reduction from 26 weeks to just three. As many as 60 people are now focused on AM at the company, with a goal of making metal AM as simple as 2D printing on paper.

Another very interesting presentation was given by Jyrki Saarinen of the University of Eastern Finland. His group worked closely with Dutch company Luxexcel to produce an AM machine with 1,000 inkjet nozzles for the printing of optical lenses in PMMA. The surface finish of the printed lenses is <2 nm RMS (less than 2 billionths of a meter), so no post-processing is required. The machine is capable of producing 40 lenses per hour, each measuring 10 mm in diameter x 2.5 mm in height, so the process is relatively fast.

I also had the privilege of visiting two world-class companies in Finland. The first was KONE, an $11 billion manufacturer of elevators, escalators, exterior revolving doors, and security entrances for commercial buildings. The company and its products are impressive. I also visited UPM, a $12.3 billion company with a strong position in paper, pulp, plywood, composites, and bio products. The company recently entered the AM industry by introducing a material extrusion filament product consisting of cellulose fiber and PLA.

Last week’s trip to Finland could not have gone better, thanks to the fine people that organized the meetings and very successful 20th annual conference. This week, the focus is on RAPID + TCT 2018, which begins tomorrow and goes through Thursday in Fort Worth, Texas. This event marks the 26th annual conference and exposition, and I’m proud to say that I have not missed a single one of them. Attendance has grown by ~2.3 times over the past four years and exhibit space has grown by ~4.5 times over the same period. If you are interested in attending one of the very best events in all things additive manufacturing, 3D printing, and 3D scanning, go to Fort Worth this week. You will not regret it.

formnext 2017

November 18, 2017

In only its third year, formnext has quickly become the additive manufacturing event in Europe to see and to be seen. I attended last year’s formnext and shared here the impression it made. In my view, it was the most impactful additive manufacturing industry event in Europe that I had attended in my 30+ years of going to them. This week’s four-day event, held again in Frankfurt, Germany, has topped it. Three of us from Wohlers Associates were there.

With few exceptions, the most important AM companies worldwide exhibited their products and services at the Messe Frankfurt Convention Center. The exhibition filled most of two large halls. Conspicuous by its absence, one fast-growing AM system manufacturer did not exhibit, and I’m reasonably certain that it is regretting the decision.

Similar to last year, all things metal was in force at formnext. Desktop Metal, EOS, GE Additive, Renishaw, SLM Solutions, and many others showed their latest machines and parts in large, elaborate exhibits. Even HP showed parts from a metal 3D printing technology it is planning to introduce next year.

The scale of some of the new machines is striking, along with the large and complex parts coming from them. The quality of exhibits, people, and announcements at formnext signaled how far the AM industry has developed and matured in the recent past. It was great to meet so many engineers, top managers, and visitors from around the world.

Congrats to Mesago for the impressive formnext exhibition and to the TCT Group for the expertly-organized four-day conference. The formnext event grew from nothing to something very special in three short years. Other events have taken a decade or longer to reach this point and many never have. Next year’s formnext is November 13-16, again in Frankfurt, so add it to your calendar now and begin to make plans. It has become THE place in Europe to conduct business in the AM industry.

CSU’s Idea2Product Lab

October 9, 2017

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education — Terry Wohlers @ 09:53

Note: The following was authored by Ray Huff, manager of the I2P lab at Colorado State University. He is an intern at Wohlers Associates.

At universities worldwide, 3D printing is unlocking doors previously unavailable to students, staff, and others. Five years ago, David Prawel introduced Colorado State University to 3D printing with a single RepRap 3D printer in the mechanical engineering department. News of the new technology spread quickly, and soon Prawel spun off a dedicated lab providing 3D printing education and services. The lab was modeled after Idea 2 Product (I2P) labs originally launched in South Africa by professor Deon de Beer.

I was introduced to the I2P lab in mid 2014. I had spent the first half of that year managing a fledgling web marketing startup in Denver, and was looking to shift into a more dynamic industry. After some preliminary research into the 3D printing industry in Colorado, I came across an open house at Colorado State hosted by the I2P lab. It included a symposium featuring Terry Wohlers, Andy Christensen, and others in Colorado. I was blown away by the amazing, cutting edge developments in my backyard. It was then I knew I had to find a way into this industry. A year later, while working at then 3D-printing startup Aleph Objects, I was encouraged to pursue a degree in engineering, and that brought me back to Colorado State and the I2P lab.

I accepted an offer to serve as lab manager during my first year and was immediately exposed to more developmental projects than I could have imagined. Entrepreneurs came to the lab seeking help in 3D modeling and proof-of-concept development. Researchers designed custom apparatuses for their experiments and fabricated them on the spot. Educators learned to think creatively in completely new ways to clearly demonstrate difficult concepts. Artists came to modify and replicate their models digitally and physically using 3D scanning and printing. Veterinary surgeons brought CT scan data to create bone and organ analogies in preparation for surgical procedures. Countless engineering students began to produce models of their designs from classes and projects. I found that with a little bit of education and guidance, people of all backgrounds can go further and faster with their ideas and innovations than ever before.

Today, the I2P lab looks vastly different than it did in the days of a single student running one 3D printer. Over the past two years, the I2P lab customer base has doubled to more than 700 registered users. The lab boasts 20 3D printers of both material extrusion and vat photopolymerization technologies. Users come from across campus and the community to make their dreams into realities.

As these technologies mature and become less expensive to implement, labs like I2P are developing and multiplying in nearly every corner of education. Already, maker spaces, schools at many levels, and even libraries are benefiting from the creative freedom offered by 3D printing, 3D scanning, and design software to empower the community. They are being challenged to transform ideas into realities that affect and improve lives.

It’s All About the People

August 14, 2017

Filed under: education,life,manufacturing — Terry Wohlers @ 07:27

Note: The following was authored by Doug Rhoda, CEO of DMS (Colorado Springs, Colorado). Rhoda was directly responsible for hiring more than 200 interns while CEO of Wolf Robotics (Fort Collins, Colorado). Today, an estimated 75% of Wolf’s permanent employees came from internships.

In my personal leadership and management journey, people that make up a team are the distinguishing factor of any business. My former mentor, now deceased, would coach me as I was growing a struggling robotic welding company, and he would say “It’s all about the people.”

Getting the right people “on the bus” is one of the most important tasks of a leader. Although not quick or expedient, I have found that building long-term mutual beneficial relationships with local universities and developing internship programs have been critical to getting the best people.

In spite of some of the headlines today, I have found reason for optimism with today’s young people. I have had the privilege of hiring and coaching so many millennials that are bright, hard-working, and capable. Like anyone, they are looking for autonomy (not to be micro-managed), mastery (to learn), and purpose in their work.

Our recipe, refined over the years, challenges young people. Our student interns start on the factory floor, getting their hands dirty, and learning our machines from the ground up. While they are in the factory, they are being evaluated by senior factory floor leaders to determine whether the individual has the right work ethic, attitude, and ability to learn.

An internship is like an extended interview. It’s an interview of the student by our staff, and it’s an interview of the company by the student. During the internship, the intern can determine whether the company and industry are of interest for long-term employment.

If the person is right and the economics justify it, we will hire graduating interns into full-time positions. In the case of engineering students, they are hired into a field service role, where they learn how the machines are applied and what customers value. We have found that after their customer service stint, the former interns discern where their passion and interests lie, and self-select—with our involvement—key roles in the business. Among them are design engineering, project management, and software development. Because of their strong foundation in the business, they contribute in unique and precious ways.

Talent recruited and developed through internships have been critical success factors in the businesses in which I have had the honor of being responsible. We will continue to invest in our internship programs to grow our business because it’s all about the people.

DfAM at Materialise

June 4, 2017

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education,event — Terry Wohlers @ 13:27

What does a major German car manufacturer, surgeon from Brazil, producer of food-making equipment, and large toy maker have in common? All are interested in methods of design for additive manufacturing (DfAM). Twenty-five people from five continents came together last week to explore, discuss, and learn how to design products for AM. Also represented were manufacturers of pumps, audio systems for cars, data projection systems, packaging equipment, heavy industrial products, and large vacuum systems. Key service providers from South Africa and China also participated.

The advanced, three-day course from Wohlers Associates took a deep dive into methods of DfAM, including the consolidation of many parts into one to reduce tooling, manufacturing, and inventory costs. The training, held in Leuven, Belgium, provided guidance on design optimization for reducing the use of material and making parts as light as possible. The participants used their own CAD software, along with Inspire from solidThinking for topology optimization and Magics Structures from Materialise for lattices and meshes.

Materialise hosted the event and provided five DfAM experts in a 75-minute panel session. The company also gave an outstanding 90-minute tour of its impressive facilities. It was helpful to those in attendance to see the wide range of machines, parts, and new businesses at Materialise. One example is the production of Yuniku 3D scanning systems for custom eyewear. The prescription eyeglasses are designed so that the optics are located in the optimal location relative to the eyes. They come with beautifully-designed frames that are produced by AM at Materialise.

We are thrilled with the participant feedback and glad the training went so well. Even so, we plan to make a number of adjustments prior to offering it again. A big thank you goes to those who attended from around the world and to the fine people at Materialise for contributing to its success. We could not have partnered with a better company.

25 Years of RAPID

May 6, 2017

Next week is RAPID+TCT 2017, North America’s largest conference and exposition on additive manufacturing (AM) and 3D printing. It also includes CAD, 3D scanning, and other design and manufacturing products and services. The event marks the 25th year for me to attend the event. Although I don’t have hard proof, I’m reasonably certain I stand alone in that category, for what it’s worth. SME, the organization that launched the event in May 1993, has generously invited me to speak at RAPID for 25 consecutive years.

RAPID has been the go-to event in this region of the world for all things 3D printing. The multi-day, multi-track conference has always been the strength of the event and a big reason why people attend. With more than 330 exhibitors from around the world, the exposition is now a very serious part of it. UK-based Rapid News Communications Group, with its strong TCT brand, has partnered with SME for the first time. RAPID+TCT has the potential to grow significantly as organizations around the world expand their use of AM.

As usual, I’m looking forward to next week. I like to attend the conference sessions and see new products and services in the exposition. Meeting people, however, is a major reason why many choose to attend. Business is conducted, ideas are explored, and new friendships are forged. The people in attendance have been a big part of why I like to participate year after year. If you’re going to be in Pittsburgh next week to attend RAPID+TCT, I look forward to seeing you there!

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