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An Overview of Modeling and Simulation at 3M Company
© 3M 2012. All Rights Reserved.
Dave Lindeman
2
Dave Lindeman
Dave Lindeman
Working together to achieve more
 Innovate with a core focus on helping customers tackle challenges and
enable progress in our fast–changing world
 Promote a culture of curiosity and creativity
 Collaborate to share knowledge and ideas between

84,000 employees

65 countries

46 technology platforms

5 market–leading businesses
 Partner with customers to achieve tangible success
3
Dave Lindeman
Driving progress around the world
Canada

Jamaica

Dominican
Republic

Denmark

Puerto Rico
Germany


UK

Latvia

Sweden

Norway
Czech 
Republic

Finland

Switzerland

Hungary

Austria

Poland

Lithuania

Ukraine

Russia

Estonia

Korea

China

Netherlands

Japan

Mexico

Hong Kong

Guatemala

Taiwan

USA

Costa Rica

Trinidad &
Tobago

Colombia

Vietnam

El Salvador

Philippines

Thailand

Malaysia

Panama

Italy

Venezuela

Peru

Ecuador

Brazil

Romania

Chile

Argentina

4
Spain

Greece

Uruguay

Portugal
Morocco


Belgium
France


Australia

Kenya

Turkey

South Africa

Egypt

India

Pakistan

Israel


Sri Lanka

UAE

Kazakhstan

Indonesia

Singapore

New Zealand

Sales & Marketing
 Manufacturing/Converting
 Technical Capabilities
Dave Lindeman
Forming connections between diverse technologies
Ab
Bi
Em
Pm
Sm
Abrasives
Biotech
Electronic
Materials
Polymer Melt
Processing
Specialty
Materials
Ac
Ce
Po
Su
Ceramics
Es
Nt
Acoustics
Nanotechnology
Porous
Materials &
Membranes
Surface
Modification
Ad
Dd
Fc
Mi
Nw
Pp
Tt
Adhesives
Drug Delivery
Flexible
Converting &
Packaging
Microbial
Detection &
Control
Nonwoven
Materials
Precision
Processing
Track & Trace
Am
Di
Fe
Fs
Is
Me
Mo
Op
Pr
Vp
Advanced
Materials
Display
Flexible
Electronics
Filtration,
Separation,
Purification
Integrated
Systems &
Design
Metal Matrix
Composites
Molding
Optoelectronics
Process
Design &
Control
Vapor
Processing
An
Do
Fi
Im
Lm
Mf
Mr
Pd
Rp
We
Analytical
Dental &
Orthodontic
Materials
Films
Imaging
Light
Management
Mechanical
Fasteners
Microreplication
Particle &
Dispersion
Processing
Radiation
Processing
Accelerated
Weathering
As
Ec
Fl
In
Md
Pe
Se
Wo
Application
Software
Energy
Components
Fluoromaterials
Inspection &
Measurement
Medical Data
Management
Predictive
Engineering &
Modeling
Sensors
Wound
Management
5
Electronics &
Software
Dave Lindeman
Enabling customer success
 Through our five market–leading business groups, we turn our ideas
into ingenious products and solutions that make life better for our
customers and end–users every day
Consumer
Industrial
Simplifying life and work
From purification to aerospace –
changing how industry works
Electronics & Energy
Safety & Graphics
Enabling the global power and
telecommunications networks and the world's
electronic devices
Health Care
Promoting health and improving
quality care
6
Keeping you safe, your world secure and
enhancing visual communication and interactivity
Consumer
From Simplifying Life at Home to Keeping You Organized at Work
 Simplifying organization and communication
 Cleaning and protecting the home
environment
 Helping you feel better faster
 Making home improvement easy with
professional results
 Inspiring creativity, crafts and hobbies
Sales
7
$4.2 billion
Dave Lindeman
Electronics & Energy
Dave Lindeman
Enabling Tomorrow’s Lifestyle Today with Power, Communications and Electronics
 Connecting the world's power grid
 Enabling global telecommunications
 Supporting high-tech electronic devices
 Integrating with customers to create
innovative solutions
 Powering projection to share information
 Enabling opportunities for energy conservation
and generation
Sales
8
$5.7 billion
Health Care
From Preventing Infections to Making Smiles Brighter
 Preventing infections
 Caring for skin, healing wounds
 Improving treatment coding, health care
reimbursement and hospital efficiency
 Enabling delivery of medicine
 Protecting the food supply
 Making smiles brighter with advanced
dental and orthodontic solutions
Sales
9
$5.0 billion
Dave Lindeman
Industrial
From Purification to Aerospace – Changing How Industry Works
 Improving surfaces from orthopedic implants to
fine furniture
 Purifying air and water, from residential to biopharma and industrial
 Modifying, bonding and protecting surfaces in
construction and manufacturing
 Improving the design, manufacture and
maintenance of land, air and water transportation
Sales
10
$9.6 billion
Dave Lindeman
Safety & Graphics
Dave Lindeman
From Protecting People & Information to Enhancing Visual & Design Communication
 Providing personal and worker safety
 Protecting people, privacy and property
 Improving performance and productivity
of building operations and infrastructure
 Creating transportation safety and
vehicle registration solutions
 Enhancing viewing and interactive
experiences
 Inspiring light and surface capabilities
Sales
11
$5.5 billion
Dave Lindeman
Working from a position of leadership and growth
 Global sales: $29.6 billion (66% international)
 Net income: $4.3 billion
 R&D related investment: $1.6 billion
 Earned 514 U.S. patents
 Global reach: sales in ~200 countries
 One of 30 companies in DJIA stock index
12
Dave Lindeman
One strong brand with many strategic brands
 3M named one of the Best 100 Global Brands by strategic brand
consultancy Interbrand in 2012
 Proud of the household names we have created with our market–leading
strategic brands
13
Dave Lindeman
My background
 Grew up in Woodbury, MN
 Graduate of the University of Minnesota

BSAE completed in 1985

MSAE completed in 1987

Emphasis on structural mechanics and numerical methods
 Participated in the co–op program at NASA Johnson Space Center during
graduate school
 Worked as a consulting engineer for KIT Corporation following graduation
 Joined 3M in 1990
 25 years of modeling experience
14
My first modeling experiences
 FEMPAC

Used in AEM 5800

Developed at the U of M

Basic linear static analysis of planar, truss, and
torsion problems

Ran on a VAX computer

Used punch card input
 ANSYS 4.2B

Used in ME 5225 and CE 8606

Input defined using a scripting language (APDL)

Graphical output obtained using MacTerminal
running in Tektronix 4014 emulation mode
15
Dave Lindeman
Dave Lindeman
Modeling within 3M
 Predictive engineering methods and tools are used throughout the
company, both organizationally, and geographically
 Due to the diversity of 3M’s products and technologies, modeling
expertise must be maintained in:







Acoustics
Chemistry
Electromagnetics
Fluid mechanics
Heat transfer
Optics
Structural mechanics
16
Dave Lindeman
Modeling as a global activity
Sweden
Germany
Canada
Korea
China
UK
Japan
Taiwan
USA
Singapore
Australia
India
17
Dave Lindeman
Software resources
 Like most companies, 3M relies primarily on commercial modeling
packages, including*:
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
CST Microwave Studio
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Remcom Wireless InSite®
Star–CCM+
TracePro®
VAOne
*
3M does not endorse the use of any particular simulation code
18
Dave Lindeman
Software resources
 Acoustics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
19
Dave Lindeman
Software resources
 Chemistry
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
20
Dave Lindeman
Software resources
 Electromagnetics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
21
Dave Lindeman
Software resources
 Fluid mechanics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
22
Dave Lindeman
Software resources
 Heat transfer
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
23
Dave Lindeman
Software resources
 Optics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
24
Dave Lindeman
Software resources
 Structural mechanics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
25
Dave Lindeman
Software resources
 Multiphysics
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
26
Dave Lindeman
Software resources
 Optimization and probabilistic analysis
ABAQUS™
Accelrys®
AdvantEdge™
ANSYS®
CAChe
CFX™
COMSOL®
Comet Acoustics
Comet Trim
Culgi
DAKOTA
Fluent™
GOMA
iSight®
Jaguar
LAMMPS
LightTools®
Mechanica™
Moldflow®
NWChem
NX NASTRAN
Star–CCM+
TracePro®
VAOne
27
Acoustics
 Applications include:

Room air purifiers

Projectors

Sound control materials for
automotive, aerospace, and
architectural markets

Stethoscopes

Active and passive hearing
protections devices
28
Dave Lindeman
Chemistry

Adhesives

Ceramics

Polymer networks

Multiphase polymer systems

Nanoparticle surface chemistry

Molelcular self–assembly

Reaction energetics

Solubility

Catalysis
29
Dave Lindeman
Electromagnetics

Electrical connectors and cables

RFID tags and antennas

Wireless systems

Sensors

Patient/offender monitoring and
tracking

Library systems

Electrosurgical grounding plates
and medical electrodes

EMI/EMC compatibility
30
Dave Lindeman
Fluid mechanics

Mixing

Coating

Extrusion

Molding

Filtration products

Drug delivery systems

Paint spray nozzles

Fuel cells
31
Dave Lindeman
Heat transfer

Reactions

Extrusion

Molding

Insulating products for automotive
and apparel applications

Electronics cooling

Fuel cells and batteries
32
Dave Lindeman
Optics

Optical films

Light guides

LED lighting systems for
automotive, aerospace, and
architectural applications

LED light bulbs
33
Dave Lindeman
Structural mechanics

Capital equipment

Adhesives

Films

Helmets and safety glasses

Filter cartridges and housings

Adhesive and tape dispensers

Abrasives

Fuel cells and batteries

Electronic devices and packages
34
Dave Lindeman
Dave Lindeman
Reasons for modeling
 Predictive engineering can be used throughout the product, process, and
technology development process to:

Increase understanding

Verify performance

Identify critical design parameters

Assess the effects of variability

Optimize designs

Demonstrate compliance

Provide customer support
Hurricane–resistant window film
35
Dave Lindeman
Benefits of modeling
 Predictive engineering provides a virtual test platform that can result in:

Reduced prototyping and testing

Shortened development cycles

Improved quality and reliability
RFID tag
(Courtesy of Riki Banerjee)
36
Dave Lindeman
Modeling trends
 Advancements in simulation methods and computer hardware have led to
the following trends:

Component/sub–assembly simulation  assembly/system level simulation

Single physics simulation  multiphysics simulation

Linear/moderately nonlinear simulation  highly nonlinear simulation

Design evaluation/verification  design optimization

Homogenous computer resource  diverse computer resources

Modeling as a luxury  modeling as a necessity

Modeling as a competitive advantage  modeling as a competitive imperative
37
Dave Lindeman
Differentiation
 Since the barriers to adoption of modeling methods have largely been
eliminated, companies must differentiate themselves from their
competitors through:

Early and broad adoption

Efficiency


Training and retaining staff

Standardizing and automating repetitive modeling tasks
Sophistication

Use of scripting languages and user–defined subroutines

Ability to use “advanced” features with confidence

Consistent investment in high–performance computing platforms
38
Dave Lindeman
Customization and automation
 Customized user–interfaces and client–side and/or server–side scripts
used to create automated analysis systems for specific, repetitive
modeling tasks
39
Dave Lindeman
Hardware resources
 High–performance computing resources include an SGI Intel® Xeon®
processor–based hybrid cluster that combines shared–memory, cluster
computing and virtualization environments

SGI Altix UV 100 with Intel Xeon processor X7560

SGI C2112–based cluster with Intel Xeon processor X5650

Red Hat Enterprise Linux® 6.1

624 cores

3.136 TB of RAM

Dell Force10 10 gigabit ethernet fabric

52 TB Panasas PAS network–attached storage

SGI ArcFiniti file–based archiving system
40
Dave Lindeman
Electrosurgical grounding plates
 3M “Safety–Ring” technology
minimizes current density
concentrations, allowing smaller pads
to be used, and permitting more
flexibility in pad placement and
orientation
 Modeling was used to explore a large
design space, effectively evaluating
the behavior of hundreds of plate
designs on dozens of test subjects
 The resulting product is now the
market–leader
Current density distribution in
idealized human thigh
41
Dave Lindeman
Optical films
 The unique optical properties
achievable with multilayered films have
enabled the generation of a wide range
of products that literally break the laws
of physics
 Modeling was critical to understanding
the optical properties (and potential) of
multilayered film constructions
 Modeling was also critical in the design
of the tentering, manifold, and die
systems required to produce these
films
42
Light guide for backlit cell phone
(Courtesy of Dave Ender)
Simulation of extrusion process
(Courtesy of Lori Holmes)
Dave Lindeman
Cubitron™ II abrasives
 Conventional ceramic abrasive grains
plow through the workpiece, causing
heat build–up, slower cutting, and
shorter life
 The precision–shaped grains in 3M
Cubitron II abrasives continuously
fracture to form sharp points and
edges – slicing cleaner and faster,
staying cooler, and lasting many
times longer
 Modeling played a significant role in
the development of a product that has
revolutionized the abrasives industry
43
Conventional ceramic abrasive grains
Cubitron II abrasive grains
Abrasive cutting simulation
(Courtesy of Fay Salmon)
Dave Lindeman
Conclusion
 The use of predictive engineering methods is increasingly critical to the
efficient development of robust and innovative products and processes
 3M has made significant investments in the personnel, software, and
hardware required to use predictive engineering effectively, and is
committed to staying on the leading edge of this technology
Innovative Modeling
Enabling
Product Innovation
44
Dave Lindeman

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