Daimler Trucks to use 3D printing in spare parts production

[kscarbel2]

Reuters  /  July 13, 2016

Daimler, the world's largest truck manufacturer, will use three-dimensional printing (3D) to produce spare parts, the latest example of how digital technologies are radically reshaping automotive manufacturing and its supply chain.

Rather than shipping vehicle parts across the globe, carmakers including BMW and Volkswagen are experimenting with so-called additive manufacturing. This relies on sending a digital blueprint of a component to a printer which creates parts by using lasers to melt powders into plastic, glass, metals and even ceramics.

By printing new parts, automakers can save logistics and warehouse storage costs and produce complex components at low volumes.

The technology is not ready to make high-volume vehicle components, so carmakers rely on conventional manufacturing methods for components like metal body panels, which are made using hydraulic metal stamping presses, costing up to 40 million euros ($44 mln) each.

But advances in laser technology, thermal and chemical processes mean 3D printing can be used for some small batches of customized components, for things like prototype vehicles and concept cars.

In a sign of the technology becoming more widespread, Daimler Trucks said on Wednesday that from September, it will use 3D printing processes for plastic spare parts including spring caps, air and cable ducts, clamps, mountings and control elements.

Daimler, which owns the Mercedes-Benz brand, has more than 100,000 printed prototype parts, and said it will expand production using 3D printing methods.

The truck maker's "printed" spare parts are created with 3D printers based on what is known as a selective laser sintering (SLS) printing process, and ordered using a special spare part number, even for parts on models that are several decades old or even out of production.

Rival Audi said on Wednesday that it is creating a 3D competence center at its factory in Ingolstadt, Germany, year end, to develop production of components made from steel and aluminium. From October onward, Audi will use printers to make steel tools.

Volkswagen and BMW have used 3D printing for years in the process of "rapid prototyping."

The cost of additive manufacturing is expected to fall by between 25 percent and 45 percent until 2020, thanks to multi-laser machines and improvements in the powder-dispensing process, management consultants Roland Berger said.

Compared to the conventional machine tool market, the metal "additive manufacturing" market has less than 1 percent market share, according to Roland Berger.

Three-dimensional printing has been used by the aircraft industry. The United States Navy has installed systems on combat ships to produce spare parts, for example to repair the nose cone of a damaged Harrier jet.

BMW has experimented with 3D technology since the 1990s, using 3D printing to make components for the Rolls-Royce Phantom, including the casing of the indicator light.

BMW sees major potential for the future application for new customer offerings, such as personalized vehicle parts, it has said.

[kscarbel2]

Mercedes-Benz Trucks uses pioneering future technology: 3D printing: truck spare parts available on demand

Daimler Press Release  /  July 13, 2016

• New feature in after-sales: spare parts from the 3D printer for the first time
• Mercedes-Benz Trucks pioneers the supply of 3D parts
• 30 units 3D spare parts available as of September in genuine-parts quality on demand – number growing continuously
• Economical and fast production even with small quantities
• Environmentally friendly 3D printing without warehousing costs

Stuttgart – Genuine spare parts for Mercedes-Benz trucks which are ordered and delivered even after many years; in the Mercedes-Benz Trucks after-sales service this has already been reality for a long time now. As the next step, Mercedes-Benz Trucks is using the latest 3D printing processes for plastic spare parts as the standard production method in the Customer Services & Parts sector. As of September already, 30 genuine spare parts can be ordered and supplied at the press of a button from the 3D printer, quickly, economically, in any quantity and always in consistent genuine manufacturer's quality ("one-piece demand").

With the use of 3D printing technology as an innovative state-of-the-art production process in after-sales, Mercedes-Benz is taking on the pioneering role and technological leadership among the global truck producers.

"In keeping with our brand promise 'Trucks you can trust', we set the same benchmarks for reliability, functionality, durability and economy for spare parts from 3D production as for parts from conventional production", says Andreas Deuschle, Head of Marketing & Operations in the Customer Services & Parts Mercedes-Benz Trucks Division. "However, 3D offers many more possibilities; this is why we shall be rapidly extending the production of 3D printed parts."

Experience and high tech ensure highest 3D quality

Today at Daimler more than 100 000 printed prototype parts are manufactured for the individual company divisions every year.

"We benefit from our extensive experience at Daimler with 3D printing processes in prototype construction", comments Andreas Deuschle. The available spare parts consist of high-quality plastic components. Covers, spacers, spring caps, air and cable ducts, clamps, mountings and control elements are just a few examples of economical spare part production in top quality made possible by using the 3D printing process.

The "printed" spare parts are created with state-of-the-art 3D printers based on the Selective Laser Sintering (SLS) printing process. For the high quality standards of Mercedes-Benz Trucks the process parameters have been optimised and determined by the Daimler research and development divisions. Every 3D spare part can be ordered by the customer using the special spare part number under which it is recorded in the order code lists and the spare parts catalogues at Mercedes-Benz Trucks. Thus, even after several decades, rapid supply to the customer is ensured via the Mercedes-Benz Logistic Supply Chain through all the sales stages – all over the world.

Advantages through secure supply of spare parts, rapid availability and economy

The environmentally friendly and resource-conserving 3D printing process is playing a pioneering role in the after-sales. The challenge in the spare parts business lies in securing supply even for model series which are no longer produced. This means that the range also includes spare parts for which there is only a low demand in small quantities every year. Producing them is thus increasingly uneconomical for suppliers – production facilities and tools often have to be retained and maintained for years. With the 3D printing process these challenges are a thing of the past. For every 3D spare part is available on demand at short notice all over the world.

The printing itself can take place within a very short time following receipt of the design definition and order, considerably speeding up the production and supply of spare parts. As spare and retrofit parts can still easily be "reprinted" even after a long time using the data stored and supplied without any complex stocking, no warehousing is required either. At the same time the burden on costs, resources and the environment is also eased, as there are no material surpluses, the disposal of which is very complex.

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[kscarbel2]

Daimler Trucks to Deliver 3D Printed Parts in Test Program

Heavy Duty Trucking (HDT)  /  December 4, 2017

Daimler Trucks North America has announced will make its first delivery of plastic parts produced using 3D printing technology in the coming weeks as part of a pilot program.

During the pilot phase of the 3D printed parts program, DTNA will release a controlled quantity of 3D printed parts and will invite feedback from customers and technicians that receive them. The company will collect data on the parts performance and assess potential future demand for 3D printed parts.

DTNA sees 3D printing as an opportunity to better service customers, particularly those customers in need of parts that have been difficult to provide through traditional supply chain models, such as for older trucks or parts with low or intermittent demand.

To print the parts, DTNA partnered with the 3D printing service bureau, Technology House, which has over 20 years of experience in additive manufacturing. The companies have made the first parts available to customers with Selective Laser Sintering. The SLS process refers to layering powder in a print chamber and then “selectively” melting a pattern with lasers before adding the next layer. The 3D printed parts have been validated to meet durability requirements and many will appear no different to the untrained eye, according to DTNA. During the pilot phase, only parts such as nameplates, map pockets, and plastic covers will be printed and delivered.

Parts that are eligible for 3D printing are being stored in DTNA’s digital warehouse. This allows a part to be printed on demand with shorter lead times. Without the need to maintain tooling, these parts will remain available to customers when needed.

On-demand 3D printing also removes the need of holding physical inventory. Currently, the order process takes 2-4 weeks, but once the program is fully launched, parts will be able to be shipped in just a few days, according to DTNA. This capability has the potential to increase uptime for our customers who may otherwise experience long wait times for a hard-to-find part.

“Over the past five years, DTNA has made significant financial and intellectual investments in the supply chain network in order to deliver parts to our customers faster than ever before,”  said Jay Johnson, general manager, aftermarket supply chain, Daimler Trucks North America. “What DTNA is launching today with 3D printing is only the beginning as we continue to develop this technology in our quest to be the benchmark for parts availability.”

[41chevy]

I use a company called Shape Ways for 3 D parts for custom parts, they will do ABS, Polystyrene, Nylon,metals and others and Desktop Metal in Massachusetts will 3 D print in  5056T6 Aluminum Chrome Moly and Titanium.