Additive manufacturing (AM) and digitization have changed how things are created and delivered in modern production. The increased flexibility and productivity of production operations are at the core of this breakthrough. Consequently, businesses will benefit from faster time-to-market periods while simultaneously improving quality standards through minimizing pollution, among other things.

The pivotal role of additive manufacturing

Additive Manufacturing (AM), commonly referred to as 3D printing, is a technology that has been known for years. Since emerging many years ago, this technology has proven to be effective in changing the way things are made. Its benefits include tangible things like design freedom, customization, or faster time-to-market that are so necessary in today’s fast-evolving marketplace.

A recent survey conducted among 327 large manufacturing companies in the United States, Germany, and Japan revealed that 80% of respondents still face challenges related to quality issues and production efficiency in their AM operations. Despite these hurdles, the consensus is clear: AM is an indispensable tool in modern manufacturing. The key challenge now is integrating AM into conventional production workflows to maximize its potential.

Addressing Misconceptions About Additive Manufacturing

Many misconceptions are to blame for the fact that AM is not widely accepted. This includes that people erroneously think that companies should go either for AM or traditional manufacturing; or that it is harder to merge AM technically; or that it almost cannot be achieved in maintaining quality and data security as far as production processes are concerned—especially when we bring in the Distributed Manufacturing and Digital Factory floor concepts into play.

The truth, however, is that AM and traditional manufacturing techniques complement each other. As such, by bringing together the two techniques, there would be an enhancement in effectiveness, a reduction in expenses, and a simplification of intricate parts and procedures. This can be evidenced by General Electric Aviation’s 63% lighter 3D-printed fuel nozzle in comparison to the traditionally manufactured one, which shows how useful AM is.

In addition, hybrid production models are specifically good for AM and suffer from shortages whenever in a hurry in industries in which fast production of spare parts is necessary, for instance, aviation. Signify [formerly Philips Lighting] has utilized AM to totally change basic items, thereby saving significant costs and increasing their life span as well.

Integrating AM with Traditional Manufacturing

The integration of AM into traditional manufacturing workflows does not have to be too complicated. Process innovation—like revamping tools, merging work steps, or small changes that involve the application of AM—normally enables the payback to be realized quickly. Through hybrid manufacturing methods, it is possible to adjust tools and modify products slightly in such a way that production line steadiness is not interfered with, thus causing fewer interruptions as well as cutting down on costs.

As an illustration, Volvo got into partnership with AM experts to devise a 3D-printed gluing jig that weighs 64 percent less and is deliverable in only a fortnight, almost at the price of the previous jig. Consequently, this type of process innovation demonstrates how AM can enrich conventional manufacturing methods.

Even more, using additive manufacturing could result in substantial efficiency gains in the production of small-volume, short-lifecycle, long-lead-time parts, which are often neglected and treated as trivial ones. Rapid, low-cost production of AM parts could lead to significant cost reductions as well as performance improvements for the entire system.

Additive manufacturing workflow

The additive manufacturing workflow involves several steps, including designing the part, planning the build, post processing the part, finishing the part, and inspecting the part. The initial design step involves modifying an existing design or starting from scratch with a true design for additive manufacturing (DFAM) mindset. 

The build process may include selecting part orientation, adding support structures, packing or nesting multiple parts, and setting printer parameters. The 3D printing process can take anywhere from minutes to days, and postprocessing may involve unpacking powder, cutting parts, cleaning, curing, heat treating, and hot isostatic pressing (HIPping). The part may also require further finishing, such as machining surfaces, drilling holes, dyeing, coating, painting, and welding or assembly. 

Inspecting the part can be done using CMM measurement or 3D scanning, while parts with complex internal features may require X-ray or CT scanning. Different parts and applications may require fewer or more steps, depending on the specific requirements. For instance, NASA's Perseverance rover's lightweight, thin-walled 3D printed housing components required multiple rounds of postprocessing and inspection before they were ready for use.

The Digitalization Journey in Metal Additive Manufacturing

The integration of digital elements into manufacturing systems, aimed at enhancing efficiency, flexibility, and product quality, is captured in the concepts of Industry 4.0, Digital Thread, and Digital Twin. When talking about AM digitalization in manufacturing, this is all about the utilization of advanced digital tools and technologies in order to make production processes more efficient and reasonable.

First of all, before one can start this path, one has to evaluate the procedures that are being used currently by manufacturers, define the directions clearly, and put up a strong structure for going digital. It consists of sensors’ hardware, among others that have been described below, which comprises software like workflow management systems as well as data analytics platforms. Implementation of major digital instruments like digital thread and digital twin would allow manufacturers to produce goods in a more efficient way that is also more adjustable to current market demands.

To successfully implement digital AM workflows, training and culture changes are important. In order to overcome resistance, employees must have the ability to use new digital tools while at the same time nurturing a culture that promotes innovation and change. It is crucial to continuously monitor and improve in order to get the most out of digitalization over time. Setting up some parameters that measure how digital projects work out in practice helps companies make adjustments where necessary and secure sustainable results.

Future-Proofing with Hybrid Production Models

3DP and traditional manufacturing are becoming one. Instead of digitalization, artificial intelligence, and robotics, AM is the new rising star in the broader manufacturing world. Accordingly, it has been reported that 94% of the people who responded have intentions of upscaling their AM operations over the next year. Whenever you have the required skills with you, all common myths will be demystified when it comes to combining AM with existing manufacturing systems. A rapid assessment of the feasibility of adopting AI can save the situation for some companies. 

Embedding it in traditional manufacturing techniques, also referred to as a hybrid production model, is essential in sectors with a demand for fast-production spare parts, such as the aviation, automotive, and medical industries. This enables them to accomplish huge efficiencies as well as cost reductions without compromising high-quality production standards.

Enhancing supply chains and sustainability

In creating a robust and eco-friendly supply chain, AM and hybrid production models possess significant advantages. This means that by making things close to home, businesses can lessen their reliance on long, tortuous supply chains, with benefits such as reduced pendency for disruptions from political or natural causes.

For example, the eyewear and hearing aid sectors have greatly leveraged AM by moving to completely digitized means of production. Consequently, enhanced efficiency and personalization have also been achieved, besides cutting down on environmental degradation through waste and energy reductions.

Additionally, smart production and decentralized production structures assure uniform quality and information safety. By offering visibility and control over all aspects of AM processes, tools like the Materialize CO-AM Software Platform make it easier for companies to blend hybrid manufacturing techniques in order to simplify their operations in various dimensions or diversify them in new ways that support technological growth without necessarily deviating from other successful strategies. Through connecting these different functions, this unification leads to routines that are repeatable as well as efficient; it spans many locations, for instance; hence, it becomes a lifeline for worldwide supply chains.

Conclusion

The combination of additive manufacturing and digitalization is changing the manufacturing industry. Businesses get better production capacities, save a lot of money, and build greener supply chains when they rely on it together with traditional methods of production. But one has to take a systematic approach if they want to undergo this process; even though it’s a long way, it pays off. As the industry evolves, those who embrace these technologies will be well-positioned to lead in the future of manufacturing.