3D printing : Potential analysis and implementation of an Additive Manufacturing system to reduce production equipment costs

Abstract: For the validation of products and processes the automotive series-production relies on specific production equipment and aids. Equipment like jigs for controlling the alignment between different parts, assembly aids or tools to provide help to the assembly worker, or protective covers, for example, to avoid during assembly damage or scratches to surfaces of other parts or equipment already fitted. Currently at Audi Brussels 94% of the equipment manufacturing is outsourced to tool suppliers. The outsourcing process is very costly and implies long delivery times. Therefore, it should be investigated whether it makes economic sense to invest in an Additive Manufacturing (AM) system in order to initiate a turnaround of outsourcing specific production equipment and by this reducing cost and shortening delivery times. If potentials for an AM system are identified and the economic feasibility is ensured, an AM system should be implemented - for this a budget of € 200,000 is planned. First, a state of the art analysis of the AM technology is performed. The analysis includes a comprehensive literature review, exchange of information with other AUDI plants already having experience with AM, visits to AM suppliers and AM service providers. Based on this research, suitable AM technologies will be further analysed with three practical examples such as the control panel protection cover, the combi instrument housing protection cover and the carrier plate of the electric hood hinge screw tightening tool to evaluate the potentials of the AM technology. As a final step a breakeven analysis will decide whether it would be economically sound to invest in an Additive Manufacturing system. This master thesis report showed that the Selective Laser Sintering technology is particularly suitable for the fabrication of equipment such as protection covers. However, it is for Audi Brussels not economically and technologically reasonable to commit themselves to a single Additive Manufacturing technology. The breakeven analysis showed that developing the equipment inhouse and outsourcing the 3D print jobs is the most economical solution. Establishing an inhouse engineering competence was identified as an area requiring action on the part of Audi Brussels as the engineering sector provides the most added value.