HYB YB-MAN MAN Hybrid 3D manufacturing of smart products Ronald - - PowerPoint PPT Presentation

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HYB YB-MAN MAN

Hybrid 3D manufacturing of smart products

Ronald Maandonks, Rob van Asselt Signify Research November 21, 2018

www.hybman.eu Contact: info@hybman.eu

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THE HE CHA HALLENGE: LLENGE: EVOLVIN LVING G ELEC ECTR TRONI NICS S MARK RKET ET

Electronics manufacturing is still heavily relying on mass production:

• Standard products and components,

rigid supply chains

• High investment cost (tooling, R&D)
• Long initial lead times (tooling, shipment)

Industries like Signify and Bosch are facing:

• Demand for customized and personalized

products leading to increased diversity

• Request for new product designs offering

improved functionality and form factors

• Need for cost effective manufacturing of small

series.

• Need faster response to changes in the market.

Need for more flexible manufacturing methods

No product specific tooling → low investment → short lead time Digital process Digital design Design freedom Integration of functionalities Local/distributed manufacturing Stock free More flexible supply chain

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THE HE SOLUTION: LUTION: HY HYB-MAN MAN

The Hyb-Man project will develop hybrid 3D manufacturing methods to enable flexible first time right production of smart systems

hybrid 3D manufacturing methods, combining:

• additive manufacturing/3D printing
• 3D electronic structure processing
• 3D assembly & interconnect

flexible first time right production smart systems

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HY HYB-MAN MAN APP PPRO ROACH ACH

Product – process relations Design guidelines Metrology

T , geometry, conductivity

Product architectures Product designs Control platform

Sense Act

Materials

structural, electrical

Processes and technologies AM

FDM, SLA, dispense

3DPE

jet, dispense, FDM

P&P

Complex set of activities

• need to run in parallel
• many mutual interactions
• broad set of competences

→ drive for cooperation in Hyb-Man Design guideline activities to link relations materials-processes-products Control platform to integrate processes and metrology

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HY HYB-MAN MAN ACTIV TIVITIES ITIES AND ND PARTNERS TNERS

Product – process relations Design guidelines Metrology

T , geometry, conductivity

Product architectures Product designs Control platform

Sense Act

Materials

structural, electrical

Processes and technologies AM

FDM, SLA, dispense

3DPE

jet, dispense, FDM

P&P

• Reden
• Signify
• Technolution
• TNO
• TU Eindhoven
• VSL
• Fraunhofer IFAM
• Henkel
• Neotech AMT
• Robert Bosch
• Xenon

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HY HYB-MAN MAN RES ESULTS ULTS – 5-AXI XIS S PL PLATFORM TFORM & L & LED ED DE DEMONSTRA MONSTRATOR OR

Processing route for 5-axis FFF/FDM

3D product design: LED cube containing integrated tracks, LEDs and connection hybrid manufactured functional product

• 1. Import Step file into Motion 3D CAD/CAM SW.
• 2. Manufacture operations (FFF, P&P, printing

circuits) programmed in single interface.

• 3. Output G-code via machine specific post

processor. 6. Main body printed with FFF. 7. Side wall circuits use 5 axis motion. 8. 16 LEDs in walls mounted with conductive adhesive.

• 4. Base printed via FFF in PLA.
• 5. 4 LEDs in base added and then

Ag circuit printed to directly contact.

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HY HYB-MAN MAN RES ESULTS ULTS – HY HYBRID RID 3D D MA MANU NUFACT ACTURI URING NG PL PLATFORM TFORM

Process and equipment development:

• Baseline stereolithography 3D printing (SLA)
• Modular
• Pick & place of components
• Interconnection by dispensing metal paste
• Metrology & control

Hybrid 3D manfacturing platform Freeform gear shifter

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HY HYB-MAN MAN RES ESULTS ULTS – THE HERMAL RMAL AND ND ME MECHA CHANICAL NICAL MO MODELING DELING

Modular AM process simulation:

• Prediction of internal stresses and warpage
• Prediction of temperature field
• Suitable for multiple AM techniques and materials

after release from build platform

3D printing simulation to predict temperature distribution (location and time)

G-code

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HY HYB-MAN MAN RES ESULTS ULTS – MA MATERIAL ERIAL AND ND PR PROCESS OCESS DE DEVELOPMENT VELOPMENT

Additive manufacturing materials (polymers) with increased functionality → Filled materials with thermal/electrical conductivity

PA Hotmelts: highly amorphous low polarity

• 1. Tuning polymer properties

Optimized product properties PA hotmelt + multiple fillers conductivity (high filler %) processability (low filler %) Balancing properties Material optimization

• doubling of thermal conductivity
• maintain good viscosity
• 2. Optimization polymer/

filler composites

Requires Results

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HY HYB-MAN MAN RES ESULTS ULTS AND ND OUT UTPUT PUT

Models Materials (Integrated) processes Product designs Know how Methods and tools SW platform Equipment and tools Development platforms Manufacturing methods

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HY HYB-MAN MAN EX EXPLOIT PLOITATION TION OF PR PROJEC OJECT T RES ESULTS ULTS

• Material sales
• Product sales
• Equipment sales
• Manufacturing services
• Simulation consultancy
• Metrology consultancy
• SW platform services
• New partnerships
• New funded projects
• Intellectual property

All

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HY HYB-MAN MAN IMP MPACT ACT ON N EU EU IND NDUSTR USTRY

Opportunities

Achievements up to Nov. 2018

Economical

Revenue

Sales of products (LED lighting, automotive sensors), equipment, tools, materials. New products, faster introduction to the market and cost savings (tooling, development).

3 R&D machines sold (> 500 k€)

(Universities and R&D product development)

New markets

Extend digital capabilities (modeling, metrology, process control). Access to new markets, like healthcare, personal care, consumer electronics, aerospace. From high volume to low volume (personalized)/fast delivery.

New supply chain and partnerships

Requires digital supply chain (materials, equipment, inspection, packaging, transportation, …). New cooperation (funded) projects for universities and knowledge institutes.

Social

Employment

Bring manufacturing back to Europe (labor cost less dominant, complexity difficult to copy). Grow in engineering/development and consultancy/services.

Education

Teach learnings from Hyb-Man, disseminate know-how (courses, conferences, papers) Educate the future digital work force.

> 20 conference contributions 2 PhD students working in Hyb-Man Societal challenges

Resources and materials use: on demand and local manufacturing. Health and well-being: e.g. personalized devices to monitor health at home. Innovative societies: include people in the design and manufacturing process.

Innovation and technology

New products/ services/ processes

New end products (design, function, use); make on demand, make local New (integrated) equipment and tools (Consultancy) services for simulation, metrology, control, manufacturing

Integrated process approach defined Pilots & demonstrators

Pilots (HW and/or SW) for the products, equipment, metrology and control. SW tools (demonstrators) for product design and simulation.

First demonstrators available (HW, SW) Manufacturing

Hybrid 3D manufacturing is digital, thereby contributing to Industry 4.0 and Smart Industry.

Hyb-Man linked to Fieldlab MM3D (NL)

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SUM UMMAR MARY Y AND ND CONCL NCLUSION USION

Huge opportunities

• product design
• manufacturing (local, on demand)
• supply chain and business model
• service offerings

Many challenges

• technologies and materials
• industrial processes
• first time right
• new product designs

Changing environment and customer demands drive the need for more flexible manufacturing methods smaller series, customized products – design freedom – faster response to changes Multi-disciplinary approach and partnerships needed to move forward materials – processes – equipment – process control – product design – manufacturing – inspection and test

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ACKNO KNOWLEDGEMEN WLEDGEMENT

Hyb-Man is a project labelled by the EUREKA Cluster PENTA, supporting innovation in micro- and nanoelectronics based components & systems