Dedagroup ICT Network

Additive Manufacturing e Stampa 3D:
La visione di Dedagroup
Renato Bocchi – Head of Industry 4.0, Dedagroup
3
What is 3D Printing/Additive Manufacturing ?
Definition
 A process of joining materials to make
physical objects from 3D CAD model, usually
layer upon layer, as opposed to subtractive
manufacturing or molding/casting
technologies
 Additive Manufacturing allows for building
metallic parts with very complex geometries
(actually impossible with conventional
methods) without tooling, fixtures and
without producing any waste material
Source:
 This is a revolution in the world of
manufacturing …
 … but to date, existing CAD systems was not
able to address the challenges of this new
technology
http://youtu.be/OhYvDS7q_V8?list=PLF992841F1A4677FA
4
What is 3D Printing/Additive Manufacturing ?
Two main Additive Manufacturing processes
 Bed-based Materials
(powder, liquid)
 Powder bed processes consolidate
thin layers of powder or liquid to
solidify scans of the sliced Computer
Aided Design (CAD) data
Source:
 Feeder-based Materials
(powder, wire, liquid)
 Focused selective material
deposition (wire, powder, liquid) and
solidification by fusion,
polymerization or cooling depending
on the process
5
Additive Manufacturing processes
Bed-based Materials (powder, liquid)
POWDER BED
FUSION
BINDER JETTING
VAT LIQUID
MATERIAL
JETTING
MATERIAL
EXTRUSION
Full color printing
Stereolithography
(SLA)
https://www.youtube.com/wa
tch?v=VBK_4ruKC8s
https://www.youtube.com/wa
tch?v=oNpAnBhgIIs
PolyJet (PJ),
MultiJet Printing
(MJP),
Wax Deposition
Modeling (WDM)
Fused Deposition
Modeling (FDM),
Fused Filament
Fabrication (FFF)
https://www.youtube.com/wa
tch?v=Som3CddHfZE
https://www.youtube.com/wa
tch?v=SPtkOmP_HoA
https://www.youtube.com/wa
tch?v=MX0HPjc-3aw
https://www.youtube.com/wa
tch?v=GxLjDNrQBgs&index=3
&list=PLwpDxJ0jrz6jpFFp4xLP9
e2B1aaRdBC3K
ADDITIVE MANUFACTURING
CATEGORIE
in Powder VAT
POLYMERIZATION
Selective Laser
Sintering
(SLS)
Selective Laser
Melting
(SLM)
Electron Beam
Melting
(EBM)
https://www.youtube.com/wa
tch?v=9E5MfBAV_tA
https://www.youtube.com/wa
tch?v=Mjf6oaMVWr8
https://www.youtube.com/wa
tch?v=BxxIVLnAbLw&index=14
&list=PLUMSQMrg3EMuAk6fQ
AkxnGsR49nrb_tho
PROCESS TYPE
https://www.youtube.com/wa
tch?v=9RuJ_Ejc4WQ
Thermoplastics
elastomers
Ferrous & non
ferrous alloys
Non ferrous alloys
POWDER BED FUSION: thermal energy selectively fuses regions of a powder
bed
Source:
Composite
MATERIAL
materialsTYPE
Polymers
BINDER JETTING: a
liquid bonding agent is
selectively deposited
Notes
to join powder
materials
VAT
POLYMERIZATION:
liquid polymer in a vat
is selectively cured by
light-activated
polymerization
Digital Materials,
Wax
MATERIAL JETTING:
droplets of build
material are
selectively deposited
onto a build bed to
develop a threedimensional object
ABS, Nylon
MATERIAL
EXTRUSION: extruding
of thermoplastic
materials
[1/3]
6
Source:
Main benefits of Additive Manufacturing technology
[2/3]
7
Source:
Main benefits of Additive Manufacturing technology
[3/3]
8
Main benefits of Additive Manufacturing technology
 Design freedom
 Leverage topological optimizations
 Hollow parts with internal lattices
become possible
 Function integration
 Weight reduction
 Topological optimizations
 Hollow parts with an internal lattice to
keep/improve mechanical strength
 Costs reduction
 No more need of expensive tooling
 Manufacturing/assembly cost reduction
with parts integration (1 single part
instead of 20)
 Function integration
Source:
 Speed up manufacturing process
 No lead time for tooling
 Shorten assembly process with “parts
integration”
 High material utilization
 No waste of material - less than 10%
 Buy-to-Fly ratio reduction
 Ability to manufacture on-site, reducing
logistics complexity
 Inventory
 Shipments
9
Proof Points
3D Print Technology – industry metrics
 3D printing market is expected to grow 500% over the next 5 years
 Survey of over 1,000 Stratasys 3D printer owners
 Almost 1/3 reported a 25% or higher improvement in product launch times
Source:
O
(NASCAR team) uses AM to accelerate new part designs
O
estimates: 3D printing helped reduce development time by as much as 75%
O
"Within 6 months we were able to go through 12 rounds of prototype
iterations that we fully tested”
10
Main industries interested by Additive Manufacturing
 Aerospace & Defense industry




Weight reduction
Function integration
Buy-to-Fly reduction
Spare parts management
 Automotive
 Weight
 Function integration
 Medical industries
 Weight reduction
 Shape customization, etc.
 Car racing (ex.: F1)
 Weight reduction
 Optimization
…
Source:
11
CAD/CAM and Additive Manufacturing
Two separated domains …
 AM: a big impact on the design itself
 New, impossible before, geometries for
manufacturing
 Old design constraints for designers vs. too
much design freedom …
 Current design decisions based on known
limits of traditional manufacturing processes
 Machining, casting, plastic injection, etc.
 3D modeling issues:
 Impossible to create specific CAD models for
AM – optimized with internal lattices
 No specific features, large models,
performance issues, etc.
 Impossible to simulate parts with internal
lattices
 Lattices created with external manufacturing
applications
 CAD reconstruction after external topological
optimization very painful and complex
 No printability check
 Design rules, supporting structure, etc.
Source:
 CAD models (exact representation)
converted into tessellated models
(approximation. E.g. STL format) to be
manipulated for 3D printing
 Often an intermediary software needed to
prepare the files to be printed




CAD/CAM
Domain
Ensure watertightness
Correct normals
Assign colors
…
 One or several software applications for each
3D printer/printer manufacturer …
 …
[1/2]
12
CAD/CAM and Additive Manufacturing
Two separated domains …
 AM: a big impact on the design itself
 New, impossible before, geometries for
manufacturing
 Too much freedom vs. new design constraints
for designers …
 Current design decisions based on known
limits of traditional manufacturing processes
Additive
Manufacturing
Domain
 Machining, casting, plastic injection, etc.
 3D modeling issues:
 Impossible to create specific CAD models for
AM – optimized with internal lattices
 No specific features, large models,
performance issues, etc.
 Impossible to simulate parts with internal
lattices
 Lattices created with external manufacturing
applications
 CAD reconstruction after external topological
optimization very painful and complex
 No printability check
 Design rules, supporting structure, etc.
Source:
 CAD models (exact representation)
converted into tessellated models
(approximation. E.g. STL format) to be
manipulated for 3D printing
 Often an intermediary software needed to
prepare the files to be printed




Ensure watertightness
Correct normals
Assign colors
…
 One or several software applications for each
3D printer/printer manufacturer …
 …
[2/2]
13
Additive Manufacturing benefits:
Still under-realized/under-achieved
A.2.1
Revised
Design
A.2
Original
Design
Lattice
creation
3rd Party Tools
Lattice
analysis
Print
validation
Lattice
optimization
Source:
[1/2]
14
Additive Manufacturing benefits:
Still under-realized/under-achieved
Lattice creation/optimization exploits the value of AM
Without specialized tools, designs are over-engineered and rarely
rd
Lattice
optimized3toParty
takeTools
advantage of Additive Manufacturing
creation
A.2
A.2.1
Original
Revised
Design
Lattice
rd party
3analysis
Printand manual effort will not
Reliance on
solutions
validation
support long-term goals
Manual lattice creation and optimization: too tedious and costly
CAD + 3rd party solutions: manual, disconnected, cumbersome,
Lattice
expensive process that cannot
be automated or optimized
optimization
Create/analyze lattice, validate geometry, recreate final B-rep geometry …
Source:
[2/2]
15
Additive Manufacturing can really
revolutionize engineering and design
 Engineers want to…
 Create innovative products not
limited by the constraints of
traditional manufacturing
 Use a single solution for: 3D print
design, analysis and geometry
optimization
 Eliminate 3rd party solutions and
avoid time-consuming rework
Key:
Source:
Lattice feature
 Companies want to…
 Apply next-generation manufacturing
techniques to overcome barriers to
manufacturing
 Deliver products exceeding quality,
performance and durability standards
 Achieve competitive differentiation
16
Creo Additive Manufacturing Extension (AMX)
Lattice feature: creation, analysis and optimization
 Automated creation of 2 ½ D , 3D and Conformal Lattices
 Single feature with parametric control over all aspect of the lattice structure
 Full B-rep geometry (NOT an approximation using facet geometry)
 Seamless analysis and optimization of lattice structure
 Lattices are optimized using Creo Simulate
 Idealized elements for faster analysis
Source:
17
Creo Additive Manufacturing Extension (AMX)
Lattice feature: creation, analysis and optimization
 Automated creation of 2 ½ D , 3D and Conformal Lattices
 Single feature with parametric control over all aspect of the lattice structure
A.2
A.2.1
 Full B-rep geometry (NOT an approximation using facet geometry)
 Seamless analysis and optimization of lattice structure
 Lattices are optimized using Creo Simulate
 Idealized elements for faster analysis
Source:
ORIGINAL DESIGN
– Material: Titanium
– Tensile Yield Stress: 139.96 MPa
– Tensile Ultimate Stress: 219.94 MPa
– Mass: 6.09 kg
OPTIMIZED DESIGN
– Material: Titanium
– Tensile Yield Stress: 139.96 MPa
– Tensile Ultimate Stress: 219.94 MPa
– Mass: 3.28 kg ( – 46.21 %)
SIMULATION RESULTS
– Max Stress (Von Mises): 36.23 MPa
– Max Displacement: 0.044 mm
SIMULATION RESULTS
– Max Stress (Von Mises): 104.22 MPa
– Max Displacement: 0.086 mm
OPTIMIZE
VALIDATE
A.2.1*
A.2.1
A.2.1M
A.2.1
18
Creo Additive Manufacturing Extension (AMX)
Other capabilities
 3D Printers connectivity
 Broadening the ecosystem
 Bi-directional exchange of
information between Creo and
3D Printers
 Tray assembly
 A repository for parts/assemblies
to be printed, assign material
and store other
attributes/parameters
 Nesting
 A method for optimizing the tray
…
Source:
[1/4]
19
Creo Additive Manufacturing Extension (AMX)
Other capabilities
 3D Printers connectivity
 Broadening the ecosystem
 Bi-directional exchange of
information between Creo and
3D Printers
 Tray assembly
 A repository for parts/assemblies
to be printed, assign material
and store other
attributes/parameters
 Nesting
 A method for optimizing the tray
…
Source:
[2/4]
20
Creo Additive Manufacturing Extension (AMX)
Other capabilities
 3D Printers connectivity
 Broadening the ecosystem
 Bi-directional exchange of
information between Creo and
3D Printers
 Tray assembly
 A repository for parts/assemblies
to be printed, assign material
and store other
attributes/parameters
 Nesting
 A method for optimizing the tray
…
Source:
[3/4]
21
Creo Additive Manufacturing Extension (AMX)
Other capabilities
❶
❷
❹
❸
❻
❺
❼
Source:
[4/4]
22
Creo Additive Manufacturing Extension (AMX)
Beyond Creo 4.0
NC/
INSPECTION/
MOLD
ADDITIVE
MFG
High-Order
Facets
(Only Output)
Tray Assembly
Printability
Checking
(Parts +
Assemblies)
Source:
2 ½ D & 3D
Lattices
3D Printer
Connectivity
Analysisdriven lattices
+
Topology
Optimization
Split large
parts
(Partners)
(Stratasys and
others)
Support
Structures
Optimization
3D nesting
ADDITIVE
MFG
Multi &
Graded
Materials
©PTC 2016 – Forward looking information is subject to change
FUTURE
PROFILO AZIENDALE
Febbraio 2017
24
Dedagroup
Chi siamo
Mission
Siamo uno dei più importanti
attori dell'Information
Technology “Made in Italy”.
Accompagniamo aziende ed
enti nella trasformazione
digitale, aiutandoli a progettare
il cambiamento.
Con i nostri clienti e per i nostri
clienti individuiamo strategie,
architetture, soluzioni e
competenze perché possano
crescere e rimanere innovativi
nel tempo. Partendo dall’Italia,
terra d’eccellenza, portiamo le
nostre soluzioni in tutto il
mondo.
Supportiamo Aziende, Enti
Pubblici e Istituti Finanziari
nelle loro strategie IT con
competenze applicative,
tecnologiche e di system
integration.
L’headquarter si trova a
Trento – terra d’eccellenza per
esperienze d’innovazione –
ma il nostro Gruppo, con filiali
in Italia e all’estero, supporta
oltre 3.600 clienti in tutto il
mondo.
Numeri
230 M€
FATTURATO
10
ANNI CONSECUTIVI DI CRESCITA
1.600+
PERSONE
40
PAESI IN CUI ABBIAMO CLIENTI
CAPACITÀ NEL SETTORE INDUSTRIALE
Febbraio 2017
26
Segmenti
DISCRETE
MANUFACTURING
PROCESS
MANUFACTURING
DIVERSIFIED
MARKETS
AUTOMOTIVE
MACHINERY
AEROSPACE
ELECTRONICS
MEDICAL DEVICES
RAILWAYS
BIOTECHNOLOGY
FOOD & BEVERAGE
OIL & GAS
CHEMICAL
GROCERY
DISTRIBUTED FACILITIES
WAREHOUSING
27
Punti di forza
DISCRETE
MANUFACTURING
PROCESS
MANUFACTURING
1.000+ CLIENTI
KNOW-HOW SULLE PRATICHE INDUSTRIALI
GRANDE CAPACITÁ DI DELIVERY
ABILITÁ NELL’INTEGRAZIONE DI SOLUZIONI E PIATTAFORME
FORNITURA DI SERVIZI SPECIALIZZATI
"CROSS FERTILIZATION"
COPERTURA TERRITORIALE ESTESA IN ITALIA E ALL’ESTERO
PARTNERSHIPS QUALIFICATE
DIVERSIFIED
MARKETS
28
Discrete Manufacturing – Expertises
SALES &
MARKETING
RESEARCH &
DEVELOPMENT
SUPPLY CHAIN
MANUFACTURING
AFTERMARKET
SERVICES
OPERATIONS &
COMPLIANCE
CRM
Financial
Planning & Analysis
Treasury & Financial
Risk Managemnt
Conformity/
Homologation
Design for MFG
Process & Shop Floor
control systems
Performance-Based
Monitoring/OEE
Technical
Documentation
Service
Part Management
Predictive/Proactive
Maintenance
Omni Channel
Demand & Supply
Planning
Inventory
Optimization
Transportation
Management
Warehouse
Management
Finite Capacity
Scheduling
Digital Marketing
MBSE/Systems
Engineering
Requirements
Management/ALM
CAD/CAM/CAE
ECAD
Repair & Tracking
Reach & CO2
Prototyping &
Testing
Material Handling
Additive MFG
SLM
Health & Safety
Additive MFG
Supplier/Customer
Collab.portals
Asset management
Health & Safety
Sentiment Analysis
MES/SCADA
Business Analytics/Big Data/Machine Learning
Augmented Reality
Product Data Management (PDM) – Product Lifecycle Management (PLM)
Internet of Things (IoT)
Quality
Product Costing
Enterprise Resource Planning (ERP)
Change Management
29
Industrial IT – Capacità
IT STRATEGY
Project & Program Management
Service management
& Governance
Transition & transformation
Application
development
Application
management
Application
integration
Qualification &
Auditing
Cybersecurity
EDI
Connectivity
Infrastructures
management
Validation
Cloud (SaaS, IaaS, BaaS)
Help Desk
IT Outsourcing
Business Process Outsourcing
Telecommunic.
HW & SW
selection
HW & SW
provisioning
Sviluppo Prodotto → Servizi

PTC, Siemens, Dassault, AutoDesk, Mentor, etc.
 VAR PTC dal 2001




Certificazione "PTC Windchill Authorized Partner" (PLM)
Certificazione "PTC Integrity Configuration and Customization" (ALM)
Certificazione "PTC's Authorized Training Partner" (CAD)
Certificazioni "ThingWorx Implementer" (IoT)
 Best practices/Metodologie
 Conoscenza dei settori industriali





Industria automobilistica
Aerospaziale e Difesa
Meccanica
Elettronica e High Tech
Scienze naturali
 Esperienza nel processo di sviluppo prodotto

Idea → Progettazione → Industrializzazione → Produzione → Servizi
 Consulenza, integrazione e infrastruttura
 Qualificazione, auditing e pratiche di validazione tecnica
Sviluppo e configurazione applicazioni
CAD, PLM, IoT, integrazione di sistemi
Fornitura di soluzioni software CAD,
PLM, IoT
Servizi di supporto per l’ingegneria
Manutenzione applicazioni, support
tecnico, SPOC
Cloud
 Tecnologie CAD/CAM/CAE, PDM, ALM, PLM & IoT
INFRASTRUTTURA INTEGRAZIONE
 Conoscenze tecnologiche e certificazioni
Generazione della “visione”
PLM/SLM/IoT, valutazioni AS-IS, business
cases, business process reenginering
CONSULENZA
7
Hosting per applicazioni aziendali,
virtualizzazione workstations e server
Fornitura e supporto workstations e
server
31
Partnerships
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[email protected]
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