Audi is pairing up with EOS who will implement modern 3D printing technology into automobile manufacturing. However, the German car manufacturer is also working with SLM and using their selective laser melting processes.
Over the course of 30 years, 3D printing has proven itself as a useful technology in the development of automobiles, as coverage on All3DP proves. Now Audi AG, the German automobile manufacturer, is expanding its 3D printing efforts to incorporate the technology even further.
Previously, Audi has used 3D printing for its motorsports division, creating equipment and building prototypes. But, to make sure they’re getting the most out of the technology, Audi has launched a development partnership with EOS, the additive manufacturing specialist.
EOS Additive Minds consulting division will work with Audi to implement 3D printing into its production. However, they’ll also be on hand to help with the development of a 3D printing center in Ingolstadt, Germany.
“The aim is to not only supply Audi with the right additive systems and processes but to also support them during applications development, when building up internal additive manufacturing (AM) knowledge and training their engineers to become in-house AM experts,” said Güngör Kara, Director of Global Application and Consulting at EOS.
However, EOS isn’t the only company working with Audi. SLM Solutions Group AG will also be collaborating with Audi who will be using their selective laser melting process. The technology will enable Audi to supply spare parts on demand.
Producing Audi Parts in an On-Demand and Cost-Effective Manner
Audi explains that the reason for setting up the competence center is to learn more about 3D printing and gain experience with the processes and materials. Therefore, pairing with EOS was essential as they can provide guidance and support.
“With this technology, we are able to integrate internal structures and functions in tools that we have not been able to create so far with conventional manufacturing methods. Especially with components in small batches, we can now produce components using lightweight construction, quickly and economically based on this technology,” explains Jörg Spindler, head of Toolmaking at Audi.
An important vision for Audi to achieve is being able to manufacture on demand, supplying spare or complex parts which aren’t regularly required but are important nonetheless. By using 3D printing, they’re saving money and time, but also using a more sustainable technology.
“The new constructive freedoms provided by this technology are especially interesting… Components for prototypes and spare parts requested extremely rarely are better suited for SLM processes than conventional manufacturing procedures thanks to the benefits of free geometric design. The load capacity of the components is comparable with parts manufactured using traditional methods,” said Harald Eibisch, who works in the technology development department at Audi.
A new quarterly report from the organization Women in 3D Printing takes an in-depth look at diversity in additive manufacturing, focusing on the employment distribution between genders, the different perceptions on professional opportunity, and the views of women who are pioneering the industry.
We’ve all seen the various reports that boldly predict the future growth of the additive manufacturing market, but it’s not too often that we take a deep look at the inner workings of industry. This is especially true when it comes to diversity in the 3D printing workplace, which, like many other manufacturing sectors, is predominantly made up of men.
A new quarterly report produced by the organization Women in 3D Printing presents a multi-faceted view at diversity within the additive manufacturing workplace. Entitled “Diversity For Additive Manufacturing: First Quarter 2018 Report”, the study is “a resource for understanding the shape and scope of diversity in the 3D printing industry”. It was authored by Sarah Goehrke, Editor-in-Chief of 3DPrint.com; and presented by Nora Touré, Founder of Women in 3D Printing and General Manager at Sculpteo.
The study presents a data-driven examination of diversity in the additive manufacturing sector, as well as subjective discussion that showcases the unfiltered perspective of women in the industry.
A Data-Driven Discussion on Gender Diversity in Additive Manufacturing
After a brief introduction to the state of additive manufacturing as a whole, the report takes a deep, data-driven dive into gender diversity within the industry. The author presents the issues involving diversity (or lack thereof) right at the outset of the report.
“Objectively, the additive manufacturing industry is growing, comprising a more than $6 billion industry. At one estimate, the workforce is made up of 87% male employees and 13% female employees. Public companies’ executive leadership structures can be observed to be made up of a majority male management structure,” Goehrke writes.
Before showcasing the direct impact this imbalance has on the additive manufacturing sector, the study presents statistics that focus on a bigger picture. The author sources a recent study from Northwestern University that suggests that career perceptions are changing among younger generations. A 2016 LinkedIn survey is also quoted within the text, which found that 23% of employees in STEM (science, technology, engineering, and mathematics) were female.
Although this sourced research indicates significant growth for women in tech, other studies shine a glaring light on the problems that women in tech constantly face. For instance, the 2017 McKinsey Women in the Workplace study shows that women are significantly underrepresented in automotive and industrial manufacturing.
As for the 3D printing industry, the report turns to a recent salary survey published by Alexander Daniels Global, which is a UK specialist recruitment company that works in the additive manufacturing field. Looking at every professional aspect across the regions of North America, EMEA, and Asia Pacific, the survey found that a whopping 87 percent of employees are male, while just 13 percent are female.
The report digs even deeper into this data, providing a breakdown of the different jobs women hold in the 3D printing industry. The survey found that 29 percent of women in 3D printing worked in marketing, followed by 16 percent in sales, and 14 percent in application and consulting.
Another aspect that the quarterly report looks at is the public employment records of Stratasys and 3D System, two of the largest additive manufacturing companies. In regard to executive positions, the study found that only two of the eleven reported directors and senior management positions at Stratasys are held by women. Out of the five executive officer positions at 3D Systems, none of them are held by a female employee.
Nora Touré, Founder of Women in 3D Printing and General Manager at Sculpteo.
A Personal Perspective of Women in the 3D Printing Industry
After presenting these telling statistics, the quarterly report takes a subjective approach on the subject, as the author herself is a prominent female figure within the 3D printing media scene. Goehrke talks about her own perspective as a woman working in the field of additive manufacturing, explaining certain experiences and epiphanies that transpired at various trade shows. At one point, the author shares a realization she had at CES 2018 in Las Vegas.
“At CES 2018, shortly after the dawn of this new year, thousands gathered in the desert for the neon spectacle that is the massive consumer electronics show. This year was my second time attending, and it seemed to me, primarily focused in as I was on the 3D Printing Zone, that more women were present in 2018 than I had seen in 2017. I took great heart from this — and then noticed an anomaly. Any woman can tell you that in a packed public space, be it an opera house or a baseball stadium, there are always lines for the bathroom. Queuing here is often a built-in part of any experience, and is less a surprising aspect of these events than an exasperating one. At CES, the line out the men’s room door wrapped around a corner in one crowded hallway between event halls; I walked straight into the ladies’ room, no queuing required. Realizing this had me look again at the makeup of attendees; while through efforts such as Women in 3D Printing it becomes clear that there are a significant number of women working in tech today — much of the visibility is clear to those inclined to look. Because I was looking for women in the crowd, I saw them. In absolute numbers, though, women still comprised a significant minority of the total attendance,” Goehrke states in the report.
Utilizing more than 100 interviews conducted by the Women in 3D Printing organization, the report also shares statements from some of the most accomplished females working in the additive manufacturing sphere. The study focuses on a number of questions, including what the subjects think of the 3D printing industry today, the challenges they’ve faced as women in STEM, and how to encourage more women to get involved with 3D printing.
At the end, the report offers a conclusion packed with actionable steps towards making the industry a more diverse space. Goehrke writes:
“Actionable steps toward evening the field of employment include establishing relationships with mentors, visibility of role models, and encouraging educational and training initiatives. Through sharing the stories of industry participants, visibility of experience is rising, positioning the next generations of the workforce to enter a more level field and creating a more complex, rich industry built upon wider-reaching creative problem solving, inventive approaches, and breadth of resources.”
Blow Molding (also: Blow moulding) and the molding process of polymers is one of the pillars of industrial manufacturing. Without this technology, we wouldn’t have access to cheap glass or plastic bottles or mass-manufactured hollow containers.
Blow molding allows industry players to produce parts and containers fast and cheap in high quantities. But how does this process work and what has 3D printing to do with it? This article will give you all the answers in a nutshell.
What is Blow Molding?
Blow molding started in the glass blowing industry where a liquid glass pulp is enclosed in a two-piece mold and then expanded by blowing into to the pulp. This causes the glass retains the contour of the mold and form a hollow area on the inside.
With the invention of polymeric thermoplastics, this technology started to rev up in the plastic bottle industry. Starting in 1977, the number of plastic containers rose from zero to 10 billion plastic bottles in 1999 due to the soft drink companies in the USA. The outcome isn’t exactly good for the environment, but if you use biodegradable materials or recycle thermoplastic bottles made from PET, things look a bit better.
Blow Molding versus Injection Molding
So, what’s the difference between parts made by injection molding and parts made by a blow molding machine? Injection molding creates solid parts, while blow molding creates hollow parts. If you are looking for something that needs only one rigid wall, injection molding is the right process. Think of bottle caps, cases, combs, and housings for computers and televisions. If you need a flexible, structural piece that even can hold fluid, you’re best off with blow molding. No wonder that billions of water bottles stand for the blow molding technology.
How Plastic Bottles are Made
Producing plastic bottles does not greatly differ from the glass blowing process. The technology used by the bottle forming process is called Injection Blow Molding (IBM). This requires a so-called preform which is much smaller than the actual bottle. The preform can be transported easily and if variants do not differ in weight it can be used uniformly. Like in the glass manufacturing process, the preform is heated up, put into the mold and inflated. Due to the preform, the material expands equally, resulting in a better flow control, surface quality and transparency. After the blow molding process, the bottle heads have to be threaded and the excess material cut off.
What are the Advantages of Blow Molding?
Blow molding scores especially at mass producing at a low price. Depending on the quality of the mold, it can produce more than over 1 million pieces before it has to be replaced. The production is also very fast compared to other molding processes, ejecting a finished product every few seconds. Thin walls and water-cooled molds also reduce cycle time. In addition, once the machine parameters are calibrated, the outputs quality is constant. This is achieved because factoring parameters are stable and controllable. The process of blow molding is also perfect for automation, reducing the need for workers working in a monotone environment.
What are the Limitations of Blow Molding?
Purchasing a molding machine may seem like the biggest investment of a company to start producing. However, before you start producing, you will need a mold. The biggest disadvantage of blow molding lies with the problem of all molding processes. For each type of product you want to produce, you need a new type of mold and this comes with a very steep price. The molds have to be machine milled and produced with a very high surface quality. The molds also have cannulas running through the walls to transport cooling fluids. In addition, the mold often has to be hardened to increase its lifespan. This high cost of molds often reduces a company’s incentive of producing prototypes, especially for low piece numbers.
How does 3D Printing Affect the Blow Molding Process?
This is where 3D printing comes in. With additive factoring, prototypes of molds can be produced faster and at a much lower cost. Unfortunately, 3D printed molds are way behind in durability than their machined counterparts. Still, it is not the goal to create a finished mold, but a prototype or a mold used only for small batches. In addition, it is less difficult and in extreme cases finally possible to create complex internal cooling pipes with 3D printing. The molds are made of metal with laser sintering or durable plastic with the Polyjet technology. The 3D printers of EOS or Stratasys are already helping to enhance the development of molds in all applications.
Which Businesses offer Blow Molding Technology?
If you are interested in acquiring a blow moulding machine or use a blow molding service, you have a choice of over 300 companies. Here are the most successful ones (according to Plastic News)
1. Amcor Rigid Plastics
Company profile: Amcor Rigid Plastics is one of the leading manufacturing companies, developing and producing high-quality packaging for food, beverage, pharmaceutical, medical devices, personal care and other products. Blow molding is an integral part of the company. Amcor is currently offering its service in 200 production sites in 43 countries. 68 percent of the production are flexibles, 32 percent rigid products.
Company profile: What started in 1970 with a simple motor oil container, has become one of the most important companies in blow moulding business. The company offers bottles and containers for food, beverage, household, auto/chem, personal and healthcare businesses. Graham Packaging was early in PET technology and still innovating it today. Also, Graham is one of the world’s largest suppliers of bottle-grade recycled plastics.
Company profile: With total annual sales of $2.7 billion, and more than 40.1 billion containers manufactured per year, Plastipak is one of the big players in blow molding. Founded in 1967, Plastipak started out providing plastic packaging to deliver water for the Young family’s water delivery company. Today, Plastipak now operates more than 60 production sites located in North America, South America, Europe, Africa, and Asia.
Company profile: The Auto Inergy Division is a subdivision of Plastic Omnium. They are manufacturing plastic fuel tank systems. The materials offer a combination of safety, cost, and weight performance (a 30% to 40% weight improvement compared with steel technologies), which are also usable in hybrid vehicles. Plastic Omnium offers solutions adapted for all kinds of engines.
Company profile: Austria-based ALPLA Werke had a turnover of €3.4 billion in 2017 with 176 production facilities and 45 countries.. They are offering plastic packaging of all sorts, including packaging systems, bottles, closures, injection-molded parts, pre-forms, and tubes. Founded in 1955, Alpla claims to be “a family company steeped in tradition, always looking towards the future”.
Grohe, the world leader in supplying sanitary and water fittings, is planning to expand its production of fittings and incorporate 3D printing technology into its prototyping processes.
Looks like Grohe Water Technology AG has big plans for 2018 including expanding its production of fittings by using 3D printing in a new pilot project.
The German company revealed they will be using the technology at this year’s ISH trade show in Frankfurt am Main — an event for the combined topic of water and energy.
Grohe has the goal of accelerating product innovation by 20 percent. As well as this, it intends on improving efficiency at the new design center in Hemer, Germany. Therefore, new technologies are an important factor in design, development, and production.
The company’s plans for the next few months, as well as using 3D printing to expand the production of fittings, are to launch its latest ceramic line in March and work on new product innovations for 2019 ISH.
Creating Prototypes at Grohe with 3D Printing
The Grohe team have been using a Dimension 3D Printer from Stratasys. With 3D printing, they’ve already noticed a huge reduction in time and cost when creating prototypes.
According to a Stratasys application story, previously the company would rely on the company toolmakers or external suppliers. However, in the first four months of use, the 3D printer ran for over 380 hours.
Friedrich Imhoff, a Grohe product development manager explains some of the benefits of 3D printing. He says: “We reduced the time to develop a flushing system by 50 percent. Product samples could be produced at an early stage of the development process… The product can be presented within a short amount of time and our product managers are able to identify themselves with the product at a very early stage.”
Thanks to its use of technology, the company has received over 300 awards for design and innovation. Grohe is especially praised for its sustainability.
Interested in finding out more? Grohe CEO, Michael Rauterkus, is speaking about “Water as a resource in times of digitalization” at the World Market Leaders Summit today.
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