Additive Manufacturing
Additive Manufacturing or AM, also known as 3D printing, is the process of creating three dimensional objects, based on a digital design model, by successively adding materials.
Compared to traditional techniques using subtractive manufacturing methods, additive manufacturing (or 3D printing) creates an object by successively adding materials. By layering material a predefined object can be created more precise and faster. Therefore additive manufacturing is extremely well suited for serial production. 3D printing guarantees faster production cycles and minimizes error margins in serial production.
Benefits of Additive Manufacturing
Freedom of Design
Additive manufacturing enables the production of complex geometries and internal features without the constraints of traditional manufacturing methods. This is often an underestimated advantage, as it offers substantial opportunities to improve product performance and functionality.
Consider, for example, the potential for weight reduction through the use of internal lattice structures or optimized topologies, or the simplification of assemblies by consolidating multiple components into a single 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
Material is deposited only where needed, significantly reducing waste compared 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
There is no need for costly molds, tooling, or time-intensive machine setups, making additive manufacturing economically viable for low-volume production. Additional cost savings can be achieved through build-to-order strategies, reduced inventory requirements, local sourcing, risk mitigation, and lower development costs.
(Mass) Customization
Additive manufacturing makes it possible to produce customized or personalized parts that meet specific customer requirements. Examples include hearing aid housings, eyeglass frames, insoles, and orthotic devices.
In practice, 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 challenge lies in 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.
What many AM applications have in common is that they serve specific needs typically found in 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.
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 therefore requires careful consideration to determine whether Additive Manufacturing is the right solution.
