Article: July 2024

Additive Manufacturing - the Productivity Benefits

Mideco accelerates dust extraction prototyping while reducing costs 30-50%

The benefits of 3D printing for prototyping and one-off or very low volume products are well known.
Now commercial quality Additive Manufacturing machinery and processes are in operation, they are moving into large scale manufacturing operations - and the benefits go beyond time to market and tooling.

1. Reduced Lead Times

Rapid Prototyping: Additive manufacturing (AM) allows for the quick creation of prototypes directly from digital models. This capability significantly accelerates the design and testing phases of product development. Engineers and designers can iterate designs rapidly, testing and refining multiple versions in a fraction of the time required by traditional manufacturing methods. This speed not only reduces the overall product development cycle but also enhances innovation by enabling more frequent experimentation and feedback.
On-Demand Production: With AM, parts and products can be produced as needed rather than in large batches. This just-in-time manufacturing approach reduces the time businesses spend waiting for parts to be produced or delivered, allowing for faster response to market demands and customer orders. This flexibility is particularly beneficial in industries where product life cycles are short or demand is unpredictable.

High-Temperature Nylon + Carbon Fibre Wing Section

2. Customisation and Personalisation

Tailored Products: AM enables the production of customised products at scale. This capability is particularly valuable in industries like healthcare, where custom-fit medical devices and prosthetics can be produced to meet the specific needs of individual patients. In fashion and consumer goods, personalisation options can differentiate a brand and enhance customer satisfaction.
Design Flexibility: AM supports the creation of complex geometries and intricate designs that are challenging or impossible to achieve with traditional manufacturing methods. This design freedom allows for the creation of innovative products with unique features and improved functionality. For example, lightweight lattice structures can be incorporated into aerospace components to reduce weight without compromising strength.

3. Cost Efficiency

Material Savings: Unlike subtractive manufacturing methods, which involve cutting away excess material, AM builds parts layer by layer, using only the material needed, and some support material for difficult geometries. This additive approach minimises waste and can lead to significant material cost savings, particularly for expensive or rare materials.

Skyzer Technologies uses custom jigs to improve assembly times and accuracy

Tooling Costs:
- For AM Printing: Traditional manufacturing often requires the creation of specialised tooling, molds, and fixtures, which can be costly and time-consuming to produce. AM eliminates the need for these tools, as parts are built directly from digital designs. This reduction in tooling costs is particularly advantageous for low-volume or custom production runs.
- For Production: Tooling can be created in-house, from hard, durable or rubber-like materials (or a combination of multiple materials in a single print). This reduces cost, finishing and re-tooling times compared with CNC machining or other traditional methods

4. Supply Chain Simplification

Localised Production: AM enables localised or distributed manufacturing, reducing the dependence on long and complex supply chains. This localisation can lower transportation costs, reduce lead times, and mitigate risks associated with supply chain disruptions, such as delays, geopolitical issues, or natural disasters.
Inventory Reduction: By producing parts on demand, businesses can reduce the need for large inventories of finished goods and spare parts. This approach minimises storage costs, reduces the risk of obsolescence, and allows for more efficient use of warehouse space.

5. Enhanced Product Performance

Wiring Systems has integrated 3D printers into its operations to streamline its manufacturing processes

Lightweight Structures: AM allows for the creation of lightweight yet strong structures, making it particularly useful in industries such as aerospace and automotive, where weight reduction is crucial for improving fuel efficiency and performance. For example, complex internal geometries can be designed to provide strength where needed while minimising material usage. Additional complexity in the design adds little or no cost.
Optimised Designs: AM supports the production of parts with optimised performance characteristics. Engineers can design parts with specific mechanical, thermal, or electrical properties tailored to their applications. The orientation of the part during the printing process can also be used to optimise the final performance. This optimisation can lead to improved product performance, longer lifespan, and better overall quality.

6. Sustainability and Environmental Impact

Reduced Waste: AM's additive process uses only the material required to build a part, and an amount of support material. This significantly reduces waste compared to traditional subtractive manufacturing methods. Thus AM contributes to more sustainable manufacturing practices and lower environmental impact.
Energy Efficiency: Certain AM processes can be more energy-efficient than conventional manufacturing methods. For example, producing parts layer by layer often requires less energy than casting or machining processes, contributing to lower overall energy consumption and reduced greenhouse gas emissions. FDM / FFF technology is particularly low in power consumption (though heated chamber machines use multiples more), and Resin technologies (SLA, DLP, LCD) are not far away. Laser powder fusion machinery can be a high consumer of electricity, but this can be sourced renewably at a cost.

7. Innovation and Competitive Advantage

Accelerated Innovation: The ability to quickly iterate and test new designs fosters innovation and accelerates the development of new products. Businesses can experiment with new ideas, refine concepts, and bring innovative products to market faster than their competitors, maintaining a competitive edge.
Market Differentiation: Offering customised, high-performance products can provide a competitive edge in the marketplace. Businesses that leverage AM to create unique and personalised products can differentiate themselves from competitors, attract new customers, and build stronger brand loyalty.