Pharma EXPO 2 – 5 November 2014 Chicago, IL 3D Printing for Packaging and Pharmaceticals Jay Beversdorf Application Engineer Stratasys 11/3/2014 Agenda • About Stratasys • Concept/Functional Prototyping • Manufacturing Tools – Injection Molding – Thermoforming – End of Arm Tools • End Use Parts • Intersection of 3D Printing and Pharma 1 Pharma EXPO 2 – 5 November 2014 Chicago, IL Quick Facts About Stratasys • Headquartered in Minnesota, US and Rehovot, Israel • Global workforce of over 1800+ employees • Global partner Network of over 260 resellers and agents • $487M combined revenue (2013) • 550 granted or pending additive manufacturing patents globally • Over 75,818 cumulative systems sold (Dec. 2013) • Over 25 technology and leadership awards Traditional Mfg. Process Design • • • • Design parts in CAD Document Quote Order Build • Machine • Inspect and assemble • Test Repeat design iterations as necessary 2 Pharma EXPO 2 – 5 November 2014 Chicago, IL 3DP- Additive Process Build Design Design Build Use Use Traditional Additive Manufacturing FDM & Polyjet Technologies FDM Polyjet Printing Head Support Material Instant UV Curing Model Material • Real thermoplastics • Photopolymers • Accuracy • 1000+ diverse materials • Durability • Multi-material product realism 3 Pharma EXPO 2 – 5 November 2014 Chicago, IL A World of Material Possibilities FDM Thermoplastics Polyjet Photopolymers Durable – ABS – Production-grade – Realistic parts – Translucent Rigid – General purpose translucent – Polypropylene-like – High-temperature – ABS-like – Transparent Functional – Anti-static – High strength – Manufacturing tools Flexible, Rubber-like – High-elongation – Wide range of Shore Scale A values (Hardness) – High Tear Resistance Industry-Ready – High strength – Sterilizable – Food & drug Medical – Biocompatible for Hearing Aids – Biocompatible clear material – Dental High-Performance – Flame retardant – Chemical-resistant – Low-toxicity – Finished parts Digital Composite Materials – Pre-defined Digital Materials™ Polyjet Digital Materials Material A: Shore 20 Digital Material: Shore 85 Material B: Rigid material 4 Pharma EXPO 2 – 5 November 2014 Chicago, IL Digital Materials Primary Applications for Additive Manufacturing Technology Additive Manufacturing Concept Models Functional Prototypes Manufacturing Tools End-Use Parts Established / Traditional Direct Digital Manufacturing (Design) (Manufacturing) 5 Pharma EXPO 2 – 5 November 2014 Chicago, IL Typical Design Cycle Design Change Design Change Prototype Early & Often to Minimize Cost of Change 80% of Product cost finalized 10,000 Relative Costs 1,000 $$ 100 10 1 $ $ Concept Engineering Detail Tooling Production Source: Rosenberg, Boston University 6 Pharma EXPO 2 – 5 November 2014 Chicago, IL Orchid Design Reduces Timeto-Revenue by 20% Needed time‐to‐market reduction – High precision design work – FDA approval – Months for new orthopedic device Objet 30 Pro Desktop Printer in house – “Prototypes for every project” – Improved quality and manufacturability Reduced overall product development time – “Reduced from weeks to hours” Helps drive more revenue – Repeat business from happy clients – Strong competitive advantage Process Development Time Traditional product development Weeks 3D printing product development Hours Objet system in-house 20% reduction in time Tooling Applications • Silicone Molding • Vacuum Forming • Injection Molding • Sand Casting • Blow Molding • Fiber Lay-Up • Soluble Core Molding • Paper Pulp Molding • Sheet Metal Forming 7 Pharma EXPO 2 – 5 November 2014 Chicago, IL Injection Molds Part description Test part Material injected PP Special features Living hinge, bosses, press fit comments • 100 parts out of 2 tools • Low pressure developed • Tools did not fail Material PP Nozzle Temp [F] 428 Inj. Pressure [psi] 8700 Hold Pressure [psi] 4351 Holding time [s] 8 cycle time [s] 180 Comments Cooling with air pressure Injection Molds Cost (US$) Turnaround (days) comments P20 Steel 3400 18 estimate Aluminum 1670 7 estimate ABS‐like 960 22 Hr. (1 day) Connex 500 Consumption: 810gr RGD535 1408gr RGD515 150gr support Time saving: 700‐1800% Cost savings: • 43% over aluminum • 72% over steel 8 Pharma EXPO 2 – 5 November 2014 Chicago, IL Thermoforming: FDM & Polyjet Roles • Primary: Thermoforming molds • Secondary: Coordinated tool sets – Plug assists, web killers – Matched dies – Trim guides • Advantages – Automated, direct from CAD • 1 to 2 day production • Less labor required – No vent drilling – Less expensive Thermoformed parts on FDM mold PJ soap box tool FDM packaging prototype Xerox Uses FDM for Quick Turn Tooling Up to 3 revisions on new products – Machined wood molds – Mold design adjustments Experimented with porosity – No vacuum holes required – Found a consistently successful solution Added value to system – Originally purchased to produce fixtures and assembly tooling Advantages – Quicker iterations – Reduction in cost per iteration = better product “So far we have not found anything we cannot do with FDM.” ‐Duane Byerley ‐ Xerox Prototype cover mold Method CNC machining FDM Savings Time Cost $1,200 7 days $100 0.5 days $1,100 6.5 days 9 Pharma EXPO 2 – 5 November 2014 Chicago, IL Manufacturing Applications • Jigs & Fixtures • Assembly / Manufacturing Tools • Testing / Inspection • Transportation • Production Line Testing • Equipment Calibration • Molding Validation • End-Use Parts (Rapid Manufacturing) • Surrogate Parts • Inserts Manufacturing Tools Classification Transportation Part carriers End of arm tools Assembly line Pallets Tool holders Assembly / Manufacturing Jigs Fixtures Drill guides Workbook holders Manufacturing line pallets Custom equipment guards Tool holders / organizers (5S) Inspection CMM part fixtures Check gauges Go / No-Go gauges Part holders / carriers Test fixtures 10 Pharma EXPO 2 – 5 November 2014 Chicago, IL End of Arm Tools • Tools used on automated machinery • Commonly found in: – Packaging equipment FDM robotic gripper – Manufacturing/assembly equipment – Testing and quality inspection equipment • Printed components for customized machinery • Replacement or “improvement” parts • Cost and down-time reduction • Greater design freedom FDM interchangeable conveyer gates – Consolidated assemblies – Complex geometries FDM vacuum gripper Production Line Testing • Example: A manufacturing plant producing medical pills • Verify that the production line is well calibrated & tuned • When the product is launched, the production line is all set • Systems need to be tuned & calibrated: • Counting unit measurements • Sorting and packaging units • Single file line systems • You can use PolyJet printed models • Highly accurate parts & uniform weight density 11 Pharma EXPO 2 – 5 November 2014 Chicago, IL ScriptPro Adopts 3D Printing for End Use Parts Needed customized equipment for customers – Pills and vials come in many sizes – Product customized for each pharmacy Utilized Fortus for prototyping – Immediately began using for DDM – Little to no post production work Significant overall savings – Elimination of machining and tooling – Saved estimated $24,900 changes (single project) Traditional approach – Re‐tooling costs on change Additive approach – Saved on design time (no tooling) – Easily adapts to new vials – No outside vendor Process Cost Tooling costs $30,000 DDM production $5,100 Savings $24,900 (79%) Intersection of 3D Printing and Pharma: 1: Design 3D printing allows rapid iteration and initial testing of designs for inhalers, nasal delivery systems, and packaging solutions Complex Requirements Varied Design Working Models Iteration to desired dose profile 12 Pharma EXPO 2 – 5 November 2014 Chicago, IL Intersection of 3D Printing and Pharma: 2: Validation and Verification 3D printing and additive manufacturing can bring real patient simulacra to the design and verification stages of drug delivery systems: A Traditional Method: Use of healthy volunteers with radiolabeled particles to verify penetration of inhaled pharmaceuticals 3D Printing with PolyJet: Convert human MRI or CT Scans into 3D printed geometry to test realistic and varied anatomies for delivery Figure 1. Hollow realistic central airway geometry of a patient produced by CT scans, 3D reconstruction software and 3D prototyping technique Intersection of 3D Printing and Pharma: 3: Additive Manufacturing Additive manufacturing allows increased part complexity, can reduce number of parts to be assembled, and can streamline production processes Complex Nozzle Design Additive Manufacturing In additive manufacturing, “complexity is free” allowing novel multi‐chambered designs of nozzles Ideal for low to medium scale production, enables designs that cannot be made by traditional molding 13 Pharma EXPO 2 – 5 November 2014 Chicago, IL Thanks! Contact me at [email protected] for further information 14
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