Scanning the press on the topic of Additive Manufacturing, there’s a lot said about the features and capabilities of equipment. Data shows the primary applications of additive manufacturing. The overwhelming use of the technology is in the form of prototyping/iterating. Of course, it makes total sense. Equipment performance is now to the point where we can iterate physical things almost as fast as we can iterate digital things.  

However, AM manufacturers and pundits strive to see additive manufacturing take on a more prominent role in end-use part production. Adoption in this role would be a shot in the arm for the AM industry as a whole as unit sales and consumables would dramatically increase. AM sales organizations are intimately involved in sales activities on the ground. They are pressured by manufacturers to pursue implementation of their equipment at production levels and pressured by potential customers to resist these initiatives.  

This blog asks, “Are We Asking the Wrong Questions?”

Minimum Viable Product (MVP) in Additive Manufacturing

Minimum Viable Product (MVP) – seeks to launch products that satisfy requirements without any ancillary features. In software, this could be something as simple as a website with a single button that just says, “buy”. It’s easy to pursue this in code as it’s “just” code. Changing is easy. Implementing this concept for physical products is a bit more challenging. Mechanical Engineers are challenged to let go of the perceived ‘industry practice’ that is considered the foundation of product development. Never mind that many of these perceptions are decades old and have never been put into question. Rather than accepting “This is how we’ve always done it”, MVP asks, “Do we need to do it that way?” For instance, take a device that has a number of injection molded parts. Several of these parts may exist internally. Things like fan brackets, routing clips, mounting fixtures, etc. may never see the light of day. Yet, it’s generally accepted that these components would be injection molded. In most instances, the choice of material is made with minimal consideration. Opting for PC-ABS is a common, effortless decision, as its capabilities usually exceed the necessary requirements. This material is readily available, and its affordability makes it an even more attractive option. An engineer’s time is expensive and taking a deeper look at such nominal components to see if other materials or processes could be used is not seen as valuable. In other words, seeing what the minimum viable design for this component is, may not seem viable in the grand scheme of the overall product. 

Engineers are hesitant to dive into other possibilities not just because it may take more time to analyze but also because the downstream functions including testing, quality control/inspection, assembly, etc. are more familiar with the performance of these ‘traditional’ materials and methods. Not to mention that certain industries have rigorous criteria for conforming to regulatory requirements. 

Capabilities of Additive Manufacturing

Manufacturers, industry press, and AM Sales organizations put a lot of effort into focusing on the features and benefits of their products. Rightly so. The AM product offerings today are staggering. Consider that there are over 2000 manufacturers of AM devices, many of which have very niche applications. The quality, accuracy, and performance of these machines rival (and sometimes exceed) traditional processes such as casting, injection molding, and machining. When someone makes the claim, “you can’t use 3D printed parts for production” they are likely basing their view on an experience they had with a consumer-grade solution and have not witnessed the capabilities that exist today in the commercial market.  

Sales organizations lead with capabilities. They ask potential customers about their current equipment capabilities and happily report how much better the capabilities are of the latest and greatest. And customers are grateful to hear about this. They are astounded to hear how this will increase their ability to iterate faster during development. Or, how much better their jigs/fixturing will be when they implement these improved capabilities. This approach does nothing to address the desire to transform volume production by implementing this technology. That’s because it is no longer about capabilities. 

A Shift in Additive Manufacturing

Sales and Marketing organizations need to re-tool their approaches. They need to take a more holistic approach to the industry to begin asking the right questions. Organizations that implement additive manufacturing see the benefits of their development efforts. The equipment is easily managed by a single person or a small team that doesn’t require full-time care. Small to medium-sized manufacturers may only print 10-15 parts/month. This is hardly fulfilling the promise of additive to be transformational.  

When the conversation turns to using this equipment for production devices, there is immediate pushback. For good reason. The sales pitch promises the ability to produce on the same machine that you proof. The ability to manage quality in line. And the ability to change quickly if needed. None of that is appealing to a manufacturer who has spent months/years developing a product, making sure it meets all requirements and conforms to all regulatory needs. 

When a product is developed, typically outside vendors are selected early in the process. These are vendors that appear on their “Approved Supplier” list. Getting on that list involved a great deal of effort on behalf of both parties. Often, manufacturers appear onsite with the vendor to ensure their processes and equipment are validated. Understanding their process control and inspection capabilities is important.  

The AM Industry is asking customers to become their own suppliers. To do this, manufacturers will need to acquire the equipment, spend time qualifying the machines and processes, establish rigorous processes to maintain that qualification as well as ensure the equipment is maintained. This requires employees, facilities planning, and ongoing expenses that they never had to worry about when just selecting an approved supplier. Not to mention the increased overhead required in their ERP/MRP systems to ensure the process runs smoothly. 

Addressing the entire ecosystem of Additive Manufacturing

Until the industry addresses the entire ecosystem around additive manufacturing and engineers become more comfortable with exploring contemporary alternatives to material and design, it’s going to be a challenge to fully adoption AM for production. 

A key component to making this happen will be establishing partnerships with leading, innovative organizations that can guide manufacturers through consultation and assessment of their current state. From there, a trusted partner can ensure viable equipment selection and process improvement will result in future success.

The top processes in Additive Manufacturing (AM) can be generally categorized as filament-based, resin-based, or powder-based. While there are some variations in these processes, the vast majority of materials fall within these three categories. Additive Manufacturing has a wide range of materials that fit many different applications and industries. From aerospace, engineering, automotive, medical, and so many more, looking at different properties can help you decide what material is best for you and your specific needs

1. Fused Filament Fabrication (FFF)

Filament-based materials are typically housed in a spool format. Filaments are commonly found in two diameters: 1.75mm and 3mm with the former being the most common. By far the largest variety of materials for AM are available as filament. The most common include:

PLA (Polylactic Acid)

PETG (Polyethylene Terephthalate Glycol)

ABS (Acrylonitrile Butadiene Styrene)

Filament-based materials are also available in some interesting variations including:

PEI and PAEK materials have exceptional thermal and mechanical properties making them ideal for aerospace and medical applications. They require very high temperatures in an enclosed environment in order to print well. They are also available as composites with carbon fiber and glass fiber.

2. Powder-Based Materials

These materials are available in fine powder. The powder is used in processes such as SLS (Selective Laser Sintering), MJF (Multi Jet Fusion), DMLS (Direct Metal Laser Sintering), and Binder Jetting.

The most common powder-based materials include:

Nylon (polyamide or PA)

Polypropylene (PP)

Thermoplastic Urethane (TPU)

3. Vat Photopolymerisation Materials

These materials use a photoreactive resin that solidifies when exposed to a particular wavelength of light. The most common processes include SLA (Stereo Lithographic Apparatus), MSLA (Masked SLA), and DLP (Digital Light Processing). One of the challenging aspects of these resin-based processes is the classification of materials. Unlike filament and powder, resins derive their properties from chemical reactions that do not rely on heat. As a result, resin materials are generally classified based on the physical characteristics of their final (cured) state.

Elastomeric

Clear

Durable

Rigid

Tough

For those who have worked with 3D printers in the early days of 3D printing over 30 years ago, their first exposure to 3D printed parts was likely a photopolymer part. In those days, the parts were extremely brittle and could barely be used for more than a visual representation of a part. Over the last few years, that has changed dramatically. Resin-based parts can hold their own when compared to other AM processes.

The amount of materials available for Additive Manufacturing is enormous and covers a wide gamut of performance, aesthetics, and practicality. That said, there is a narrow band of materials that are most popular. Manufacturers of these materials encourage AM users to explore beyond this narrow selection in an effort to promote end-use adoption of AM as a viable production solution. There are many cases where 3D-printed parts have matched (or even exceeded) the performance of parts produced using injection molding or machining. By selecting a material that can be used for both prototyping and end-use, the development and production processes can be seamless.

Do you feel like you’re constantly racing, trying to stay one step ahead of your competitors and barely keeping up with your product development timelines? The world of manufacturing never slows down, and it can sometimes feel like you’re caught in an endless, frenetic rat race. Staying ahead of the competition requires continuous innovation and the ability to bring new products to market quickly. Additive manufacturing (AM) is transforming the industry by offering unparalleled innovation through design flexibility and enabling rapid prototyping and low-volume production.

Design Freedom with Additive Manufacturing

One of the most significant advantages of additive manufacturing is the design freedom that you cannot get with traditional manufacturing methods. Traditional manufacturing methods often impose limitations due to the constraints of molds, tooling, and subtractive processes. Additive Manufacturing builds objects layer by layer, allowing for the creation of complex geometries and intricate designs that were previously impossible or too costly to produce.

Take the aerospace industry, where weight reduction is crucial for improving fuel efficiency and performance. Additive manufacturing enables the production of lightweight, high-strength components with complex internal structures, such as lattice designs, that reduce weight without compromising strength. This level of design freedom allows engineers to optimize parts for performance, leading to more efficient and innovative aerospace components. Similarly, in the automotive industry, companies like Ford are using 3D printing to produce parts with optimized shapes and reduced weight, improving fuel efficiency and vehicle dynamics. This ability to design and produce complex parts quickly accelerates the innovation cycle and brings cutting-edge automotive technologies to market faster.

Rapid Prototyping with Additive Manufacturing

Rapid prototyping is another one of the key benefits of additive manufacturing, enabling companies to quickly iterate on designs and test new ideas. Traditional prototyping methods can be time-consuming and expensive, often requiring specialized tooling and multiple production steps. AM simplifies this process by allowing designers to create prototypes directly from digital models.

In the consumer electronics industry, rapid prototyping with AM has become a game-changer. Companies can now develop and test new product designs in a fraction of the time it would take using traditional methods.

For instance, tech companies use 3D printing to create prototypes of new devices, from smartphones to wearable technology. This speed and flexibility enable them to refine their designs rapidly, bringing innovative products to market ahead of the competition. The healthcare field also benefits significantly from rapid prototyping. Medical device manufacturers use Additive Manufacturing to create prototypes of surgical instruments, implants, and other medical devices. This allows for quick validation of design concepts and functional testing, ensuring that the final product meets stringent regulatory requirements and performs as intended. By accelerating the development process, additive manufacturing helps bring life-saving medical innovations to patients more quickly.

Case Studies: Real-World Applications of Additive Manufacturing

To show the impact of additive manufacturing on product innovation, let’s explore some real-world use cases for different industries.

Aerospace: GE Aviation

GE Aviation is a pioneer in using additive manufacturing for aerospace components. The company uses AM to produce fuel nozzles for its LEAP jet engines. These nozzles, made from a nickel-based superalloy, feature intricate internal geometries that improve fuel efficiency and reduce emissions. Traditional manufacturing methods would require multiple parts to be welded together, but with Additive Manufacturing, the nozzle is produced as a single piece, reducing weight and increasing durability. This innovation not only enhances engine performance but also simplifies the manufacturing process and reduces costs.

Automotive: Bugatti

Bugatti, the luxury car manufacturer, has leveraged additive manufacturing to produce a high-performance brake caliper. This titanium brake caliper is the largest functional component made using 3D printing in the automotive industry. The complex geometry of the caliper, which optimizes strength and reduces weight, would be challenging to achieve with traditional manufacturing methods. By using AM, Bugatti was able to create a part that meets their exacting standards for performance and quality, showcasing the potential of 3D printing in producing critical automotive components.

Healthcare: Johnson & Johnson

Johnson & Johnson has embraced additive manufacturing to revolutionize the production of custom medical implants. Using patient-specific data from medical imaging, the company creates personalized implants tailored to the unique anatomy of each patient. This approach not only improves the fit and performance of the implants but also reduces surgery times and enhances patient outcomes. Additive manufacturing enables Johnson & Johnson to offer highly customized solutions that were previously unattainable with conventional manufacturing techniques.

Customization with Additive Manufacturing

Consumer demand for customized products is on the rise, and additive manufacturing allows this demand to be met. The ability to produce tailor-made items efficiently opens up new business opportunities and enhances customer satisfaction. In the fashion industry, Additive Manufacturing is being used to create custom-fit footwear and accessories. Companies like Adidas have introduced 3D-printed shoes that offer a perfect fit for each customer. Adidas can produce shoes that match the specific pattern of movement for athletes, providing superior comfort and performance. This level of customization attracts customers seeking unique products and sets a new standard for innovation in the fashion industry.

The dental industry is another area where customization through additive manufacturing is making a significant impact. Dentists and orthodontists use Additive Manufacturing to produce custom dental implants, crowns, and aligners. These products are created based on precise digital scans of the patient’s mouth, improving treatment outcomes. The ability to produce custom dental solutions quickly and accurately enhances patient satisfaction and streamlines the workflow for dental professionals.

Overcoming Challenges of Implementing Additive Manufacturing

While the benefits of additive manufacturing for product innovation are clear, successful implementation requires overcoming several challenges. These include material limitations, print speed, post-processing requirements, and ensuring consistent quality. Material limitations are being addressed through ongoing research and development, with new materials being introduced that offer improved properties and performance. Advances in print speed and scalability are also being made, with newer machines capable of producing larger volumes more quickly. Post-processing, such as removing supports and finishing surfaces, remains an important consideration, but automated solutions are being developed to streamline these steps. Quality control is crucial to ensure that 3d printed-produced parts meet industry standards and perform reliably. Implementing robust quality assurance processes, including non-destructive testing and in-situ monitoring, helps maintain consistency and reliability in AM production.

The Impact of Additive Manufacturing

Additive manufacturing is reshaping the landscape of product development. By offering design freedom, enabling rapid prototyping and production, and allowing for customization, AM empowers businesses to innovate faster and more efficiently. As companies continue to explore and adopt additive manufacturing, it is essential to address the associated challenges and invest in the necessary technology, skills, and processes. By doing so, businesses can unlock the full potential of AM and drive the next wave of innovation in manufacturing.

Embracing additive manufacturing today means positioning your company at the forefront of technological advancement, ready to lead in a rapidly evolving industry. The future of manufacturing is here, and it is Additive.