Additive Manufacturing
Additive Manufacturing or AM, also known as 3D printing, is the process of creating three-dimensional objects from a digital design model by successively adding materials.
Additive manufacturing (or 3D printing) creates an object by layering materials, creating objects more precisely and faster than traditional manufacturing techniques can. 3D printing guarantees faster production cycles and minimises error margins. This makes additive manufacturing extremely well suited for serial production.
Benefits of Additive Manufacturing
Freedom of Design
Additive manufacturing enables the production of complex shapes and internal features without the constraints of traditional manufacturing methods. This is often an underestimated advantage of AM, as it offers substantial opportunities for improving product performance and functionality.
Consider, for example, the potential for weight reduction through the use of internal lattice structures or optimised topologies, or the simplification of assembly by consolidating multiple components into a single 3D printed part.
Additive manufacturing also allows for the integration of advanced features, such as internal cooling channels for improved fluid flow or flexible, functional elements like living hinges.
Material Efficiency
In 3D printing, material is deposited only where needed, this creates significantly less waste in comparison to subtractive manufacturing methods.
Reduced Lead Times
Shorter production cycles from design to finished part enable faster turnaround times and efficient manufacturing of end-use components in series.
Cost-Efficiency for Small Batches
Traditional manufacturing methods require costly moulds, tooling, or time-intensive machine setups. Additive manufacturing does not, making it economically viable for low-volume production. Additional cost savings can be achieved through build-to-order AM strategies, reduced inventory requirements, local sourcing, risk mitigation, and lower development costs.
(Mass) Customisation
3D printing makes it much easier to produce customised or personalised parts that meet specific customer requirements. Examples include hearing aid housings, glasses frames, insoles, and orthotic devices.
Additive Manufacturing is the only process that truly meets the definition of Direct Digital Manufacturing, enabling the direct production (3D printing) of end-use parts from a CAD file. Although AM allows for direct part production, prototyping remains essential to mitigate risks and to support the ongoing development of a part throughout its lifecycle.
Despite being primarily used for (rapid) prototyping today, Additive Manufacturing holds significant potential for the production of end-use parts.
The key to integrating 3D printing in production, is identifying and addressing the gaps left by conventional manufacturing processes, and exploring how Additive Manufacturing can complement and enhance existing production methods.
Applications of AM
Additive Manufacturing is used across a wide range of industries, including aerospace, semiconductors, medical equipment, machinery, electronics, and implantable medical devices, many of which are High-Mix Low-Volume (HMLV) markets.
A common pitfall when introducing Additive Manufacturing is approaching it from a technology-first mindset. Starting with the technique tends to narrow the focus to its limitations rather than encouraging a broader view of product development or innovation through AM.
Instead, one should start from the user or application perspective. In other words, begin with why (the application), and arrive at what (the technology).
In between lies the how – the process of aligning the application’s requirements with the relevant benefits of AM. Every unique application comes with specific needs and requires careful consideration to determine whether or not Additive Manufacturing is the right solution.
