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Additive Manufacturing - Make or Buy
Additive Manufacturing - Make or Buy
Additive
Manufacturing
Make or Buy?
An overview
of today’s supplier
market and cost
structure for metal
AM parts.
INSIGHTS GAINED:
• Cost structure of metal Additive Manufacturing
• Key decision factors to make or buy Vol. 1
October 2017
• Today’s market pricing
Insights gained
Management summary
Additive Manufacturing became a game changer in The majority of service bureaus is concentrated in
many industries. Especially for SMEs, however, high Southern Germany. Market prices range between
part cost are still the main restriction for further 3-10 €/cm³ for finished aluminum parts, represent-
wide-spread adoption of this production technology. ing a spread of 35-240% around the mean value. The
For Laser and Electron Beam Melting (LBM and price spread for titanium parts is significantly lower
EBM), a significant part of the (AM) manufacturing/ with market prices around 5-7 €/cm³.
production costs results from high machine hourly
rates of 40-50 €/h paired with relatively slow build- The surprisingly large spread in market prices per-
ing speeds. sists even when larger lot sizes resembling a con-
tinuous serial production are requested. Comparing
Ampower Insights gives a detailed calculation of different materials, aluminum offers the largest
production costs and introduces the ratio of cost per margins on the supplier market while stainless steel
unit of volume for an easy comparison of technolo- yields much lower returns.
gies and materials. Today, the in-house production
cost ranges between 0,86 €/cm³ for aluminum alloy Ampower Insights closes with procurement guide
AlSi10Mg to 3,20 €/cm³ for light-weight and medical lines and key factors for a Make or Buy decision.
grade titanium alloy Ti-6Al-4V. The decision to Make or Buy generally depends
on the amount of parts printed per year. For alu-
The existing market of metal service bureaus is ana- minum a profitable in-house production starts
lyzed for a representative depiction of market prices. at approximately 125 kg per year. For stainless
The AM capacity at suppliers currently consists of a steel, the break-even is reached at 420 kg per year.
total of approximately 120 machines installed in ser- Therefore, even with in-house production it might
vice bureaus in the selected study region Germany, be beneficial to secure supply for low volume
Switzerland, and Austria. parts and materials.
3
Content
Infrastructure investment..........................................................................................15
Cost in numbers..........................................................................................................17
Geographical distribution..........................................................................................21
Market pricing.............................................................................................................22
Make or buy.................................................................................................................25
About Ampower
The consulting company Ampower specializes in The Ampower qualification procedure for machine
industrial Additive Manufacturing. It offers identifi- technology provides robust manufacturing pro-
cation of products suitable for AM and qualification cesses and ensures that the production line excels
of personnel and infrastructure. Ampower strives at all certification requirements. The Ampower
towards developing valuable business cases for its founders have a strong industrial background in
customers. The training program focuses on qual- Additive Manufacturing with a combined experi-
ifying personnel along the whole value chain from ence of over 20 years. Ampower enables their cus-
R&D, design, production and quality assurance to tomers to successfully implement the challenging
procurement as well as management. Additive Manufacturing technology.
5
Cost of metal
Additive
Manufacturing
6
Hype versus business case –
growth continues despite high cost
Over the past two years the industry the middle of defining their position
became witness to a significant in- within this promising market. In 2016
crease of interest in Additive Manufac- the Gartner hype cycle suggests that
turing spreading over all kinds of in- the Industrial Addititive Manufacturing
dustries and sectors. For Consumer 3D technology nearly reached the plateau of
Printing, the technology is widely known productivity. Market consolidation is the
as 3D Printing while the industrial sector logical consequence, best-known from
prefers the term Additive Manufactur- the take-over of Additive Manufacturing
ing. For industrial applications gartner pioneers Concept Laser and Arcam by
predicts a consolidated market around General Electric in 2016.
2020, meaning the industry is right in
E X PA C T AT I O N S
TIME
Innovation Peak of inflated Through of Slope of Plateau of
trigger expectations disillusionment enlightenment productivity
S O U R C E : G A RT N E R 2 0 1 0 - 2 0 1 7
7
$5.200 M
$2.200 M
$250 M
1983 1987 1992 1994 2001 2003 2006 2007 2011 2012 2014 2015 2016 2017
Invention of Selective Laser Laser Cusing Trumpf discontin- 2011 Renishaw Trumpf re-enters GE buys concept
Stereolithography Sintering by DTM by Concept Laser ues powder-bed enters market by AM market; HP Laser and Arcam;
by Charles Hull Corp (now 3DS) activities acquiring MTT announces Multi Siemens invests
technologies Jet Fusion Tech- 21,4 M € in AM
nology Facility.
3D Systems Direct Metal Trumpf enters Arcam introduces GE Aviation Canon and DMG MORI takes
market entry Laser Sintering metal AM first A2 Electron buys Avio Toshiba announce over majority of
(C. Hull) (DMLS) by EOS market Beam Melting system AM Acitivities Realizer
S O U R C E : W O H L E R S R E P O R T, A M P O W E R
Most industrial users currently focus on about pricing. It may be available in R&D
part screening, identification of poten- departments, but typically does not
tial AM applications and new business consider the whole production chain.
models. However, the actual cost struc-
ture in Additive Manufacturing is treated Yet, it is worth having a closer look at
with little attention. the cost structure of Additive Manufac-
turing since it will become the focus of
Today, procurement and purchase de- attention of companies on their path to
partments have very limited knowledge industrialization.
S O U R C E : A D D I T I V E M A N U FA C T U R I N G –
N E X T G E N E R AT I O N ( A M N X ) S T U D Y B Y R O L A N D B E R G E R A P R I L 2 0 1 6
8
The technology has
to match the application
AM blank cost of a 54 mm
medical acetabular cup
Laser Beam Melting: 144 €
Electron Beam Melting: 76 €
Milling (EBM and LBM): 41 €
9
Cost breakdown of blank medical acetabular cups
76 € 144 €
Machine cost dominate the EBM cost breakdown for The cost breakdown for acetabular cups in low vol-
acetabular cup production. Since parts are not fixed ume Ti-6Al-4V LBM production shows high cost for
by supports to a base plate and become thus stack- wire eroding and qualified heat treatment. For high
able, the volume per build can be up to three times volume serial production, such post processing
higher than compared to LBM. Cost for heat treatment cost will be reduced by Economies of scale.
is limited to the HIP (hot isostatic pressing) process.
www.am-power.de/insights
1100
The cost structure
along the process chain
Data preparation Machine setup Machine run time Machine unpacking Heat treatment & HIP Support removal
V t h
tD·CL tM·(CL+CAM ) (MM + MM · FM ) · CM + (tV + ( P M· F ) + ( 3600
R
· s ·1000
B
) + tC ) · CAM tU · CAM + tB · CL tP · CL
CP = + + M L
+ + CH +
L
NT NB NB NB NB
11
Abbreviations Presets
CP Cost per part [€/part] Material for comparison: Ti-6Al-4V
tD Time for data preparation [h] Build rate LBM: 14,4 cm³/h (excl. recoating)
tM Time for machine preparation [h] Build rate EBM: 22 cm³/h (incl. recoating and heating)
tV Time for producing vacuum (only EBM) [h] Multi-laser: Dual laser with build rate x1,5
tC Time for cool down (only EBM) [h] Layer thickness LBM: 60 µm
tR Recoating and QS system time (Only LBM) [s] Layer thickness EBM: 50 µm
tU Time to unpack the machine [h] Time for data preparation: 2 h
tB Time to unpack the build job [h] Time for support removal: 0,1 h
tP Time to remove the supports per build job [h] Machine h rate LBM: 33 € (excl. maintenance)
hB Total build job height [mm] Machine h rate EBM: 32 € (excl. maintenance)
SL Layer thickness [μm] Machine type LBM: midsize Dual laser system
VM Volume of parts incl. Supports per job [cm³]
MM Mass of parts incl. Supports per job [kg]
PM Build rate (at EBM incl. recoating, heating, QS) [cm³/h]
FL Laser utilization factor
FM Material loss factor [%]
CL Labor cost [€/h]
CM Material cost [€/kg]
CAM Machine hour rate incl. energy consumption
and consumables [€/h]
CH Cost for heat treatment per part [€]
CC Cost for machining per part [€]
NB Number of parts per build job
NT Total number of parts
12
Investment from human
resource perspective
AM personnel
13
SOURCE: ARCAM AB
14
Infrastructure investment
Infrastructure
Assumptions
Dual laser mid size AM System
5 year depreciation
6816 productive hours per year
240 hours downtime for maintenance.
15
The AM machine represents about 60% of the total infrastructure
investment when considering internal AM capacity.
Un-
packing
AM machine
Software
Wire eroding
Sieving
Powder
storage
Facility Process
monitoring
Basic heat
Hand
workplace
treatment
16
Cost in numbers
During the phase of business case identi- decreases. From the graphic below, the
fication, it is often necessary to estimate manufacturing cost for each material
the manufacturing cost without a final can be estimated, if the total volume of
design. For this purpose it can be help- parts in one build job is known. Since
ful to derive a rough estimate using the the Laser Beam Melting process speed
cost per volume. With increasing build depends on more than just the build vol-
job volume and thus higher utilization of ume, the cost is displayed within a range
the build chamber, the cost significantly of a high and low boundary.
TOTA L B U I L D J O B V O LU M E [ C M ³ ]
17
Powder cost
500 €
While machine costs are not likely to drop
significantly in the near future, the produc-
Machine OEM Independent Supplier
tivity is expected to increase which will re-
375 €
sult in reduced production cost.
2,27
2,03
324
255
0,86
1188
Today’s metal
market pricing
19
Supplier market today
Supplier distribution
ISO Certification
General management certifications are the base of However, there is no widely acknowledged certifi-
a qualified supplier. Over 70 % of the suppliers are cation with regards to the quality of Additive Man-
certified according to ISO 9001. ufacturing.
20
Geographical distribution
Quantity
>50 0
2211
Market pricing
MEAN PRICE
Pricing spread
The difference between the mean price offer and It is also notable, that the offer spread does not
the highest offer can be up to 230 %. The lowest reduce when requesting a large quantity of parts.
offer can be at 30 % of the mean value. This leads to Suppliers that offer the cheapest prototypes of-
the assumption that price comparison is more than ten also offer the cheapest serial parts. The offer
advised in Additive Manufacturing. spread is largest for AISi10Mg material.
22
Ti-6AI-4V
Utilization
Margin
Layer thickness
AISi10Mg
T O TA L B U I L D J O B V O L U M E [ C M 3]
23
Key decision
factors to
make or buy
24
Make or buy
1.000 k€
M A C H I N E A N D M AT E R I A L C O S T
800 k€
600 k€
400 k€
200 k€
K I L O G R A M M A N U FA C T U R E D P E R Y E A R
k€
0 100 200 300 400 500
With increasing volume manufactured per year, the investment into internal
AM capacity becomes more attractive. The break-even calculation assumes
annual fixed cost of 300,000 € for a mid-sized dual laser machine including
machine space, staff, and infrastructure.
25
Make vs. Buy
Development of protected
IP protection insufficient
material parameters
2266
A quick guide on
procurement of AM parts
1.
Data
2. Specifications
27
3.
Focus
Material properties
4.
A reliable supplier is tracking quality
constantly. Do not accept default ma-
terial data sheets from the machine
manufacturer. Have a look at the ma-
terial properties and its consistency
over time. Density, tensile strength and
analysis by micrographs are standard
quality assurance results that a sup-
plier should be able to provide.
5. Personal contact
2288
Thinking ahead – metal pricing 2022
GERD WEBER
Head of Plant Varel, Premium AEROTEC GmbH
29
“As a result of the future increase in the productivity
and automation of AM factories and the intelligent
AM design, comparable product costs will drop by a
factor of 10 to 100 in the next 5-10 years and thus
numerous applications will be profitable.”
P R O F. D R . - I N G . C L A U S E M M E L M A N N
CEO of Laser Zentrum Nord GmbH
S T E FA N I E B R I C K W E D E
Head of AM, Deutsche Bahn
Managing Director Mobility goes Additive
30
“Today, our customers in orthopedics and aerospace
produce parts with Electron Beam Melting technology
that are cost competitive. Ongoing developments
such as higher build speed, in-process verification and
lower powder cost will drastically reduce cost and
make the technology attractive for a wider range of
applications and industries.”
MAGNUS RENÉ
President and CEO of Arcam AB
OLIVER EDELMANN
Global Sales Manager, GE Additive
31
“The often anticipated question about the business
case is completely overrated. It takes several years to
develop and qualify a new AM product and to estab-
lish the engineering knowledge within the team.
In the meantime, the powder market has responded
to the growth, and the machine developments to the
industrialization requirements appropriately.”
PETER SANDER
Head of Emerging Technologies & Concepts at Airbus Operations
JENS HENZLER
CEO Robert Hofmann GmbH
A D D I T I V E M A N U FA C T U R I N G FA C T O R Y AT R O B E R T H O F M A N N G M B H , O N E O F T H E M A J O R M E T A L S U P P L I E R S
32
About the authors
Eric Wycisk
Matthias Schmidt-Lehr
3333
Special thanks
34