Additive manufacturing - 3D printing in mass production
Unlike rapid prototyping, additive manufacturing is not about the quick and cost-effective production of a prototype or an illustrative object. Instead, it is about mass production. Similar processes are available to you for additive manufacturing – albeit in a different design with different materials and, above all, with a completely different focus in the approach.
In terms of sequence, the production of a prototype comes before additive manufacturing. If you are satisfied with the test runs and have perfected your prototype to such an extent that you want to start mass production, additive manufacturing is ultimately the right approach.
What exactly characterizes additive manufacturing?
Over the years, the term 3D printing has become synonymous with this type of production. There is a simple reason for this. A form of 3D manufacturing is generally used for the various additive manufacturing processes. In addition to these two terms, the term generative manufacturing is also used from time to time.
This type of production has actually become increasingly important in the industrial sector in recent years. This is because, for example, components with a high degree of individualization and complexity can be produced effectively. Generative manufacturing is a type of production in which a finished product is created by adding material.
This type of production is primarily designed for mass production. Quantities of 1 – 10,000 can be produced quickly and easily. The whole process works without the use of tools and also largely without additional personnel costs. Only the post-processing of the finished products can cause additional personnel costs. However, this depends on the selected printing process, the customer’s requirements of the service provider and, of course, the complexity of the objects to be produced.
What are the advantages of additive manufacturing?
The advantages of additive manufacturing are manifold.
In general, material consumption is comparatively low with this type of production. As this type of production is a type of layer printing, only the material that is actually required for printing the finished product is used. The waste in the form of possible support structures or smaller areas that need to be sanded down during post-processing is very low.
The situation is different with conventional production methods where, for example, a finished product has to be milled out of a block of material. The material consumption here is significantly higher.
In 3D printing, which is designed for mass production, materials and techniques are also used that make the finished product extremely durable and robust. For example, components for engines that may come into contact with oil, heat and chemicals can be produced in this way.
The finished products are also generally completely UV-resistant. Due to the very precise production method, parts for medical purposes can also be produced with 100% accuracy tailored to the respective patient.
In general, this production method is an extremely cost-effective option – if it is used correctly.
Conventional manufacturing processes often increase in price when products become more complex in geometry or when multiple parts are required to create interiors and other special features in a finished product. With 3D printing, this is no problem at all.
From an integrated thread to cavities and cable ducts in the product itself to complex geometries and intricate shapes.
Ultimately, the 3D printer does not care what the finished model looks like. Printing is always simply carried out according to the specifications of the respective CAD file. This also means that the more complex and complicated the parts to be produced are, the more worthwhile 3D printing becomes.
For simple products that are not very complex, on the other hand, a conventional production method is more worthwhile.
In addition, 3D printing is now a very fast production method. Of course, this also depends on the technology used. However, we can deliver products to you within a day or, in the case of larger quantities, within a few days. The ongoing development of additive manufacturing is also clearly noticeable here.
Unlike other production processes, every 3D printed workpiece comes without seams or similar weak points.
In fact, every additive manufacturing product is a continuous piece and therefore particularly robust in design.
The most important advantages at a glance
Production using the additive manufacturing process is cost and time efficient.
Production is carried out without tools and with minimal manpower.
The implementation of complex and intricate geometries is possible without any problems.
Internal structures - whether simple or complex - can also be implemented without any problems.
The material consumption is comparatively low.
Before mass production, a prototype can be produced to accompany research and development.
In this way, components as well as tools or complex components of high-quality machines that have to withstand heavy loads can be produced.
Not only prototypes can be produced here, but also fully functional workpieces from all technical and industrial sectors.
The materials used are extremely durable and very resistant to chemicals, UV radiation and other stressful external influences.
Various processes in the field of additive manufacturing
There is a whole range of additive manufacturing processes that can be used in a wide variety of areas. Some are more suitable for private use or exclusively for use in schools or research. Others are tailored to the requirements of production for industry and complex areas such as aerospace.
There are currently a total of 11 processes that are used in additive manufacturing. However, the Fraunhofer Institute for Casting, Composite and Processing Technology IGCV and numerous other comparable research institutes are still conducting research in the field of additive manufacturing. According to their own information, 30 scientists are currently involved in ongoing research into additive manufacturing.
As a service provider for 3D printing products, we naturally regularly take on board the ongoing developments in this area and incorporate them into our service portfolio. Among the numerous manufacturing methods, we would like to mention two in particular at this point.
- Selective laser sintering
- Selective laser melting
Both processes are very similar – only completely different materials are used. While plastic powder is used in selective laser sintering, selective laser melting works with metal powder.
Both variants naturally involve techniques from the field of layered construction. In this process, layers are joined together layer by layer in a closed construction area in a 3D printer. The respective layers are fused together using laser beams that are adapted to the material used.
This creates completely seamless products. The specific appearance of each product is determined by the CAD file that is created beforehand. This is something like the image that the 3D printer “traces”.
These materials are used here
You can choose from the full range of materials in 3D printing. Various plastics as well as different metals are used here. Which material is used in each case depends primarily on the intended use of the finished product. Both the plastic polymers and the metals are processed in powder form and then melted together.
In the plastics sector, there are various mixed polymers that are enriched with glass (PA 12 GF) or aluminum (Alumide), for example. Others, such as the plastic PA 12 FR, come with additional flame protection and can be used in particularly hazardous areas.
The situation is similar for metals. Here too, the metal used is selected according to the intended use of the product to be manufactured. This is simply because each metal has its own small advantages and disadvantages and is sometimes different in terms of functionality:
- Aluminum
- Inconcel
- Stainless steel
- Automotive industry
- Tool steel
- Cobalt-chrome alloy
As a finished product, these can be exposed to very high stresses – whether thermal or mechanical. These products must therefore be of particularly high quality in terms of processing and material selection. For this reason, additive manufacturing is exactly the right choice here.
How additive manufacturing works
The generative manufacturing process is usually as follows:
1
It all starts with the idea for a new or improved product
2
In many cases, the first step is to print a rapid prototype in order to optimize the planned product using a prototype
3
Once the CAD file has been improved and adapted in the necessary places following a detailed study of the prototype, this new CAD file can now be used for additive manufacturing.
4
The product you have planned then goes into mass production with quantities of up to 10,000 units in a production series.
Our promise to you when it comes to additive manufacturing
Alongside rapid prototyping technology, additive manufacturing is one of our main fields of activity. Here you will find a wealth of expertise, extremely high-quality products and, above all, the opportunity to influence your design and the resulting finished products right up to the last second.
We deliver 3D printed products to you quickly, efficiently, cost-effectively and, above all, with high-quality workmanship.
Additive manufacturing is particularly interesting for these areas of application
Additive manufacturing is hardly seriously limited in its range of applications. This is demonstrated, for example, by the fact that this process can be used to produce mass quantities of up to 10,000 pieces as well as individual parts that would be extremely expensive to manufacture using another process.
Whether in model making, the production of small batches or even larger product ranges – 3D printing offers you almost endless possibilities. The most important sectors in which this type of production is regularly used include
- Medical technology
- Aerospace
- prosthetics
- automotive industry
Numerous industries and companies can benefit from the use of 3D printing. Whether accompanying the development of new products or simply in connection with the planned production of various components or other workpieces. As an experienced service provider in the field of additive manufacturing, we are happy to provide you with advice in this matter.
