International Conference 2005:
Future Industrial Applications of Rapid Prototyping & Manufacturing

Presented by

Date and Time: Friday 2 December 2005, 9:30 – 17:00
Location: Exhibition Center Frankfurt, Hall 9.1, Room Logos
Organizer: DEMAT GmbH (Frankfurt, Germany)
Chairman: Terry Wohlers, Wohlers Associates, Inc.

Conference Language: English
Fee Per Session: EUR 70 + 16% VAT. Includes entrance into the conference and trade fair, technical papers, lunch, GARPA reception and party, and a chance to win valuable prizes. 
Registration: Phone 49 69 27 40 03 30, fax 49 69 27 40 03 40,

Now in its seventh year, this conference has established itself as one of the most important events at EuroMold. Each year, world-class speakers focus on emerging applications, developments, and trends in additive fabrication. Through the careful selection of speakers, each with something very special to share, this conference has gained a reputation of delivering on its promise.

Additive processes for applications, such as rapid prototyping, are becoming increasingly popular in a growing range of industries. Aerospace and automotive helped to pioneer its use in the late 1980s and early 1990s. Consumer products, such as hand held electronics, footwear, power tools, sporting goods, and other industries subsequently benefited from additive processes. Most recently, medicine, dentistry, architecture, jewelry, and micro systems are benefiting from the technology as new applications are discovered that were before unthinkable.

9:30     Dr. Eberhard Döring, Chief Executive
               DEMAT GmbH (Germany)

           Growth of Industrial Applications
           Mr. Terry Wohlers, President
           Wohlers Associates, Inc. (USA)

The automotive and aerospace industries continue to serve an important role in the application of additive fabrication technology. However, companies that design, prototype, and manufacture consumer products and electronics have emerged as the leading industrial sector to embrace additive processes. Surprisingly, parts used by all organizations for fit and function applications have declined 6.1% to 27.8% from 2004 to 2005. Meanwhile, parts used for visual applications have increased 5.8% to 31.6%. It is believed that the rapid growth of 3D printers accounts for this change.

Session 1 Automotive

10:00   Automotive Industry's Past, Present, and Future
           Mr. Graham Tromans, Manager of the Rapid Manufacturing Consortium
           Loughborough University (England)

The automotive industry has used additive fabrication technologies extensively as a stand-alone process or in combination with other processes, such as metal casting and tooling. This industry is still seen as one of the pioneers in the use of additive processes and their integration into product development. The industry has progressed considerably since those heady days of the early 1990s, so much so that some of the technologies in certain industries are now being used as production processes. Tromans will focus on how additive technologies have developed to allow for more functional parts and will look into the future of rapid manufacturing and custom part production.   

10:30   Future of Rapid Manufacturing
           Mr. Martin Augsburg, Research & Process Engineer
           BMW Group (Germany)

The automotive industry has a high interest in rapid manufacturing due to the potential speed, cost savings, and flexibility that it offers. In the future, low production volumes will be made possible from the 1) development of specific technologies that hold the most promise, 2) identification of applications that offer the most cost savings, and 3) transfer of know-how, such as freedom of design, into adaptable organizations. Looking beyond, visions of future technologies become possible that may lead to completely new automotive applications. 

11:00   Break

Session 2 Aerospace and Military

11:30   Exploitation of Additive Manufacturing at Airbus UK
           Mr. John Hammond, Group Leader
           Airbus UK (England)

Airbus UK has been active in additive manufacturing technologies for 13 years. Additive processes have been widely adopted for wind tunnel model testing across Europe. Most recently, Airbus faced a wind tunnel model design challenge involving the delivery of high-pressure air to power turbine engines within a limited space envelope. Laser sintering was found as the only design and manufacturing solution that would meet the commercial budgets and project deadlines. The efforts and experiences in exploiting today's state of the art additive technologies by the wind tunnel community are recognized as a key validation platform for the wider manufacturing enterprise.

12:00   Laser Sintered Parts in Manufacturing
           Mr. Roger Spielman, Technology Development Manager
           Solid Concepts (USA)

Spielman will present a review of the past and present efforts in using laser sintering technology to manufacture series production parts. The review will begin with the first qualification of the technology for use in man-rated space environments during the mid 1990s. He will then focus on the technology's commercialization into the private sector and what the future holds. Also, he will describe some of the benefits and pitfalls of dealing with an emerging technology.

12:30   Buffet Lunch

Session 3 Medical and Dental

14:30   Current State of Medical Applications
           Mr. Andrew Christensen, President
           Medical Modeling LLC (USA)

Creating physical models from medical imaging data using additive fabrication is but one example of how medicine is embracing the technology. Surgeons around the world now rely on physical anatomical models for planning surgeries so complex that they would not have attempted them several years ago without this technology. Medical device manufacturers have also grasped the concept of medical modeling, taking patient-specific images and turning them into valuable databases for the next hip or wrist prosthesis design. Researchers studying everything from bone density to fracture healing are using the latest in imaging technology in combination with additive techniques to see what otherwise could only be imagined. Today’s medical applications are much more than bone modeling, yet the medical industry is still only scratching the surface.    

15:00   Creating Dental Devices with Additive Manufacturing
           Dr. Stephen Schmitt DDS, President
           Dental Implant Technologies, Inc. (USA)

Advances in medical imaging, CAD software, and additive manufacturing technology have created an ideal environment to create custom dental devices. The traditional manufacturing methods are labor intensive and quality is inconsistent. The manufacture of custom dental restorations attached to dental implants is an area of intense interest because the cost of the traditional process is very high. These new technologies have the potential to reduce cost and improve quality. Dr. Schmitt will illustrate methods of data capture, prosthesis design, and additive manufacturing using 3D printing, selective laser melting, and investment casting.

15:30   Break

Session 4 Architectural and Jewelry

16:00   Opportunities in Architecture: The Challenges of a New Market  
           Mr. Charles Overy, Founding Principal and Director of Engineering
           LGM (USA)

Additive fabrication has always held tremendous potential for the architectural and land planning markets. In the past year, some of the promise has turned into reality with architects, service providers, and machine manufacturers demonstrating significant interest in each other’s businesses. However, rapid and successful growth into new markets requires an understanding of the unique process requirements, market drivers, and technology synergies that exist. It is important that the challenges presented by this new market are understood and addressed.

16:30   Laser Sintering of Gold Jewelry
           Ms. Lena Thorsson, Co-owner
           Particular AB (Sweden)  

Innovative design of high-end precious jewelry is hindered by the geometrical constraints imposed by standard methods of manufacturing. Therefore, companies are having difficulties in differentiating themselves in the market place. Also, the large number of manufacturing steps, from designer’s sketch to prototype, complicates the process of reducing time-to-market for new products. Particular’s solution to the problem is to manufacture 18k gold jewelry using laser sintering. The process allows for more efficient production of elaborate products with new and unique designs. Thorsson will compare and discuss traditional and new methods of jewelry manufacturing.

17:15   GARPA Party & Reception

Meet representatives from the Global Alliance of Rapid Prototyping Associations (GARPA) and win valuable gifts and prizes.