March 15, 2019 at 12:335 reasons to switch to 3D printing of metal products
If you are engaged in the design or manufacture of metal parts, then you already know about some of the possibilities of 3D printing with metal. You may have already thought about using additive technologies to implement a project. So what's stopping you? Maybe you are trying to build a system of arguments for this yourself, or the benefits are not yet entirely clear to you. In this article, we present our arguments for 3D metal printing - to help you work out your own.
First of all, it should be noted that 3D printing is now easily accessible - both in terms of materials and properties that can be achieved, and in terms of software for design, assembly and process control. At the same time, subcontracting or 3D printing as a serviceprovide access to a wide range of printing technologies and materials, so you do not need to immediately commit yourself to a specific machine or method.
The obstacles to using 3D printing are diverse, some of which are stronger where traditional metalworking methods are deeply rooted. Nevertheless, as we shall see, it is in this area that the main advantages of additive methods can give the greatest positive result.
The obvious, well-known advantage of additive manufacturing as a whole is a faster transition from the project to the finished part. Time is saved in large part thanks to the equipment.
3D printing does not require holders for parts of a certain shape; the maximum of what you need from special tools is the support that is generated during the printing process.
Thus, you spend several days instead of long weeks. InMotion, the team of the ambitious electric racing car project for Le Mans 2019, was able to design and manufacture a new lightweight titanium suspension in a week.
No matter what you print, software, used to prepare for 3D printing, now allows you to automate or otherwise optimize many of the most time-consuming aspects of setting up and preparing the design, which provides highly efficient 3D printing processes.
Of course, time is money, so saving time on reducing downtime, reducing the transition time from project to product and increasing productivity makes sense. But 3D metal printing can give an even more direct financial effect.
If your activity is related to machining, then you know how much material is needed to begin the process of processing the part, and how much it will remain when the part is ready. The rest is expensive scrap. It needs to be removed, transported, recycled and paid for what - in the case of metal - at the beginning was an expensive raw material.
When you print metal parts on a 3D printer, you apply the material only where necessary. Waste is minimal. Almost all source materials are used in the final part (minus the created supports). In addition, when designing using traditional methods, it is often necessary to add unnecessary materials to avoid complexity or to ensure manufacturability. The pneumatic grip that Materialize redesigned for 3D printing with aluminum weighed about a quarter of the weight of the previous version, and cost less than a third of its previous price.
A more efficient use of the material gives a chain reaction effect. For example, it provides more compact manufacturing operations because less material needs to be purchased, stored and moved. Weight reduction also affects not only the production of the part, but also the operating costs and productivity. This is especially important in the aerospace industry, where every gram matters (sending one kilogram into orbit currently costs $ 20,000).
Another significant factor affecting the cost is equipment again. Think about the number of specialized tools, fixtures, shapes or patterns that are involved in the manufacture of parts by traditional methods. Now imagine that most of them are in the past.
3D printing breaks the fundamental pattern regarding working with metal - that which is difficult is bad. In metal parts printed on an additive unit, complexity no longer leads to a rise in price. This means that you can combine different functionalities in one part printed on a 3D printer, without fear of increasing the complexity of this part.
If your design used to have several separate parts, bolted or welded, you can now print one complete part in one go. And even whole nodes. This, in turn, will save on assembly costs, as well as on maintenance of the line, since the production of units eliminates risks such as leaks or damage to parts due to operator error during assembly.
You can also expand or improve functionality by adding to the project add-ons. Additive methods allow the implementation of complex internal structures , grilles and channels that improve airflow or lubricant flow. External textures and surface reliefs can be created, for example, to improve tactile sensations or grip, or to connect to another part.
If earlier we created a project for launching into production, taking into account the restrictions imposed by casting or machining, now 3D printing allows us to put functions first and form second. We can design the part as it should be; Now we depend on the tools used in its manufacture.
Such a removal of restrictions allows you to approach the design of parts in completely new ways and create forms and structures that were previously impossible or too expensive. Significant potential for innovation opens up.
3D printing is suitable for use in evolutionary projects. It makes it possible not only to accelerate the release of the final product, but also to develop the final design solution using fast iterations, with the opportunity to experience the real detail every time. This means that the time interval between the manufacture of each prototype is sharply reduced, which creates space for experimentation and innovation. The result is the best end product.
All of the above will help maintain your competitive advantage as a manufacturer, designer or innovator, but 3D printing also offers new opportunities to differentiate your product range. Additive manufacturing modifies all perceptions of economies of scale. Due to the low initial costs, it becomes economical to produce products in small batches, on order or with customization for mass customization. Thus, it is possible to provide services in those niches that used to be too expensive. New opportunities are emerging.
Potential for creating new business modelsor product development strategies and the freedom of design that 3D printing provides require a new, different way of thinking. Just as we learned how to design parts for milling, turning and casting, we need to learn to think in terms of additive manufacturing. However, you can speed up your learning by starting small and share success stories in your team or company. This ensures that additive manufacturing will become a natural part of your toolbox.
3D metal printing is on the verge of transition to the category of basic technologies. Be one step ahead - start implementing projects using this method.
Translation from English. The original of this material is on the Materialize website .
First of all, it should be noted that 3D printing is now easily accessible - both in terms of materials and properties that can be achieved, and in terms of software for design, assembly and process control. At the same time, subcontracting or 3D printing as a serviceprovide access to a wide range of printing technologies and materials, so you do not need to immediately commit yourself to a specific machine or method.
The obstacles to using 3D printing are diverse, some of which are stronger where traditional metalworking methods are deeply rooted. Nevertheless, as we shall see, it is in this area that the main advantages of additive methods can give the greatest positive result.
1. Save time: spend hours or days, not weeks and months
The obvious, well-known advantage of additive manufacturing as a whole is a faster transition from the project to the finished part. Time is saved in large part thanks to the equipment.
3D printing does not require holders for parts of a certain shape; the maximum of what you need from special tools is the support that is generated during the printing process.
Thus, you spend several days instead of long weeks. InMotion, the team of the ambitious electric racing car project for Le Mans 2019, was able to design and manufacture a new lightweight titanium suspension in a week.
No matter what you print, software, used to prepare for 3D printing, now allows you to automate or otherwise optimize many of the most time-consuming aspects of setting up and preparing the design, which provides highly efficient 3D printing processes.
Of course, time is money, so saving time on reducing downtime, reducing the transition time from project to product and increasing productivity makes sense. But 3D metal printing can give an even more direct financial effect.
2. Save money: build-up as opposed to grinding
If your activity is related to machining, then you know how much material is needed to begin the process of processing the part, and how much it will remain when the part is ready. The rest is expensive scrap. It needs to be removed, transported, recycled and paid for what - in the case of metal - at the beginning was an expensive raw material.
When you print metal parts on a 3D printer, you apply the material only where necessary. Waste is minimal. Almost all source materials are used in the final part (minus the created supports). In addition, when designing using traditional methods, it is often necessary to add unnecessary materials to avoid complexity or to ensure manufacturability. The pneumatic grip that Materialize redesigned for 3D printing with aluminum weighed about a quarter of the weight of the previous version, and cost less than a third of its previous price.
A more efficient use of the material gives a chain reaction effect. For example, it provides more compact manufacturing operations because less material needs to be purchased, stored and moved. Weight reduction also affects not only the production of the part, but also the operating costs and productivity. This is especially important in the aerospace industry, where every gram matters (sending one kilogram into orbit currently costs $ 20,000).
Another significant factor affecting the cost is equipment again. Think about the number of specialized tools, fixtures, shapes or patterns that are involved in the manufacture of parts by traditional methods. Now imagine that most of them are in the past.
3. Do more: kill several birds with one stone.
3D printing breaks the fundamental pattern regarding working with metal - that which is difficult is bad. In metal parts printed on an additive unit, complexity no longer leads to a rise in price. This means that you can combine different functionalities in one part printed on a 3D printer, without fear of increasing the complexity of this part.
If your design used to have several separate parts, bolted or welded, you can now print one complete part in one go. And even whole nodes. This, in turn, will save on assembly costs, as well as on maintenance of the line, since the production of units eliminates risks such as leaks or damage to parts due to operator error during assembly.
You can also expand or improve functionality by adding to the project add-ons. Additive methods allow the implementation of complex internal structures , grilles and channels that improve airflow or lubricant flow. External textures and surface reliefs can be created, for example, to improve tactile sensations or grip, or to connect to another part.
4. Do better: no limits
If earlier we created a project for launching into production, taking into account the restrictions imposed by casting or machining, now 3D printing allows us to put functions first and form second. We can design the part as it should be; Now we depend on the tools used in its manufacture.
Such a removal of restrictions allows you to approach the design of parts in completely new ways and create forms and structures that were previously impossible or too expensive. Significant potential for innovation opens up.
3D printing is suitable for use in evolutionary projects. It makes it possible not only to accelerate the release of the final product, but also to develop the final design solution using fast iterations, with the opportunity to experience the real detail every time. This means that the time interval between the manufacture of each prototype is sharply reduced, which creates space for experimentation and innovation. The result is the best end product.
5. Keep your competitive edge
All of the above will help maintain your competitive advantage as a manufacturer, designer or innovator, but 3D printing also offers new opportunities to differentiate your product range. Additive manufacturing modifies all perceptions of economies of scale. Due to the low initial costs, it becomes economical to produce products in small batches, on order or with customization for mass customization. Thus, it is possible to provide services in those niches that used to be too expensive. New opportunities are emerging.
Potential for creating new business modelsor product development strategies and the freedom of design that 3D printing provides require a new, different way of thinking. Just as we learned how to design parts for milling, turning and casting, we need to learn to think in terms of additive manufacturing. However, you can speed up your learning by starting small and share success stories in your team or company. This ensures that additive manufacturing will become a natural part of your toolbox.
3D metal printing is on the verge of transition to the category of basic technologies. Be one step ahead - start implementing projects using this method.
Translation from English. The original of this material is on the Materialize website .