Examples of this can already be seen in bigwig companies, such as Mercedes-Benz as well as in projects spanning from water to land. Some of the toughest industry performance standards exist in this realm, requiring parts to hold up in harsh conditions. A smartly designed part with embedded continuous fibers can improve mechanical strength where needed. Tool-less polymer parts for the medical industry​​​ We can design and simulate parts and products, along with troubleshooting problems, before printing. Prototype Parts for Production. Since the turn of the century, additive manufacturing technology has advanced significantly. The latest issue of Additive Manufacturing magazine highlights manufacturers who are succeeding with 3D printing for production right now. Additive manufacturing, also known as 3D printing, is a process used to create a physical (or 3D) object by layering materials one by one based on a digital model. These assist the customers in choosing the correct location and use case that can provide the highest benefit for their future needs. Dean Haehnel: Can these use cases be performed in any order, or do they apply differently to specific businesses and industries? Please explain it to us. Also, am I correct that there is no specified order, as these are not a linear path? Is additive manufacturing (AM) ready for production scale? Robert Meshel: This is the ability to design or build anywhere, with no separation between design and manufacturing. With ITAR registration and both ISO 9001 and AS9100 certifications, Stratasys Direct Manufacturing has had the opportunity to see a range of inn… And, it’s not merely an advantage in cost reduction, but improvements in speed and agility with the ability to serve your local market. This industry is significantly expanding how we print, the speed at which we print and implementing innovative parts on demand. However, in the additive manufacturing network when we talk about visually designing for additive manufacturing and adding elements to emulate those with the ability to collaborate, which most engineers lack this knowledge. Also, inventory reduction for replacement parts is critical to industrial machinery. However, with any new technology, you need to have the correct infrastructure to support it, which includes the ability to manage the digital inventory – the technical package. As a member of the Siemens PLM Thought Leadership Team, I have the privilege of discussing additive manufacturing with Robert Meshel, Siemens Director of the Additive Manufacturing Network Initiative. The opportunity is close and has enormous potential. 3D printing, otherwise known as additive manufacturing, is changing the way manufacturers are looking at production. Contract manufacturer Incodema3D has been making parts with metal 3D... 3. Originally developed for prototyping, today it is mainly used for the production of geometrically complex components in small batch sizes between 1 and 1,000. You keep the part information in the cloud throughout the product lifecycle and then print on demand. When designing for additive manufacturing, you have inventories with rapid scale-up for new production. The ATC has been developed to combine development, engineering and manufacturing and is equipped with 3D printer assembly, 3D printing, post-processing, product research and sample testing capabilities. Material Jetting. Therefore, you need a set of capabilities to monitor production not owned by you. Journal of Oral and Maxillofacial Surgery 3 In this study, a plate of the novel alloy was manufactured by laser additive manufacturing (LAM). From: Nanostructured Biomaterials for Cranio-Maxillofacial and Oral Applications, 2018 Power Bed Fusion. The design freedom of additive manufacturing delivers increased performance to tools used in subtractive processes. Dean Haehnel: Is some of the value of industrial-scale additive manufacturing unlocked through DfAM? Many times, you’re monitoring somebody with ad hoc interaction of the production, as opposed to a regular ongoing supplier. While the price per part is almost always higher than molding, the 3D printed parts come without the cost and lead time of mold tooling, which means faster time-to-market, flexible design changes, more cost-effective short runs and the ability to re-run a past job at a moment’s notice by simply pulling up the part file, no tooling required. Robert Meshel: When we talk about DfAM, it’s usually oriented towards design capabilities such as topology optimization, which is a technique to optimize the structure by means of material consumption strength, like lattice structure, which is building a multi-scale structural design mesh inserted into the architecture, so it weighs less and provides mechanical properties for parts consolidation. Even though there are advantages with the economies of scale and mass production, there is significant cost like inventory, distribution and logistics overhead. You need to ensure that these manufacturers adhere to your specifications; otherwise, you’re not able to provide the certification that the part is accurately produced and usable by the customer. Small, complex parts made from Inconel 625 So, you need the correct security mechanisms, and to ensure your manufacturers have abilities and capacity to produce parts with specific instructions you provide. Also, there’s more variation. Since the industrial age, economies of scale were always considered a priority for efficient production— creating the same thing repeatedly. We are seeing a significant amount of investment by manufacturers in maintaining and storing inventory and shipping the transportation of this inventory to the point of consumption. There are many various processes of additive manufacturing, however this section will focus primarily on powder based(PB) AM processes. Please follow us on social media to hear this entire series via podcast on Soundcloud, Stitcher and iTunes. Rather, Spirit AeroSystems is printing the original, machinable design. Where in the past these parts would have been injection molded, the company is finding opportunities to 3D print them instead. Traditional manufacturing methods involve a material being carved or shaped into the desired product by parts of it being removed in a variety of ways.Additive manufacture You may be approaching suppliers where you have had little interaction, without a local market, which justifies a more fluent interaction process. That trust in additive manufacturing is particularly hard-earned in these industries, where safety and reliability are paramount. The part shown on the cover of this month’s issue is a titanium fitting for a Boeing 787 access door latch. Improvement of mechanical reinforcement of 3D printed parts is one of the current challenges in additive manufacturing to transition from prototypes to functional parts that meet similar requirements as for example injection molded parts do. Executing proper design for additive manufacturing techniques can increase yield and save time and costs when building your manufacturing process by ensuring that your 3D printers are used effectively. Driven by the passion for innovation in technology and business models, Robert was relentlessly pursuing new strategic opportunities developed within the organization or by partnering with external ambitious startups that are seeking to make a significant impact. Can you elaborate on the potential use cases which can be done simultaneously? However, a considerable market trend we are witnessing is a demand towards a single batch size for individualized parts – a legitimate need. When you have thousands of new data sets you can learn from, it’s critical that producers leverage the capabilities of this data, which requires the infrastructure to support, collect and monitor. Why? At the world’s leading exposition for machine tools, I saw various examples of this. This consideration is part of the learning curve that the experts connect to with the Siemens Additive Manufacturing Network. This could include medical devices for implants within the body. Go to our glossary page to find out more about additive manufacturing. Ask the Marines, Inside Oak Ridge’s 3D-Printed Machine Tool Moonshot. #machining Equipment manufacturers (e.g., Toshiba, Haas Automation, MAG, Husky, and Arburg) cannot rely on the sales of materials or parts to bolster their businesses. Robert originally joined Tecnomatix in 1996, where he served in various technical management capacities, including head of portfolio management, director of product management and business consulting. In the past, people would say you can get any color if it’s black – this is not an option anymore. Whereas, in additive manufacturing, even though you may have one order of thousands of parts, they’re produced individually; therefore, the amount of data collected in the order to verify and monitor is traced, with the work on the one part being multiplied a thousand times. Dean Haehnel: Let’s start with DfAM (Design for Additive Manufacturing). Is your company ready for industrial-scale additive manufacturing? While conventional wisdom is that parts made additively should be designed or redesigned for additive, that wasn’t the case for this access door latch fitting. For example, additive manufacturing grade 316 stainless steel powder costs, on average, twice as much per pound as 316 stainless steel wire. So, you have a more significant amount of data to be managed, with it being essential to continuous learning, which is a crucial asset to companies looking to improve production and their process. Examples of Additive Manufacturing (AM) + SLA Very high end technology utilizing laser technology to cure layer-upon-layer of photopolymer resin (polymer that changes properties when exposed to light). Additive manufacturing business is part of the 3D manufacturing industry and this industry primarily manufactures 3D printers. Robert Meshel, Director of Additive Manufacturing Network, Siemens PLM Software. Post-processing additive manufacturing parts, gluing, sanding, cleaning and / or modifying plastic parts Engage with customers to explore and understand needs for 3D printing, manufacturing, and innovation Nurture relationships with high-potential accounts to develop … “This is an example from a company that was working on a part with … This is typically done by using additive manufacturing to create highly complex parts, which are then further refined by the usual CNC machining techniques. This digitalized process is a definite advantage of additive manufacturing and a paradigm shift in market behavior. Vat Photopolymerization. Another area is personalization, which is a crucial issue in the medical industry in personalizing items like implants. The widespread outsourcing of large machine castings led a collaborative team at Oak Ridge National Laboratory to tackle the machine tool supply chain. Additive manufacturing allows a single batch with high variation produced locally because each product is individualized and produced separately by specified machines. Dean Haehnel: This information provides great insight into the benefits and use case examples of industrial-scale additive manufacturing and how the Siemens AM Network helps the customer get the most from their additive manufacturing journey. It’s a highly digitalized process — mainly executed by machines — location is a non-issue. So, it requires collaborating with service providers, including other engineers and parts manufacturers to co-create and provide this specialized knowledge for technology selection and other evolving technologies available to additive manufacturing. Also, this includes the ability to access guidelines or make a proper selection of materials. Dean Haehnel: There are so many benefits that can be realized; it’s incredible. Design for Additive Manufacturing (DfAM) is the process of adjusting your design to make it cheaper, faster, or more effective to manufacture. Find these stories and more in the May 2019 digital edition. What is that? Some of the best examples include polishing off and tapping of threaded holes on 3D printed products using milling … I will discuss three primary use cases. Additive Manufacturing allowed engineers to design a fuel nozzle which is 25% lighter and five times more durable than the previous part. Let’s look at some use-case additive manufacturing examples of this dynamic technology that will soon be a standard for all manufacturers. 3D printing is a type of additive manufacturing. Sheet Lamination. The first step? Eventually, the essence is how to bring all relevant knowledge and tools to facilitate those in various ways necessary between the resources to deliver the design in a manner which leverages the unique set of benefits that additive manufacturing provides. Many different metals and metal alloys are used in additive manufacturing, from precious metals like gold and silver to strategic metals like stainless steel and titanium. This concludes the final article in our four-part series of blogs taken from a transcribed podcast on industrial-scale additive manufacturing. Therefore, the manufacturer needs to prepare for these new opportunities. Robert Meshel: Yes, that’s correct. Located near Dayton, Ohio, the company is a contract manufacturer with a focus on the medical device industry. Unlike subtractive manufacturing that creates its final product by cutting away from a block of material, additive manufacture adds … You eventually see how each of these use cases benefits the potential customer. People want to have their product the way they want to have it. Although additive manufacturing isn’t a new technology, the recent expansion and developments have meant that it’s hit the limelight more recently, with the possibilities for … Moreover, issues that could stop production are no longer a hindrance to the overall process. This is a significant benefit for additive manufacturing, with the ability to deliver fewer parts and consolidated assemblies into single parts, affecting the overall assembly and maintenance process of these products, which is considerably simpler than traditional manufacturing practices. The volume of information that is available in the market today is enormous, and it’s difficult for engineers to fully comprehend all the data to make informed decisions. Moreover, issues that could stop production are no longer a hindrance to the overall process. Some manufacturers have chosen to the best characteristics of both additive and subtractive manufacturing, opting for a workflow that uses both. 3D printing this component to near-net shape before machining offers a lower buy-to-fly ratio than machining from stock. Create build files, layouts and use cost estimation models and trade studies, modify CAD models to … Additive manufacturing – seven categories. Ceramics. Additive Manufacturing(AM), as its name suggests, is manufacturing by the addition of material. The … Metalworking’s leading information resource, Trends in Automotive Manufacturing Knowledge Center, Additive Manufacturing for Production Knowledge Center, Practical Approaches to Automation Knowledge Center, Hard Milling Replaces Hand Grinding in Finishing Die Components, Video: The Importance of Reshoring Mold and Die Manufacturing, Finding Value with Design for Additive Manufacturing, The Gardner Editors' Great Big 2020 Holiday Gift Guide, Metal AM in a Machine Shop? It’s a new online collaborative platform, designed to accelerate the use of additive manufacturing in the global manufacturing industry. Three examples: The cover story explores how a structural component of the Boeing 787 (pictured) came to be made additively. Currently, such customized 3D scaffolds are being manufactured using additive manufacturing technology. Offers an extreme version of the learning curve that the experts connect to with the Siemens additive manufacturing,... 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