3D PRINTING IN CONSUMER ELECTRONICS

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3D PRINTING IN CONSUMER

ELECTRONICS

[email protected] Wuhan Mar 2 ^nd

西门子工业软件

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CHALLENGES

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Challenges for the Consumer Electronics Manufacturer

Price pressures Localization of products Product liability Compliance & regulations

Uncertain demand Complex global supply-chain

Short product lifecycles

= rapid product development

Intellectual

property protection

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Product Development is a HUGE Investment!!

Source: http://arstechnica.com/gadgets/2016/04/dyson-hair-dryer-supersonic-uk-details/

Dyson claimed to have invested £50 million and four years of research into development of the new technology, making it quieter and – apparently – less damaging to hair. The resulting device has a motor that the company said was eight times faster – and a lot smaller – than those used in the most

popular hair dryers sold in Japan, where we are told 96 percent of the population owns one. So, perhaps unsurprisingly, Dyson’s hair dryer will go on sale in Japan first.

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Intellectual property (IP) theft is a growing global challenge that costs legitimate businesses

worldwide:

The Cost of Stolen IP

- 2.5 million legitimate jobs at risk - US$945 billion in lost sales annually

counterfeiting and piracy cost G20

governments more than US$135billion a year in lost tax revenues

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Consumer Electronics Product Development Process

Who are your customers?

• Corporate Purchasing Agents/Buyers

• Retail Salespeople

• End Users

• “Other”

Product Definition

Industrial Design

Product Concept

Review

Engineering Specifications

Tooling &

Supplier Management

Final Product

Review PRODUCTION

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• Increased R&D costs

• Poor product quality & increased product liability

• Product not aligned with definition = low product demand

• Supplier quality issues or delays lead to an inability to fulfill production demands

Poor Communication Causes Many Issues

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3D PRINTING

OPPORTUNITIES

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Product Development & Engineering

• Idea generation models & product design reviews

• Form, fit, ergonomics and function

• Vibration, drop, EMI, thermal, destructive testing

• Compliance & regulatory review models

• Rapid component fabrication

• Test stands (life cycle, wear testing, electronic validation testing, alpha/beta)

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Logitech 3D Printing During the Design Process

Concept modeling, product definition, product concept reviews

Lower-level (engineering specification) design review Functional prototypes

can be used for fit testing, impact testing and mechanism design

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Idea Generation

Models & Product Design Reviews

PRODUCT DEVELOPMENT & ENGINEERING

RESEARCH &

DEVELOPMENT

Form, fit, ergonomics and function

Vibration, drop, EMI, thermal, destructive

testing

Compliance &

regulatory review models

Rapid component fabrication

Test stands (life cycle, wear testing, electronic validation testing, alpha/beta) Idea generation

models & product design reviews

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Articulated hernia mesh fixation device prototyped with logo

Synergy can go to their clients with multiple designs on the first meeting Rendering models onscreen can be done

quickly but prototyping can takes weeks to achieve

Synergy Communicates Quicker with its Clients

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Form, Fit,

Ergonomics and Function

PRODUCT DEVELOPMENT & ENGINEERING

Form, fit, ergonomics and function Idea generation

testing

Compliance &

Test stands (life cycle, wear testing, electronic validation testing, alpha/beta)

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Top Notch Design Produced High End Prototypes Quickly

Mockup product fitment and layout

Final prototypes used for tradeshow &

marketing purposes (<1 month)

Prototype sealing &

rubber touch pads with Tango material

Parts painted in-house to get sharp lines and nice logo

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Vibration, Drop, EMI, Thermal, Destructive Testing

PRODUCT DEVELOPMENT & ENGINEERING

testing Idea generation

Compliance &

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Christie Digital Functional Prototyping & Testing with 3D Printed Parts

“We have had a mindset change with our engineers. Now they are not willing to live with one prototype and hope it works.”

Mark Barfoot, Christie Digital Systems

Prototype lamp assembly, operates at 120°C.

Evaluation mockup evolved into finished product – baseline communication model throughout project

• Fitment and life cycle testing

• Ergonomic testing (soft-touch) – remote controls

• Vibration & Drop Testing

• EMI Testing

• Thermal chamber testing

Soft-touch rubber-like material used for ergonomics study of remote controls

Build. Test. Optimize.

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RedDOT Designs Rapid Functional Testing

ULTEM 9085 High

temperature & functional fan blade

Four simultaneous iterations of testing a groove (sealing with a rubber gasket)

Nylon 12 impeller for functional testing

& design verification

Durable Nylon 12 parts for high strength testing (snap fits, drop testing and high requirement) Nylon 12 switch assembly with integrated spring

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Compliance &

Regulatory Review Models

PRODUCT DEVELOPMENT & ENGINEERING

Compliance &

regulatory review models Idea generation

testing

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Black & Decker Keeps Up with Compliance and Regulations

Source: http://www.designworldonline.com/how-3d-printers-help-black-decker-get-products-to-market-faster/#_

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Black & Decker High Quality Eden Prototypes

Printed PJ part that has been chrome plated and polished to give final product appearance

Print and painted hard handle component from PJ

Overmolded components printed with PJ Tango material

Source: http://www.designworldonline.com/how-3d-printers-help-black-decker-get-products-to-market-faster/#_

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Rapid Component Fabrication

PRODUCT DEVELOPMENT & ENGINEERING

Rapid component fabrication Idea generation

testing

Compliance &

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3D Printed Molds Help Drive Product Validation & Testing

• Traditionally no prototyping of injection molded parts prior to investment in production mold

• Enabled the customer to functionally test prior to investing in tooling:

• ESD testing

• Fit testing

• End use materials – PC, ASA and TPU “This new flexibility enables us to try out two or three different solutions at the same time to get the best result. The

confirmed quality of our products produced using these functional prototypes has accelerated our R&D processes.”

Andreas Krause Head of Technical Department & Manufacturing at Berker

3,800 22,350 3 28

Traditional Tooling

3D Printed Tooling

Traditional Tooling

3D Printed Tooling

Time (Days)

Cost (USD)

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Test Stands

life cycle, wear testing, electronic validation testing, alpha/beta

PRODUCT DEVELOPMENT & ENGINEERING

Test stands (life cycle, wear testing, electronic validation testing, alpha/beta) Idea generation

testing

Compliance &

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Custom Engineering Test Fixtures & Tools

FC 720 Valve design test stand

Mouse life cycle testing (improved repeatability) Pneumatic testing stand for valve (Parker

Hannifin)

Simultaneous life cycle testing stand

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Manufacturing

• Design & Manufacturing NPI Communication Models

• Production line setup & support

• Assembly and processing fixtures

• Inspection & check tools

• Customized product manufacturing

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Design & Manufacturing NPI Communication

Models

PRODUCT DEVELOPMENT & ENGINEERING

Design & manufacturing communication models

Product line setup and support

Assembly and processing fixtures

Inspection and quality assurance checking tools

Customize product manufacturing

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Microsoft Surface Tablet Development for NPD

Over 300 prototypes printed during development of the Microsoft Surface

Files can be sent via email so the latest design revision can be tested at the production facility in China

Source: http://www.3ders.org/articles/20130313-3d-printed-prototypes-help-microsoft-to-form-the-idea-of-surface.html

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Product Line Setup and Support

PRODUCT DEVELOPMENT & ENGINEERING

Product line setup and support Design & manufacturing

communication models Assembly and

processing fixtures

Inspection and quality assurance checking tools

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Automated Production Line Set Up & Tooling

Robotic arm tooling for quick adjustment & setup

Complex geometry & functionality printed directly in part

Production line setup & quick product line set up components

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Assembly and

Processing Fixtures

PRODUCT DEVELOPMENT & ENGINEERING

Assembly and processing fixtures Design & manufacturing

communication models

Product line setup and

support Inspection and quality

assurance checking tools

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• Sub-assembly offered as a value added service (single supplier)

• Unique projects & custom geometry, manual assembly

Printed Fixtures Help with Product Assembly

Assembly fixture printed with rubber-like over molded material to prevent product scratches & scrap

Drill guide for sub-assembly with press fit bushing for alignment

(Right) Nesting fixture for heat-stake insert post processing (left) check gauges for product quality

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Hand Assembly Tools

Wiring difficult to assemble into connector – custom jig for assembly

Difficult to keep mouse housing stable during

assembly – nesting fixture holds in place Geometry directly taken from

CAD file & printed

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Inspection and Quality

Assurance Checking Tools

PRODUCT DEVELOPMENT & ENGINEERING

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Quality Assurance and Inspection

Product QA inspection fixture

Electrical test fixtures with integrated

“pogo” pins for quick product quality assurance

Inspection fixture nest used for holding parts in a CMM

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Customized Product Manufacturing

PRODUCT DEVELOPMENT & ENGINEERING

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Send a picture of your ear into the mobile app

Earphone custom designed to

your specifications

Custom designed earphone printed on 3D

printer

Product shipped (in less than 48

hours) How it works:

Customized Headphones with NORMAL

• Customized product to fit user’s ear

• Traditionally used silicone molding (into custom fabricated molds) but process was too time consuming

Manufacturing is done in store- front in plain view of customers

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THANK YOU

2017用户大会

3D PRINTING IN CONSUMER ELECTRONICS