From prototype to series production
Determining the correct route
The challenge in delivering a functional prototype is to mimic the final product (produced in series) as closely as possible. After all, the primary goal of a prototype is to investigate whether a concept works, not to produce hundreds or thousands of units.
Delivering a prototype presents various challenges in this regard:
- The material for printing is often not the same as the final product,
- Tolerances that have never been validated under production conditions,
- Wanddiktes die één keer goed printen maar in serie kunnen vervormen.
- Of andere zaken die relevant kunnen zijn zoals afmetingen, bouworiëntatie, krimp, etc.
Nevertheless, the value of prototypes for testing and validation remains undeniable. However, it is important to make a clear distinction between delivering a prototype and delivering a final product, especially if the final technology for series production has not yet been determined.
Series production through Additive Manufacturing
To determine whether additive manufacturing is suitable for series production, several matters will have to be clearly determined:
- Complexity of the design
- Production quantities or batch sizes
- Final production or run; quantities/batches
- Degree of non-standard batches (mass) customization
- Possible design modifications during the life cycle of the end-use product
- Improving functionality; topology, hollow structures, optimal air or fluid flows
- Adding functionality such as component integration, hinge functions, or specific surfaces.
Applying Design for Additive Manufacturing for series production
Net als elke productietechniek heeft Additive Manufacturing ook eigen ontwerprichtlijnen. Deze richtlijnen wijken ook nog af per printtechniek. Daarbij dient een gedegen ontwerp ook rekening te houden met bouworiëntatie, building envelopes, nabewerkingsprocessen, consistentie, en dergelijke.
Design for Additive Manufacturing can typically reduce the cost per part by 30–60% compared to one-to-one printing of a prototype.
Validatieon for series eproduction.
Series production with additive manufacturing requires—just like other techniques—validated tolerances, material certainty, and a reproducible production and post-production process.
OUR APPROACH
INTAKE
By gaining insight into your application, we determine which technical and economic aspects are decisive for choosing additive manufacturing for series production. A short ‘scope call’ of approximately 30 minutes is often planned for this.
FEEDBACK
Based on the intake and the shared information, you will receive our feedback and advice regarding:
Technique:
Based on your application and requirements, the material is determined, as well as the tolerances, volumes, and geometry to be applied. These determine the final production process: additive manufacturing or a combination with other techniques. The possible post-production processes are also determined at this stage.
Design for Additive Manufacturing (DfAM).
Design optimization of your parts for manufacturability: making optimal use of build orientation, wall thicknesses, minimizing support structures, and design freedom for additive manufacturing.
DEFINITION
After various interactive sessions, both online and at your location, a complete proposal is drawn up including:
- The final techniques; additive manufacturing and/or other techniques
- Post-productie; nabewerking en assemblage
- The agreed quality level and control
- Final prices based on agreed volume and batches.
VALIDATION &
ON-BOARDING
Zero series, dimensional checks, functional tests, and an established production protocol. This is how the best and most consistent quality for series production is achieved.
