Matt Sand, President of metal additive manufacturing company 3DEO, made this presentation at MD&M East, a leading conference in manufacturing medical devices and surgical instruments. His presentation covered the trends and emerging technology in metal 3D printing. This article summarizes the main trends he highlighted in the presentation.

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3DEO, Inc. © 2018
Metal 3D Printing
Trends & Emerging Tech
June 14, 2018

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Introduction

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Matt Sand
▪ President of 3DEO
▪ Serial entrepreneur with
venture capital experience
▪ Officer in U.S. Air Force
▪ MBA from UCLA
▪ Email: matt.sand@3deo.co

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3DEO – Low-cost Production Metal AM
www.3DEO.co

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Today’s Presentation
▪ Intro to Metal Additive
Manufacturing (AM)
▪ Metal AM will change
manufacturing
▪ Industry Trends
▪ AM vs. Traditional
Manufacturing

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Intro to Metal
Additive Manufacturing

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Setting the Stage…
▪ Forget everything you know about plastic 3D printing
▪ AM = Additive Manufacturing
▪ AM = 3D Printing
▪ Sintering
▪ Don’t hesitate to ask questions!

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Understanding Additive Manufacturing
3D model → Slicing → Printing → Post Processing

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Different metal AM Processes
▪ Powder Bed Fusion
▪ Binder Jetting
▪ Extrusion (FDM)
▪ Directed Energy Deposition
▪ Material Jetting
▪ Intelligent Layering®
▪ And more soon…

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Powder Bed Fusion
Advantages
▪ Highly complex geometries
▪ Widest range of materials
▪ Large parts
▪ Good material properties
Disadvantages
▪ High cost, degrading process
▪ Slow process
▪ Rough surface
▪ Weaker Z axis

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Binder Jetting
Advantages
▪ Lower cost than PBF
▪ Faster than PBF
Disadvantages
▪ Matrix composite materials
▪ Degrading inkjet process

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Extrusion (FDM)
Advantages
▪ Lower cost
▪ Great for prototyping
▪ High precision, fine layers
Disadvantages
▪ Limited production
possibilities
▪ High binder content
▪ Shrinkage in sintering
▪ Supports required

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Directed Energy Deposition (DED)
Advantages
▪ Fast builds with rapid
material deposition
▪ Fully dense parts
▪ No need for supports
Disadvantages
▪ Poor surface finish
▪ Wire less accurate
▪ Significant post processing

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Material Jetting
Advantages
▪ Nanoscale = high resolution
▪ No loose powder,
easier/safer to handle
▪ Very nice surface finish
Disadvantages
▪ Expensive, slow process
▪ Small parts

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3DEO’s Intelligent Layering®
Advantages
▪ Very low-cost process
▪ Nice surface finish
▪ Meets industry standard
▪ No degrading processes
Disadvantages
▪ Shrinkage limits geometries
▪ Smaller parts

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It’s complicated…

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Metal AM will fundamentally
Change manufacturing

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Gartner’s Technology Hype Cycle

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False start around 2012

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This time, the hype is (mostly) real

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Why AM will fundamentally change mfg.
▪ New, previously impossible designs
▪ Design for FUNCTION
▪ Mass customization
▪ Parts consolidation, light-weighting, internal channels
▪ On-demand manufacturing
▪ Eliminates inventory, supply chain becomes “demand chain”
▪ Low lead time, immediate turnaround
▪ FAST innovation / product development

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Light-weighting, honeycomb structure

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Part Consolidation
Previously 20 pieces, now 1; 25% lighter, 5x stronger

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Extremely Complex Internal Channels

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Optimized Design for Function

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Combination of consolidation & function
20% less fuel, 5% lower weight, 855 parts → 12 parts

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Broad 3D Printing
Industry Trends

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Explosion of different types of 3D printing
▪ Plastics & metals, of course
▪ Organs?!?
▪ Food: Chocolate & Pancakes
▪ Real estate – entire homes!

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Broad adoption is at an inflection point

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This is the year of metal
▪ 80% increase in sales of metal AM machine in ’17
(1,768 machines)

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Main Trend: Focus on Production
▪ Until now, 3D printing has been prototyping tech
▪ Every 3D printer wants to get into production
▪ What’s missing?
▪ Scalability of tech
▪ Consistent part quality
▪ Reduce the cost of parts

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Scalability of technology
▪ Different approaches
▪ Parallel manufacturing - 3D Systems Figure Four
▪ New technologies

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Consistent Part quality
▪ Verifying part quality can be 40-50% of part cost
▪ Terabytes of data generated in a build
▪ How can we be sure the build is good?

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reduce the cost of parts
▪ Part cost breaks down to four main components:
▪ Machine time
▪ Materials cost
▪ Labor cost
▪ Secondary operations

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Flood of New Entrants
▪ FDM & Binder Jetting patents expired
▪ MANY new METAL companies
▪ Stealth technologies – many innovations in the works

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Dose of Reality
▪ Previously – “3D Printing will take over
manufacturing!”
▪ Now – “3D printing will be one of many tools in the
toolkit!”
▪ We better understand where 3D printing fits, and
applications that make real business sense

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Advances in Software
▪ Will become much easier to optimize a design for AM
▪ Streamlined workflows
▪ Integrated software

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Advances in Automation
▪ Factory of the Future
▪ Automation of processes
▪ Hybrid technologies
▪ Figure 4
▪ 3DEO’s fully automated line

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Additive Vs. traditional
manufacturing

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AM Vs. Traditional manufacturing
Traditional AM
Tooling Yes (can be costly) None
MOQ Thousands One
Lead Times Months to years Days to weeks
Ease of Innovation Difficult & costly Easy & inexpensive
Material Waste Medium to high Low
Complexity Costly “Free”
Quantities High Low to medium

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Cost vs. Complexity

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Cost vs. quantity
Traditional Mfg.
Additive Mfg.

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Low-volume Example cost calculations
Tool/Setup
Costs
CPP 100 CPP 1,000 Lead Time
Machining $500 $25.75 $22.00 8 Weeks
AM $0 $11.44 $11.44 10 Days
MIM $50,000 $503.23 $53.23 100 days

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Questions?
Matt Sand
President
Matt.Sand@3DEO.co
(310) 694-6847
Company Contact
www.3DEO.co
info@3DEO.co
(844) 49-METAL