December 17, 2019 | Volume 15 Issue 48 |
Manufacturing Center
Product Spotlight
Modern Applications News
Metalworking Ideas For
Today's Job Shops
Tooling and Production
Strategies for large
metalworking plants
By Jesse Marin
Chances are you've heard about the use of 3D-printing applications for design and manufacturing. Maybe you've even considered building 3D elements into your process. You're not alone.
According to the Wohlers Report 2019, an industry-leading report on additive manufacturing, revenue for all 3D-printed products and services worldwide is expected to more than double by 2024 -- a large segment of which is derived from manufacturing.
With 3D printing, bringing an idea from prototype to production is no longer bound by the constraints of traditional manufacturing methods. But while the use of 3D printing is expected to grow, successful adoption of the technology and techniques requires preparation and a degree of finesse. It's not without its challenges.
If you've been wondering how to implement 3D printing into your design process, here are some recommendations to get started.
1. Don't limit yourself to one type of technology
When deciding on the right technology for your project, there are several considerations to ensure you move efficiently and effectively. The requirements for each application are unique, and demand careful examination and planning to identify the best 3D-printing process to meet project needs.
For example, functional prototype components that need to resist impact or high temperatures can use FDM® (Fused Deposition Modeling), the most widely employed 3D-printing technique, for its strong, durable parts from a host of high-performance materials (more on materials below).
If a part's design calls for a complicated undercut for airflow or a durable living hinge, however, laser sintering may be the ideal process. These considerations can be complicated, but careful deliberation of the full spectrum of part performance requirements is needed before beginning the printing process.
2. Don't limit yourself to one type of material
3D-printing materials that are available today are substantial for creating prototypes and production parts in hundreds of plastic and metal materials. Here are just a few that you should consider, which cover an array of applications.
This anatomical model was 3D printed in multiple photopolymer materials. The opaque organs and transparent body were built simultaneously, creating a unique effect.
3. Don't use 3D printing for just rapid prototyping
Rapid prototyping with 3D printing is one of the easiest, most cost-effective ways to turn a great idea into reality. But it's not the only area where 3D printing delivers value.
4. Don't forget post-processing and finishing needs
From sanding and painting to providing inserts or special coatings, post-processing can include many different methods. Consider the aesthetic goals of the prototype. Does the process you've chosen to use provide the tolerance and smoothness you need for your application straight from the machine? Or will you need to include post-processing time and costs into providing the right part?
It's important to remember that not only are some technologies more expensive, but the need for post-processing can also drive costs upward.
5. Do consider outsourcing even if you have in-house equipment
Purchasing and setting up a new manufacturing technology is a significant investment. That's why many additive manufacturing users choose to outsource a variety of production methods and materials through a service provider, instead of depending on in-house equipment.
There's relatively low risk in trying out new options by outsourcing to an additive manufacturing provider, and you may discover that the new technology can integrate into your operations. Outsourcing can also allow you to explore new 3D-printing technologies and materials that your business might be interested in purchasing.
6. Do consider build orientation
With added manufacturing processes, orientation determines several features found in the final product. Certain build orientations are better for curved or square features, while delicate features require special consideration. For example, because of the build process, orientation can determine the cosmetics of the part, what supports may be needed during the build, and often the overall strength of the part.
Orientation should be considered in the early design stages to avoid these common pitfalls.
7. Do prioritize industry requirements and standards
Many 3D-printing materials have been formulated to meet strict industry standards and requirements. For example, FDM material PC-ISO meets certifications for its strength and medical compatibility, and FDM ULTEM 1010 meets food-contact and bio-compatibility application requirements.
These certifications increase the fields in which 3D printing can make an impact. When designing and manufacturing for applications requiring certifications, it is important to ensure your project is handled in an appropriately certified facility.
8. Do hire a team to champion 3D printing at your company
A dedicated champion who believes in the power of 3D printing can take the time to educate an organization on the technology's potential, and identify areas where 3D printing can improve and advance processes within the company.
This person or team will take on the responsibilities of learning the key elements of the technology and its impact, helping define and communicate its financial, business, and engineering value.
Conclusion
In the era of Industry 4.0, manufacturing with additive can help you reimagine ways to bring your designs to life more easily, efficiently, and cost effectively. While adapting a new technology into your process may be challenging, the benefits abound. 3D printing can open a world of new possibilities for manufacturing productivity in your company.
For more information on Stratasys Direct Manufacturing or to get in touch with one of our customer service experts, visit stratasysdirect.com.
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About the author
Jesse Marin is the Design Services manager at Stratasys Direct Manufacturing. He lends key consulting and hands-on 3D design expertise on custom additive manufacturing optimization projects across various industries including the automotive, aerospace, and consumer product sectors.
Published December 2019