What is Additive Manufacturing?
Additive manufacturing is a transformative approach to production in which digital 3D design data is used to build up a component in layers by depositing powder-based material and gluing the powder together with the help of inkjet printing technology. Being preferable over traditional processes in many applications, the most well-known feature of AM is that it provides manufacturers with immense flexibility in geometry and details, which compensates its high cost.
What is not Additive Manufacturing?
In general, it is common to denote additive manufacturing as 3D printing, however, one should realize that additive manufacturing (AM) techniques are not used only for printing or prototyping as its name suggested but also involves potential for making large quantities of parts in the future. Having said that, it is important to comprehend what additive manufacturing really is by making a comparative analysis with traditional methods of manufacturing and how it has impact on industry both today and in the future.
Comparing Additive and Traditional Methods of Manufacturing...
To make comparison between conventional methods and AM, main differences can be denoted as followed,
the need for material removal processes
flexibility in part geometry (design freedom)
cost
product quality
ability for customization
time
Starting with the need for material removal, one can said that in traditional methods material removal processes like drilling, grinding and so on are needed to get the final shape probably after bulk deformation or CNC machining. However, using data computer-aided-design (CAD) software or 3D object scanners to deposit powder-based material layer by layer, additive manufacturing is based on the idea of creating the product by adding material on it. It indicates that AM is intrinsically a bottom-up process in which we are able to build up freeform geometries without the need for material removal . It implies that
AM is incredibly resource-efficient, conversely to traditional manufacturing, since it prevents the wastes through process.
Specific example can be given that in simple desktop 3D printer which uses polymer extrusion we can build variety of geometries without the need for tooling, however if we used injection molding instead 3D printing we would have need probably cutting as after process since excess material occurring after cooling must be trimmed from the part. Moreover, injection molds require the use of extra materials to fill the mold which usually become scrap after process, of course it is possible to recycle these scraps, but it costs time and labor force.
Again, by the same reason, which is denoted before as AM is bottom-up process, but conventional methods are not, it is possible to make internal cavities and complex parts easier in AM, which brings immense flexibility over product. To manufacture the same product, we must assemble different parts with combining different operations in conventional methods which requires time and work force.
However, in AM, complex part and geometries can be achieved faster in less step. That conclusion brings us to another difference that additive manufacturing can be used more efficiently than conventional methods in terms of fast prototyping or change in existing prototype which provides higher customer satisfaction, less need for time to develop new product and less risk since investing the right tool determined by evaluation of the prototypes.
In a traditional assembly line same would require more time to retool the line just to churn out a small handful of parts. We can exemplify it by indicating that PepsiCo uses 3D printing for potato chip models which enables them to easily change the shape of product according to customer demand and check whether this demand is satisfied or not.
AM’s ability to create more complex parts easier is used by companies for customization as well.
Giving example of Nike, many companies uses 3D printing for customizing their product faster which makes sense i think, since in today’s conditions faster customization becomes more important to keep pace with rapid changes.
Beyond these differences, it can be denoted that multiple materials can be deposited in AM which enables to create new mixed or to combine existing materials with purpose of higher quality. For example, in LOM, Laminated object manufacturing metals can be joined together for better characteristics.
All these features of AM which are superior to conventional methods comes with its cost, high initial investment. It means purchasing and maintaining the equipment in AM would be more expensive than traditional methods. Moreover,
AM is more convenient for producing complex parts at low production volume quickly so in terms of mass production AM still have deficiencies compared to traditional methods.
But Why?
The reason for that is 3D printing requires each object to be assembled one layer at a time and although 3D printing has shorter lead time it is still not enough to compete with traditional assembly line. More specific example can be given that FDM, fused deposition modeling, is an AM process like injection molding since both uses thermoplastic parts but it can be more efficient for producing low quantities in low time than injection molding. By considering the comparisons stated above, it can be stated that AM techniques are more convenient for producing complex-shaped parts in low volume quickly, but traditional ones are still leading the industry when high volume, mass production desired.
Today & Future Importance of AM
Having done the comparative analysis of AM, its impact on industry can be stated as that many companies see business potential and major industry and government investments exists to encourage the growth of the AM because of its advantages over traditional methods. The overwhelming interest in AM can be a result of the high chance for welcoming new folks to enter, grow in the rate of increase and significant momentum caused by the fact that many 3D printing company patents expired but this gap could be stopped by new innovative ones.
Some Examples...
To exemplify the interest in AM and its impact on industry we can mention that GE, General Electric, has invested over a billion dollar for 3D printing its jet engine components in which they aimed to improve efficiency by increasing combustion temperature in the hot zone.
Another example, Airbus uses printing for producing lighter brackets being used in aircraft while also saving from fuel. In medicine, 3D printing is also utilized for producing biocompatible implant for an infant which probably cannot be produced with traditional methods since it is too small. One of the interesting examples is Hollywood, they used 3D printing for making a car in the movie called Skyfall which was more cost-effective than using traditional car manufacturing since the car will be damaged through the movie many times. One more example is tooling, AM enables conformal cooling channels close to the surface of an injection mold with more uniform shrinkage and reduced cycle time.
One more application, this is last i promise, that I want to add is from todays “coronavirus” conditions. It is known that government and many companies encourage people to produce shield masks in their 3D printer to increase the mask stock. We can suggest that using 3D printer is more secure than traditional methods since in traditional methods we probably have to switch between workshops to get the final product and such traffic within factory would increase the risk of coronavirus obviously, however with 3D printing people can produce their shielded masks even in their home.
Considering the usage field and industries given above, we can conclude that additive manufacturing is a relatively new but ongoing manufacturing process which has growing impact on industry with its advantages over traditional methods.
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