How is RM Masterclass structured and what does it cover?
RM Masterclass has been developed to provide delegates within a one day course with the tools needed to gain the most out of available additive layer manufacturing technologies.
The six RM Masterclass sessions follow a structured RM implementation methodology developed by RM consultancy Econolyst Ltd, and used by Econolyst clients around the world.
The methodology starts by assessing the business benefits and drivers behind ‘why’ RM could be used to gain commercial advantage in your business.
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The methodology then considers the materials implications of the part or assembly required, before looking at the additive manufacturing technologies capable of processing the identified materials. Having considered the process capabilities and constraints of the identified technologies, the methodology then looks at the direct cost of component part or assembly manufacture, before closing the methodology loop by comparing the overall supply chain benefits against the initial perceived commercial advantage.
Detailed Program
| Session 1 – | Introduction to Rapid Manufacturing implementation and the business benefits of RM adoption |
In this first session we introduce the concept of Rapid Manufacturing through a series of ‘real-life’ applications case studies. We then look at how to identify the specific business benefits that can be gained through the adoption of additive manufacturing for the production of end use parts. This includes:
| - | How RM can be used to enable the manufacture of component parts that cannot currently be economically manufactured by formative, subtractive or fabrication based techniques? |
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- | How RM can be used to manufacture parts with increased geometric complexity providing a commercial advantage or competitive edge for your company? |
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- | How RM can be used to increase the functionality of components, that cannot be achieved using traditional single stage manufacturing processes |
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Session 2 - Material considerations and selection of additive manufacturing mechanisms
Having gained an understanding of the business drivers to the implementation of RM, we will then consider the range of materials that can be processed using current additive manufacturing technologies, including organic, ceramic, polymeric and metallic materials.
In this session we will address primary material selection criteria, such as the mechanical strength of the material required, thermal stability, thermal or electrical conductivity and corrosion resistance. We will also consider product life-cycle implications, such as thermal cycling, cyclic loading and environmental issues such as humidity, moisture and the operating temperature of the RM part. Finally we will look at the customer’s perception of different RM materials, such as natural colour, texture and tactility. This will be supported through the use of physical sample parts.
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Session 3 – Polymeric additive manufacturing process selection for RM
Having considered the available materials that can be processed using additive layer manufacturing for RM application, we will then considers which technology platforms are capable of processing different materials.
We will start by focusing on the polymeric processes such as Selective Laser Sintering, Stereolithography, Polyjet, Profactory and Voxeljet amongst other. We will look at the capabilities and constraints of each technology platform, and through case studies, how these technologies can be used for Rapid Manufacturing applications. This session will be supported with multimedia animations of processes and video footage of machines in operation, giving delegates a more realistic perspective of the available technologies.
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Session 4 – Metallic and ceramic additive manufacturing process selection for RM
In this session we will look at both direct and in-direct additive manufacturing processes capable of generating both metallic and ceramic parts. Processes under discussion will include Electron Beam Melting (EBM), Direct Metal Deposition (DMD), Direct Metal Laser Sintering (DMLS), indirect laser sintering and 3D Printing, Selective Laser Melting (SLM) and Laser Cusing. We will look at the capabilities and constraints of each technology platform, and through case studies, how these technologies can be used for Rapid Manufacturing applications. This session will be supported with multimedia animations of processes and video footage of machines in operation, giving delegates a more realistic perspective of the available technologies.
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Session 5 – Rapid Manufacturing cost modelling and supply chain management
Having considered the constraints and capabilities of different additive manufacturing technology platforms and available materials, we will then look at how both direct and in-direct costs can be attributed to Rapid Manufacturing and how these compare to processes such as CNC machining, injection moulding and casting. In this session we will also look at the relationship between build time and part cost and how subtle changes to an object geometry or build orientation can affect the cost of parts made using different systems.
Within this session we will also look at the hidden costs of rapid manufacturing, such as raw material utilisation, part post processing and process consumables and servicing, in addition to direct costs, such as machine and material price and technology depreciation.
Finally we will discuss the current status of the global Rapid Manufacturing supply chain and how delegates can purchase in confidence as ‘intelligent RM customers’.
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Session 6 - Technology transfer session and delegates review workshop
In this final session, delegates will be given an opportunity to review what they have learned through a hands-on technology transfer session and company parts workshop. Delegates are encouraged to bring ‘real-life’ potential RM projects to this workshop, which will then be reviewed by Econolyst staff and other delegates. Scenario based RM problems will also be given to delegates, who will be expected to work in small groups to find solutions. Groups will then be expected to feedback their potential RM solutions to the rest of the workshop delegates.
This session will be supported with both printed and electronic material made available in the delegates pack and also through access to on-line resources.
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