With the advent of Industry 4.0, the manufacturing industry is going through a major paradigm shift. Over the years, manufacturing has been defined by its innovative tooling and technology. One such exciting technology is additive manufacturing tooling, commonly referred to as 3D printing.
Between 2020 and 2023, the global additive manufacturing market had been expected to grow by some 17 percent annually, according to Statista. Is 3D printing the future of manufacturing and production? Let’s discuss.
What is Additive manufacturing?
Also known as 3D printing, additive manufacturing is the process where products are created by adding one layer of material at a time. Traditional manufacturing methods always involved cutting or shaping a solid material to create a new object – for example, cars.
However, 3D printing begins by creating a digital (or three-dimensional) model of the product, followed by building the actual product one layer after another. Overall, 3D printing is faster and more effective than traditional manufacturing methods.
3D printing comprises the following 3 types of solutions:
Fused deposition modeling (FDM)
Also known as fused filament fabrication, FDM tools can build a layered part by depositing molten material in a predetermined path. Typically, this solution uses thermoplastic polymers to form the final physical product. It also represents the largest share of 3D-printed products.
Stereolithography (SLA)
Also referred to as SLA 3D, stereolithography is another popular method used in 3D printing. This method uses a low-power laser to harden a liquid resin to create the desired 3D product. This method can convert photosensitive liquid into solid plastic in a layered fashion.
Selective laser sintering (SLS)
Selective laser sintering, or SLS, is typically used for lightweight products, including jigs, fixtures, and spare parts. This method of 3D printing uses a high-power laser to sinter small parts of polymerized powder into a 3D solid structure. This method is popular for its cost savings, high productivity, and suitability for a range of applications, including rapid prototyping and custom manufacturing.
Next, let’s discuss the business benefits of additive manufacturing tooling and tools in production facilities.
Benefits of Additive Manufacturing Tooling
3D printing offers a host of benefits in the manufacturing industry. Here are some of the main benefits:
1. Lower initial costs
With traditional tools, the initial costs of manufacturing can be extremely high. For example, to manufacture a new product, manufacturers need customized tools that can cost a lot. On the other hand, additive manufacturing tooling can cost comparatively less, as manufacturers only need to feed the product design into the 3D printer.
2. Less waste
Traditional manufacturing is designed around cutting a larger piece of metal or wooden block into the final product. This results in a lot of resource waste. On the other hand, additive manufacturing tooling reduces waste substantially by adding layers to form the final product.
3. Easier customization
With additive manufacturing tooling, manufacturers can design and build customized products based on their digital blueprints. Each product can have a unique design and be built to meet individual preferences. For instance, customized splints and supports can be individually tailored in the healthcare industry.
4. Faster production
Traditional manufacturing is typically associated with longer durations and high costs. This is not necessarily the case for this type of manufacturing. Prototype products can be immediately approved and put into production, resulting in faster deliveries of final products to the market. Greater throughput and velocity are possible.
5. Faster prototyping
Additive manufacturing tooling is built for rapid prototyping, which is among its main benefits. At a lower cost and with less waste, first-product prototypes can be easier to create and test in any production environment. Besides, manufacturers may be able to make quicker, more on-the-fly modifications to existing prototypes without repeating the entire process. First prototypes can be built using readily available, less expensive materials, while later prototypes can use the final materials to be used in the product.
6. Fewer environmental impacts
As it reduces waste, additive manufacturing tooling may be considered better for the environment. This method can manufacture any product with less material and time than traditional manufacturing. Besides, this form of manufacturing can use a variety of environmentally friendly materials to produce the final product.
Is 3D printing the Future of Production?
3D printing is now the forefront technology for Industry 4.0. This form of manufacturing is now being adopted by different industries to accelerate their manufacturing processes at lower costs. That’s because 3D printers or additive manufacturing tools are already being used for a variety of industrial applications, including:
Molding of ventilator parts
Custom solutions for work-holding
Cutting tools and equipment
Aerospace tooling
Much more
Conclusion
According to Forbes, 3D printing is among the top 10 future trends for the manufacturing industry. Going ahead, 3D printing will become more cost-effective and scalable, thus making it more suitable for different manufacturers. Among the future trends, 3D printing could also be implemented for mass production.
To remain competitive, manufacturing companies have always adopted new technologies that are cost-efficient and can improve faster production. At the Illinois Manufacturers’ Association (IMA), we are committed to providing manufacturers with information on all technologies that can reduce downtime and improve the production process.
Regardless of your method of manufacturing, we are pointing members to information, resources and solutions – to help better streamline your production for more consistent and profitable outcomes, at every turn.
