Metal Additive Manufacturing - Basics Zero to One - June 2018b

MetalAdditiveManufacturing
GettingStarted–AZerotoOneBrief
Matthew Burris
September 2017, minor revisions June 2018

1 Matthew Burris | www.LinkedIn.com/in/MrBurris
MetalAdditiveManufacturing-Hypevs.Reality
http://sloanreview.mit.edu/article/getting-past-the-hype-about-3-d-printing/
http://www.tandfonline.com/doi/abs/10.5437/08956308X5606193
Hype – Promise Reality - Limitation
One click – print anything Multiple materials are very
difficult to combine effectively
Economies of one – affordable
single part manufacturing
Machine, materials, and design
expenses keep costs high
Complexity in designs is free Within the limitation of the
process and cost of design
Manufacturing will become
local
Consolidation of service and
manufacturing centers
Mass customization Yes, with a digitization method
Everyone will own the means
to manufacturing
Access yes, but not ownership
With all of the complexities and challenges of Metal Additive
Manufacturing (AM), it may never live up to its hype. But it has
already begun to reshape parts of the manufacturing landscape,
especially in aerospace, injection molding, and medical
applications.
Metal AM is still in its infancy, has a steep learning curve, little
infrastructure, and high costs. These limitations shape its
applications today. The economics of Metal AM are improving and
additive design approaches are able to deliver significant
performance improvements in the right applications.
The hype around additive is strong, but it is becoming a preferred
manufacturing method when compared to many traditional
manufacturing approaches. Metal AM has already begun to have a
significant impact in the aerospace industry with the potential to
reduce manufacturing costs by 25% according to GE, a significant
economic improvement in a mature industry.
“3D Printing is going to be way bigger than what the 3D printing companies are saying.”
– Credit Suisse, 2013
KeyTakeaway-Don’tlethypedistractyoufromtheimpactandvaluethatmetalAMcandelivertoday

MetalAdditiveManufacturingisComplexandHardtoMaster
Metal AM is far from a simple
process. With over 100 variables
that can impact the printing process
of laser powder bed fusion, it is
much more complex than CNC
machining. Metal AM has more in
common with semiconductor
manufacturing than traditional
manufacturing processes. It even
shares several of the process
parameters and challenges such as
feature size, environmental
controls, and stress build up.
Dialing in the parameters is
essential to manufacturing parts
with the desired properties.
Process Parameters in Metal Additive Manufacturing
Additive has the potential to change the balance of power between OEMs and suppliers. Traditionally, machinists added value through their
deep experience operating machines, applying that knowledge to turn a drawing in to a part. Additive manufacturing embraces digital
feedback and control systems at a fundamental level, enabling the machinists touch and skills to be directly embedded in to the design files.
When OEMs can specify precise manufacturing details, the role of the supplier may shift and with it the value and need for skilled machinists.
http://www.sintavia.com/services/am-parameter-optimization/
Complexity Abounds in AM

MetalAdditiveManufacturingisStillinitsInfancy
Metal AM’s knowledge base and support ecosystem are immature,
although parts of the ecosystem are more developed than others. The
complexities of the process make adopting AM a challenge across the
board. Some of the major challenges include:
• A lack of established design rules and limited simulation support
lead to low first time print success rates.
• A limited number of available materials with known material
properties limit applications.
• The number of variables in the process make developing new
materials with predictable properties time consuming and
expensive.
• The technology and support software is improving so rapidly that
the gap between mastering the current generation and the arrival of
the next generation is minimal.
• Machine to machine and OEM to OEM variances create lock in for
many production applications on single platforms.
• Process complexities are impacted significantly by the entire supply
chain from material suppliers through post processing.
• Limited number of skilled and experienced engineers, designers,
and machine operators
• Increased expense in certifying additively manufactured parts as an
acceptable manufacturing method
First time print success rate is low
Lack of standard material properties
Time to master technology vs time for
new technology to emerge
Machine to Machine & OEM to OEM
output variances
Standards beginning to emerge (ASTM &
ISO)
Large learning curve for additive designing
https://www.ansi.org/standards_activities/standards_boards_panels/amsc/Default.aspx?menuid=3

MetalAdditiveManufacturingGrowthProjectionsareStrongDespite
CostsandChallenges
Metal AM has seen an average growth
rate of over 45% for the last five years and
is predicted to remain above 25% for the
next decade.
The Additive Manufacturing Market has
been projected to grow to become as
much as 5% of the $15T manufacturing
market, according to Terry Wohlers,
industry expert and author of the Wohlers
Report on Additive Manufacturing. This
projection supported by McKinsey’s
estimate for the value of the additive
industry to grow to more than $450B by
2025, if it is adopted for production
applications.
With GE’s recent metal AM acquisitions,
Airbus’s goal of using additive to make
50% of their future aircraft parts, and
Michelins development of a metal additive
system to make injection mold inserts, it is
clear that major manufacturers are
planning for a production focused future
for Metal Additive Manufacturing.
Major Metal AM
Adoptors
https://www.rolandberger.com/publications/publication_pdf/roland_berge
r_additive_manufacturing_next_generation_amnx_study_20160412.pdf

GeneralElectricFoundValueinMetalAMtoJustify$15BofInvestment
http://www.ge.com/sites/default/files/ge_webcast_presentation_009062016_0.pdf
GE’s metal AM journey began in the early 2000’s working with Morris
Technologies to develop an additive design for a fuel nozzle on the LEAP
engine. Their +10 year journey taught GE Aviation where and how they
could extract value from AM. GE has been a strong, public voice supporting
the adoption and advancement of AM because of the massive
performance improvements they have found. Such as:
• Up to 5x greater engineering productivity enabling smaller teams
• Up to 300:1 reduction in part count
• 40 data systems consolidated to 1
• 50 manufacturing and inspection source reduced to 1
• 5 repair sources reduced to 1
GE’s experience with AM lead them to embrace a transformational
productivity strategy with AM at its core. GE’s Projected Wins with their
Transformational Productivity Strategy and Metal AM include:
• 25% lower service costs for GE Aviation
• 25% lower production costs
• 4x faster product development
• Production savings of $140k to $650k per engine
GE expects an internal demand of 1,000 systems by 2025, an estimated
$800M commitment.
The Impact of AM Across GE’s Supply Chain

GeneralElectricMaximizedtheValueofMetalAdditiveManufacturing
byCombinedMultipleValueLevers
Catalyst Engine
The Catalyst Engine (formerly the Advanced
Turboprop Engine) was designed from the
ground up with additive manufacturing. The effort
had a massive impact on the design, cost, and
capabilities of the engine.
• Removing 845 parts
• Reduced cost by 20%
• No structural castings
• Reduced weight by 35%
http://www.ge.com/sites/default/files/ge_webcast_
presentation_009062016_0.pdf
Fuel Nozzle
The culmination of working with Morris
Technologies (acquired by GE Aviation) since the
early 2000’s, was the fuel nozzle for the CFM LEAP
engine (a GE-Safran partnership). The unique
design enabled by additive delivered:
• 18 to 1 part reduction
• 5x increase in durability
• 25% lighter weight
• Cost savings
http://www.geglobalresearch.com/innovation/3d-
printing-creates-new-parts-aircraft-engines
Control Valve
GE Oil & Gas used metal additive to produce a
control valve with hundreds of narrow holes and
flow channels in the valve wall for the Kariwa
Nuclear Power Plant in Japan in one year.
• 4x faster manufacturing speed (2 weeks
instead of the typical 3 months)
• Reduced part count. Multiple parts that were
brazed together were printed as a single part.
http://additivemanufacturing.com/2015/03/02/ge-
the-human-touch-these-japanese-metalworkers-
use-their-hands-to-take-3d-printing-to-the-next-
level/
Key Takeaway – GE used multiple value creation techniques on each successful part and redesigned each part to
get the most value from using additive manufacturing.

TheAdditiveManufacturingValueLevers
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
Reduce total part count by combining assemblies, or parts of assemblies, in to a single part, reducing overall post processing,
easing assembly and increasing reliability.
Common Ways Value is Created With Metal AM
Optimize and tailor thermal performance with cooling channels that follow the surface geometry, integrated thermal management
designs, and optimizing surface roughness for desired thermal performance.
Only place material where it is needed for the desired part properties and performance. Reducing mass speeds up print times and
uses less raw materials, reducing costs.
Use AM design freedom to create value added features specific to your industry or application, such as tailored thermal expansion,
load deformation, surface finishes, variable density, variable crystal structure, or complex lattices.
Reduce raw material lead times from months to weeks, manufacture parts closer to their final destination, consolidation of
supplier sources and support systems, energy savings, and on-demand sparing.
Economical production of low volume parts by reducing the need for tooling, setup times, material logistics, and overhead.
Custom part or feature generation based on digital inputs from 3D imaging, CAT scans, or other digital sources. Enables
individualized custom manufactured parts at scale.
RuleofThumb–Ifyoucan’tapplyatleasttwooftheAMvaluelevers,thendon’tuseAMforproduction.

TheAdditiveManufacturingValueExample–InjectionMolding
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
EOS Case Study - Innomia Injection Molding
An automotive injection mold insert for a center arm rest was redesigned
for metal AM. The original water cooling channels were replaced with 3mm
diameter channels that followed the surface of the insert. Additionally the
original beryllium-copper insert was replaced with a steel alloy that was
hardened to 50 HRC.
Value Delivered:
• 17% reduction in cycle time over the original beryllium-copper mold
• Maximum water cooling temperature increased from 16C to 60C
• Improved part quality by uniformly cooling the part in the mold
• Maintenance interval increased by 400%, from every 1-2 weeks to every
5-6 weeks. After 370,000 shots and over $20,000 euros saved, additional
optimizations
• +$20,000 euro savings after 370,000 shots with additional design
improvements identified
Read the full case study at
https://www.eos-na.com/press/case_studies/Innomia
Insight–Improvingoneareaoftenhasacascadingimpactinaddedvalue

TheAdditiveManufacturingValueExample–LightWeighting
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
Insight–Organicdesignbecomeseconomicaltomanufactureanddeliversgreatmechanicalproperties
Read the full case study at:
https://www.eos.info/case_studies/additive-
manufacturing-of-antenna-bracket-for-satellite
EOS Case Study – RUAG Satellite Bracket
A satellite antenna bracket was redesigned by RUAG for the Sentinel satellite
to try to save up to $20,000 euros per kilogram of mass while maintaining
the required strength to survive the high-g launch forces and work in the
harsh conditions of space. The bracket was designed with the assistance of
topology optimization design tools, printed of an aluminum alloy (AlSi10Mg)
and exceeded all flight qualifications.
Value Delivered:
• Rigidity requirements exceeded by 30% using an organic design
• Achieved over a 40% weight savings on final design, 0.96kg compared to
the original 1.6kg design
• Reduced internal stress
• Single piece assembly

TheAdditiveManufacturingValueExample–PartReduction
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
Insight–BroadenyourscopetoincludetheentirevaluechaintoextractthemostvaluewithAM
General Electric – GE Aviation Examples
General Electric has been working with Metal Additive Manufacturing for
over 20 years across the company. GE Aviation has begun to apply additive
techniques to their portfolio with substantial impact.
Value Delivered – Fuel Nozzle:
• 18 to 1 part reduction
• 25% lighter weight
• 5 x increase in durability through improved cooling
• 3x faster production at 2 weeks from 6 weeks with cost reduction
Value Delivered – Advanced Turboprop:
• 845 parts eliminated
• No structural castings
• Significant weight savings
Read more at:
http://machinedesign.com/3d-printing/3d-printing-
goes-big-time-small-production-runs
https://www.youtube.com/watch?v=W_Rw63GIxnM
https://www.ge.com/sites/default/files/ge_webcast_pr
esentation_009062016_0.pdf

TheAdditiveManufacturingValueExample–UniqueFeatures
Design
Operations
Thermal
Management
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Insight–GreatergeometricfreedomandengineeringR&Dcanleadtodisruptiveimpacts
Read the full case study at:
https://www.eos-na.com/industry-euro-k-3d-printed-
micro-burners-for-the-optimized-combustion-of-
gaseous-and-liquid-fuel-29efbc0c6d3b7545
EOS Case Study – Euro-K Micro-Burners for Turbines
A turbine engine micro-burner was redesigned to take advantage of the
design flexibility of additive manufacturing. Printed in Inconel 718, the new
design enables turbines to burn liquid or gas fuels with the same micro-
burner, previously only possible with a lengthy turbine conversion. The
micro-burner enables utilities to quickly adapt to fluctuating fuel prices.
Value Delivered:
• Assembly cost reduced by 20%
• Enables reduction in combustion chamber size by 20%
• Adds fuel source flexibility – accepts liquid or gas fuels with the same
design

TheAdditiveManufacturingValueExample–Lattices
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Insight–Complexlatticesdelivertailoredproperties,lowermaterialscosts,andfasterprintingspeed
Read more at:
https://www.linkedin.com/pulse/lightweight-lattices-
liberate-new-product-performance-marc-saunders
Example Round Up – Lattice Structures
Cellular or porous lattice structures offer a new design freedom for additive
manufacturing that unlocks several unique benefits.
Valued Delivered with Lattice Structures:
• +50% weight savings using an internal lattice
• Up to 4x faster manufacturing speed using lattices, saving time and
materials costs
• Optimized and tailored heat flow
– Improved cooling efficiencies in heat exchanger designs
– Improved thermal insulation
• Tailored mechanical and thermal properties throughout the part
• Tailored center of gravity

TheAdditiveManufacturingValueExample–Logistics
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Logistics
Low Volume
Production
Generated
Designs
Insight–Smallpartsavingscanscaletobecomemassiveacrossanindustry
Case Study – SAVING Project
The SAVING Project, out of the UK, wanted to demonstrate the potential for
additive manufacturing to provide substantial energy savings over the life of
a part. One of the items they designed for additive was an airline belt buckle
out of titanium that matched or exceeded the strength of approved
aluminum or steel belt buckles.
Value Delivered:
• Weight savings of 55% compared to a 155g steel belt buckle and 45%
compared to a 120g aluminum belt buckle with the redesigned titanium
belt buckle at 68g
• 160 lbs weight savings on Airbus 380 (853 seats) equates to an annual
fuel savings of over $200,000 and reduce CO2 emissions by 0.74MTons
over the life of the plane.
• Adopting Metal AM belt buckles across American Airlines +940 aircraft
could save +$33 million annually, a 1.2% increase in FY16 annual profit
after the cost of certification and manufacturing is recovered.
Read more at:
https://www.3trpd.co.uk/portfolio/saving-project-
saving-litres-of-aviation-fuel/
https://energy.gov/sites/prod/files/2015/02/f19/QTR
%20Ch8%20-
%20Additive%20Manufacturing%20TA%20Feb-13-
2015_0.pdf
Part Reduction

TheAdditiveManufacturingValueExample–LowVolumeMfg
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
Insight–Lookforcomplementarywaystoaddvalue
Renishaw Case Study – Hydraulic Block Manifold
A customer partnered with Renishaw to redesign their current aluminum
hydraulic block manifold with the goal of saving weight. Traditionally,
machining the complex hydraulic circuit connecting pumps, actuators, and
valves together requires specialized fixtures and tooling, as well as blanking
plugs to plug up unneeded access holes that break the hydraulic circuit. The
end result is abrupt directional changes in the hydraulic flow paths which
result in poor efficiency. Redesigning for additive helped smooth out the
transitions and optimize the performance of the hydraulic block manifold.
Value Delivered:
• 60% improvement in flow efficiency
• Mass reduced by up to 79% with aluminum, or 37% in stainless steel
• Compatible with existing design
• Faster design and development Read the full case study at
http://www.renishaw.com/en/hydraulic-block-
manifold-redesign-for-additive-manufacturing--
38949

TheAdditiveManufacturingValueExample–GeneratedDesigns
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Logistics
Low Volume
Production
Generated
Designs
Insight–Don’toverlookthevalueofloweringpostproductioncosts
EOS Case Study – Dental Copings
BEGO USA, a division of BEGO Gmbh, adopted additive for production of
their dental copings, replacing a lost wax casting process. Each coping is
custom designed based on a 3D scan of the patients teeth. A batch process
combines multiple customer’s dental frames for production simultaneously.
With a final rubber wheel finishing process, the dental coping is ready for
veneering or ceramics.
Value Delivered:
• Success Rate improved from 50-60% to 90-95%, reducing post
processing and customer wait times
• Up to 22.5x times production increase from 20 dental frames per day
scalable with additive up to 450 dental frames per day
Read the full case study at
https://www.eos.info/press/customer_case_studies/b
ego
Part Reduction

TheAdditiveManufacturingValueExample–LowVolumeMfg
Design
Operations
Thermal
Management
Weight
Reduction
Unique
Features
Part Reduction
Logistics
Low Volume
Production
Generated
Designs
Insight–Microcustomproductionrunsbecomemuchmoreaffordable
NASA Case Study - Turbopump
To test designs for high-performance multi-fuel turbopumps for the engines
for the Mars lander, NASA turned to additive manufacturing. They were able
to quickly develop and test designs that worked well with liquid methane
and liquid hydrogen propellants that delivered 600 gallons of semi-
cryogenic liquid per minute and producing over 22,500 lbs of thrust. All test
data is available on NASA’s Materials and Processes Technical Information
System (MAPTIS).
Value Delivered:
• 20x cost savings versus conventional manufacturing methods - $220,000
for one compared to $20,000 for two turbopumps out of inconel.
• 45% fewer parts
• Open access materials property data
Read the more at:
http://www.padtinc.com/blog/additive-mfg/beyond-
the-hype-additive-manufacturing-and-3d-printing-
worldwide-a-summary-of-terry-wholers-thoughts
https://www.nasa.gov/centers/marshall/news/news/r
eleases/2016/nasa-rocket-fuel-pump-tests-pave-
way-for-methane-fueled-mars-lander.html

AdditiveManufacturinghasthePotentialtoReshapeMajorIndustries
The aerospace industry is able to take
advantage of several value levers with AM.
Light weighting can deliver $1500 per year
for every kg removed, a potential fuel
savings of over $1M per aircraft annually.
Part consolidation and operating life
improvements offer the potential to lower
manufacturing and lifecycle costs for the
aerospace industry by 25%.
The injection molding industry can benefit
greatly from thermal management techniques
available in AM. Conformal cooling can double
production speed. Combined with lattice
optimization, this can result in fast mold
production and reduced mold costs. Today
injection molding applications are limited to
inserts and high end molding. Improving unit
economics will increase AM adoption.
The automotive industry can use AM to
improve tooling costs and reduce lead
times. Up to 20% of spare parts can be
printed cheaper than traditional
manufacturing options and drop lead
times to 1-2 weeks by using AM. Improving
unit economics offer possibilities for low
and full volume production support.
The medical device industry is a great
fit for AM’s ability to deliver economical
low volume manufacturing and its ability
to make complex geometries, especially
when combined with generative design
from medical scans. Custom designed
implants have reduced surgery time by
25% and recovery time by up to 75%.

BasicGo-NoGoforSuccesswithMetalAdditiveManufacturing
Can youuseat leasttwo valuelevers?
•If you cannot add significant value with at least two of the value levers, additive may not be a
good option yet.
Are materialsandmachinesavailableandcapable?
•Are the materials you need available with proven process parameters and acceptable
material properties?
•Can the machines handle your part and feature size?
Do youhavetheresourcesfor essentialNRE to designfor additive?
•If you do not redesign you parts for additive, most benefits of additive will be unavailable to
you. Do you have the time and the budget to support these essential efforts?
•Can you support the certification effort for AM parts to be used in you application?
1
2
3

AchievingDesiredROIandStrategicImpactRequiresLookingAcross
theValueChain
Technical
Capabilities
Costs Ecosystem Strategic
• Do the machine
capabilities deliver the part
features and properties
you need?
• Can they work with the
right materials?
• Can the required quality
be delivered?
• How will you maintain
quality control?
• Do you have access to
skilled AM talent?
• Are the economics right
for prototyping? For
production?
• In-house or outsourcing?
• Capex investment
needed?
• How much will service,
system maintenance, and
consumables cost?
• What operating life do you
expect?
• Will you do post-
production in house or
outsource it?
• How much will upfront
and ongoing safety cost?
• Do suppliers have enough
capacity to support your
production needs?
• In-house or outsource AM
mfg? QC? Repair?
• Material and systems
availability to support
production volume? What
are typical lead times?
• Training available tailored
for your industry?
• Maintain ownership of
trade secrets of AM design
& mfg or build up supplier
capabilities?
• Is there potential for
significant industry impact
due to AM value levers?
• How fast are your peers
adopting metal AM?
• Can AM enable a
fundamental shift in how
you can service your
customers or enable new
business models?

EachMetalAMTechnologyFamilyProvidesDifferentCapabilitiesand
Values–ThereisNoOneSizeFitsAllMetalAMTechnology
http://web.ornl.gov/sci/manufacturing/docs/pubs/The%20metallurgy%20and%20processing%20science%20of%20metal%20additive%20manufacturing.pdf
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/
Powder Bed Fusion
A process where powdered metal is consolidated with directed
energy, typically from a laser or electron beam. Typically
delivers the finest feature detail and part quality at the
expense of build speed and smaller build volumes.
Binder or Material Jetting
A process where a combination of a metal and binder is
deposited or a binder is deposited on metal powder to build up
a part layer by layer. Delivers fast build speeds and good feature
sizes but requires post processing to deliver a solid metal part.
Sheet Lamination
A process that selectively cuts and binds sheets of metal
together to build a part layer by layer, often with ultrasonic
energy. The low heat process enables other materials and
sensors to be embedded during the printing process.
Directed Energy Deposition
A process that feeds a metal feedstock in to a focused energy
source, often a laser, electron beam, or an electric arc. The
fastest metal additive technique with the largest build volumes
but often with poor feature detail.
Metal AM Process Build Speed and Feature Size
Each of the four broad metal AM technology spaces bring unique
manufacturing capabilities. Every process has different design
rules, material availability, post processing options, and unit
economics. Even process with similar resolution may deliver
significantly different part properties due to how material is
consolidated. Available build volumes are often limited by process
constraints as well as OEM system availability. At the end of the
day, the requirements of your application will drive the selection
of the metal AM process.

UnitEconomicsofLaserPowderBedMetalAdditiveManufacturing
Source:
https://www.rolandberger.com/publications/publication_pdf/roland_berger_additive_m
anufacturing_next_generation_amnx_study_20160412.pdf
Roland Burger’s breakdown of the hourly machine rates for
laser metal additive manufacturing is a good foundation for
understanding the costs of AM. Be aware:
• First print successes are uncommon, especially when
starting out. It can take +5 iterations to successfully print a
part, dialing in settings and support structures. Better
modeling software is improving the success rate.
• Providing suppliers with additive CAM and machine
operation experience is critical to achieve good production
numbers. Training a supply network can benefit your
competitors, especially if there are strong part similarities,
such as in the case of the GE Fuel Nozzle and Morris
Technologies.
• Material costs range from $40 to $500 per kg and Material
build rates range from 0.3in3/hr to over 3 in3/hr, depending
on the machine. Metal powder can age due to atmospheric
exposure and repeated print cycles.
• Metal powders for AM are often hazardous or even
explosive, as in the case of titanium and aluminum
powders. Added safety training and operation costs are
part of AM.
• The cost of post processing to achieve the desired surface
finish, final dimensions, and part properties through
annealing or hot isostatic pressing can run more than 3x as
much as the metal AM printing costs.
Laser Powder Bed Fusion Hourly Machine Rates

MetalAM UnitEconomicsandDesignImpact
https://dspace.lboro.ac.uk/dspace/bitstream/2134/.../HopkinsonAnalysisofRapid.pdf
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𝑩𝒖𝒊𝒍𝒅 𝑹𝒂𝒕𝒆
+
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∙ 𝑳𝒂𝒚𝒆𝒓 𝑹𝒆𝒔𝒆𝒕 𝑻𝒊𝒎𝒆 ×
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𝑪𝒐𝒔𝒕 𝑴𝒂𝒄𝒉𝒊𝒏𝒆&𝑺𝒆𝒓𝒗𝒊𝒄𝒆
𝑷𝒂𝒚𝒐𝒇𝒇 𝒉𝒓𝒔
+
𝑻𝒊𝒎𝒆 𝑫𝒆𝒔𝒊𝒈𝒏 𝒇𝒐𝒓 𝑨𝑴 ∙ 𝑹𝒂𝒕𝒆 𝑬𝒏𝒈𝒊𝒏𝒆𝒆𝒓∙ 𝑫𝒆𝒔𝒊𝒈𝒏 𝑪𝒐𝒎𝒑𝒍𝒆𝒙𝒊𝒕𝒚 𝑭𝒂𝒄𝒕𝒐𝒓
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑷𝒂𝒓𝒕𝒔 𝑷𝒓𝒐𝒅𝒖𝒄𝒆𝒅
+
𝑽𝒐𝒍𝒖𝒎𝒆 𝑷𝒓𝒊𝒏𝒕𝒆𝒅 ∙ 𝑪𝒐𝒔𝒕 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 +
𝑪𝒐𝒔𝒕 𝑩𝒂𝒕𝒄𝒉𝑪𝒐𝒏𝒔𝒖𝒎𝒂𝒃𝒍𝒆𝒔 + 𝑪𝒐𝒔𝒕 𝑸𝑨 + 𝑪𝒐𝒔𝒕 𝑷𝒐𝒔𝒕 𝑷𝒓𝒐𝒄𝒆𝒔𝒔𝒊𝒏𝒈 + 𝑷𝒓𝒐𝒇𝒊𝒕 𝑴𝒂𝒓𝒈𝒊𝒏
Build Time Factors
With the potential for thousands of layers
per inch, part orientation, support height,
and the time to setup each layer can
significantly impact print time.
Machine & Service Costs
Machine and service costs are a
significant source of part costs, good
operations and usage rates can
effectively lower costs, but watch out
for consumables expenses.
Complexity Factor
Complexity impacts design time, QA, and
print difficulty rather than print time
directly, unlike traditional manufacturing.
Volume Based Material Costs
Removing unneeded material pays dividends in
lower material costs and faster printing speeds.
QA & Post Processing
Part design and build orientation will
impact part properties, post-processing
cost, the need for additional fixturing, QA
costs and QA pass rates.

AsPrintedPartPropertiesRarelyMeetRequirementsandMustBe
PostProcessedtoPassAcceptanceRequirements
Source: https://www.rolandberger.com/publications/publication_pdf/roland_berger_additive_manufacturing_next_generation_amnx_study_20160412.pdf
Internal Stress Voids Surface Finish
Dimensional
Accuracy
Non-uniform
Properties
Internal Cracks
As printed limitations and problems commonly encountered in metal Additive Manufacturing.
No manufacturing method is perfect, and highly
detailed metal AM parts can have miles of controlled
welds or material deposition per cubic inch. As a
result, parts often require several post processing
steps to meet specifications. Post processing often
includes removing internal stress, minimizing voids,
and improving surface finish and dimensional
accuracy. Good design practices and using the best AM
process can minimize the amount of post processing.
Key Takeaway – Plan for post processing
to cost to be ~3x AM printing cost
Common Post Processing Options for Laser Powder Bed Fusion Metal AM
Sawing/Wire
EDM
Typical process used to remove printed parts from the metal base
plate.
Hot Isostatic
Pressing (HIP)
Common process for minimizing voids, cracks and improving
density for mission critical parts.
Heat
Treatment
Removal of built up stress (up to +100ksi) may need to be removed
with a thermal anneal before removal from the build plate.
Machining Critical dimension features, flat or mating surfaces will often need
to be finished with CNC machining.
Surface
Treatments
Surface treatments like shot peening, sand blasting, and polishing
are common to improve surface finish and part properties.
Quality
Inspection
CT scanning is the gold standard for detecting internal voids and
other quality issues for metal additive.
Plan for Post Processing of Metal AM Parts

MetalAdditiveManufacturingOftenRequiresSpecificSafety
Considerations,EspeciallyforPowderedMaterials
http://www.additivemanufacturing.media/articles/changing-the-rules
http://www.additivemanufacturing.media/blog/post/safety-tips-for-metal-am
Materials Operating Environment
• Flammability Risks – The metal powders used in Metal AM
can be very flammable or even explosive under certain
conditions. Powdered aluminum and titanium, two common
materials are especially flammable.
• Material Handling – Powdered material is often sold in bulk
containers and must be properly stored for safety and to
extend the material life. Bulk powder is often loaded
manually in to machines which can cause material to
become airborne.
• Personal Protective Equipment – Powdered material may
required gloves and respirators to protect machine
operators from absorbing carcinogenic powder through
their skin or inhaling airborne metal particles.
• Material Waste – Disposal of metal powder may fall under
several environmental regulations both on national and the
local level.
• Electrostatic Risk – When metal powders can be ignited by a
single spark, proper grounding of machines, operators, and
the operating environment become critical.
• Breathable Atmosphere – Reactive materials, like aluminum
and titanium, must be worked in an inert atmosphere that
prevents the material being exposed to oxygen. Detecting
leaks is critical to maintaining a breathable, oxygen rich
atmosphere for personnel.
• Fumes & Exhaust – AM welding creates fumes which need to
be scrubbed, exhausted and/or disposed of. Deposited fumes
can be extremely flammable, and exhausted fumes can
contain harmful contaminates. Filtering is often required.
• Laser & Light Risks – The high energies involved in Metal AM
can easily harm operators if the proper safety precautions are
not followed. Reflections from the lasers used in Metal AM will
cause instant eye damage if they are viewed without proper
safety gear. Other welding techniques also create harmful
emissions that can damage unprotected eyes.

Today Metal AM production capacity is severely limited, with a
world wide production class system install base of ~2700
systems. In 2013, GE stated they would need 60 systems to
meet the projected production requirements for the LEAP fuel
nozzle, well beyond the capabilities of any single service
provider to support. The lack of existing service providers
forced GE to build their own production facility and spend $50M
to purchase metal AM systems to make a single part. Even in
2017 there is not a single service provider in the world that
can handle the full production volume of GE’s LEAP fuel nozzle.
Today’s world-wide install base can only handle 50 parts
manufactured on the same scale as the LEAP fuel nozzle. The
limited production capacity of metal AM has significant
implications for the industry. For AM system OEMs, parts scaling
from prototyping to production on their platform will drive
significant sales. For manufacturers, a more strategic decision
must be made. Whether to build up the capabilities of their
supply chain or build in-house production capabilities. With the
cost of scaling a single part from prototyping to production in
the tens to hundreds of millions of dollars, the infrastructure
investment decision rises quickly to a strategic board level
decision for most OEMs.
MetalAMProductionCapacityisLimitedBytheSmallInstallBase
Greg Morris – GE Aviation AM Strategy & BD Manager - TCT Show 2013 - https://www.youtube.com/watch?v=W_Rw63GIxnM
Annual Sales of Metal AM Systems 2000 to 2014
Install Base of Metal AM Systems in Service Bureaus
Survey of 100
Service Bureaus in
USA & Europe in
2017 Q1/Q2
(OEM Service
Bureaus Excluded)

AdditiveManufacturingTechnologyisImmaturebutAdvancingRapidly
As the unit economics, post processing costs, material costs and design
costs of metal AM improve, the scope of where and how metal AM will
be used will shift. The need to find ways to add significant value
through metal AM’s value levers will be reduced and AM will become a
viable alternative to traditional manufacturing processes. Improving
economics and availability of metal AM will impact how manufacturers
approach production runs, with smaller volume runs becoming more
economical.
Metal AM technology and its support software are still in its
infancy and improving rapidly. Heavy investments in R&D are
being made by research organizations, governments, and
corporate R&D labs. GE’s projected technology improvements
could reduce powder bed Metal AM unit economics by as much as
50%. New Metal AM processes could deliver better economics and
production capabilities. Combined with falling material costs, this
could put Metal AM within striking distance of many traditional
metal manufacturing processes.
Active GE Research Additive Manufacturing Programs
KeyTakeaway–ImprovinguniteconomicswillmakemetalAMaviablealternativetoCNCmachining,
Metal-Injection-MoldingandInvestmentCasting

MetalAMHighLevelTechnologyComparison
http://www.metal-am.com/introduction-to-metal-additive-manufacturing-and-3d-printing/metal-additive-manufacturing-processes/
http://www.femeval.es/proyectos/karma/Documents/DL%201.1_Report%20on%20technologies_5_11.pdf
https://futurerobotics.files.wordpress.com/2015/10/epma_introduction_to_additive_manufacturing_technology.pdf
Powder Bed Fusion vs.
Binder and Material Jetting
With good resolution, material compatibility, and
fast printing speed, binder and material jetting
technologies are a strong alternative to powder
bed fusion. Jetting approaches rely on post-
processing to turn the lightly bonded direct
output in to a solid final part.
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/po
wderbedfusion/
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/bin
derjetting/
Powder Bed Fusion vs.
Direct Energy Deposition
Powder Bed Fusion and Direct Energy Deposition
(DED) are at opposite ends of the large & fast vs
slow and detailed spectrum. Powder bed working
volumes are often 15.7x15.7x15.7” and deposit
>1lbs/hr while DED systems can make parts ~20ft
long and deposit 20lbs of material an hour.
http://www.sciaky.com/additive-manufacturing/wire-am-vs-
powder-am
Laser vs. Electron Beam
Powder Bed Fusion
E-beam prints faster with less stress, which allows
layers of parts to be build with minimal supports.
However, the E-beam is controlled with strong
magnetic fields making it difficult to work with
ferrous alloys. The pre-heating of layers also limits
its internal structure printing capabilities.
http://www.farinia.com/additive-manufacturing/3d-
technique/metal-additive-manufacturing-production-systems
Powder Bed Fusion
• Better detail,
accuracy, and raw
surface finish –
Finer part features
and undercuts
possible
• Internal Geometry
Direct Energy Dep.
• Great for service
and repair - Can
build on any
accessible surface
• CNC upgrade path -
CNC Tool Heads
Available
Laser Powder Bed
• Greater material
flexibility - Ferrous &
Non-ferrous alloys
• Better internal
structure control
and detail – Better
energy focus and
control
E-Beam Powder Bed
• Faster builds with
less stress –
Greater power
output and use of
Pre-heating
• Non-Ferrous alloys
only
Powder Bed Fusion
• Good as printed
properties – Post
processing dials in
material properties
• More established –
Better tools and
knowledge base
Binder/Material Jetting
• Fast with good
detail – Similar
resolution with
greater speed
• Strength from post-
processing – Green,
low strength as
printed parts

TheInterconnectedNatureoftheMetalAMEcosystemCreates
PowerfulNetworkIncentivestoControlEnd-to-EndSolutions
Value of
Produced
Goods
Machine
Materials
SoftwareProcess
Data
The Value of AM is a Combination of Five Key Areas
With Metal AM, the skill and knowledge advantage of designers,
quality engineers, and machinists can be captured in a single
digital thread with material, machine, build, CAD/CAM, and
quality data.
Historically these factors have been loosely connected and
controlled by separate players. The complexity of AM and the
digital thread tying these factors together have the potential to
reshape the landscape of manufacturing as a whole.
AM enables complex supply chains to be recaptured and
consolidated by OEMs. Additionally, less manpower is required
and with less experience to manufacture complex parts.
ThebattlesunfoldinginmetalAMareforcontroloverthefutureofmanufacturing
WheredoesAMfitinyourbusiness?

AbouttheAuthor
Matt Burris
Matt Burris is an entrepreneurial engineer who is known for operating at the
intersection of business and engineering, finding practical solutions, new product
innovations, and business models that create substantial value. My passion lies in
understanding a market deeply, combining fuzzy front end insights with product
technologies and business models to create meaningful solutions with +$50M
revenue potential. I have generated more than $17 million in funding
opportunities for commercial, defense, and special operations projects by
connecting technology applications to strategic business needs.
As the founder of MatterFab, I led a technical team that designed and built a laser
diode based affordable metal additive manufacturing system (3D Printer), raising
nearly $10M from General Electric, Autodesk, private equity, and other investors.
I currently live in the Greater Atlanta area where I am getting to know the local
startup community, building a new workshop, exploring blogging and a Youtube
channel. I have published books, bottled a custom rub recipe, and have even
been deported to Afghanistan.
Schedule a Call
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Metal Additive Manufacturing - Basics Zero to One - June 2018b

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