Hand in hand: additive manufacturing and the digital process
Manufacturers are constantly looking for new ways to optimize their design tasks and become simpler, more flexible and more agile to keep up with customer customization demands. This includes investing in manufacturing tools and machinery that are designed to meet the needs of the companies and contribute to achieving broader strategic goals.
Forward-thinking manufacturers are preparing for this trend in advance and opening up to emerging technologies – one of the most important customization opportunities is combining additive manufacturing and the digital process.
Additive manufacturing, also known as 3D printing, is the process of building physical objects layer by layer. Creating new parts and products has traditionally been a time-consuming and expensive process, requiring the reconfiguration of manufacturing systems (production and assembly lines). The cost associated with setup and changeover time is a financial disadvantage, especially for unique products. This cannot happen in today’s fast-paced world of customized products – additive manufacturing offers a solution to this problem.
the most common additive manufacturing technologies Among FDM and PolyJet manufacturing technology are suitable for the rapid and cost-effective production of parts and prototypes. PolyJet technology is known for its detail, while FDM technology focuses on the production of durable, end-use parts. If mechanical strength and durability are key for the part, FDM is the best choice.
How do you know which technology is right for your parts? >>> Learn all about PolyJet and FDM technology!
The digital process is key to the scheduling of additive manufacturing
Additive manufacturing enables the rapid production of new prototypes, parts and products without large-scale conversions of production equipment. Cost savings can be significant even for unique products – for example, consider a machine failure when a replacement part can be produced using an on-site 3D printer. To fully exploit their potential, it is worth combining additive manufacturing and the digital process. In the example above, IoT (Internet of Things) and analytics allow us to prepare for equipment maintenance in advance and take proactive measures. By feeding a virtual model of the required spare part from the digital inventory into the 3D printer, we can produce the replacement part in a short time and avoid costly downtime.
IoT can also provide key performance data that can be used to create a closed-loop feedback loop for product designers. Real-world product usage data can be accessed by designers planning to create the next product version through the digital process.
Generative design and the digital process
Artificial intelligence (AI) is transforming industries, companies, and the roles they play. Product design and engineering roles are being equipped with AI-powered generative design tools to create smaller, more efficient future product variants.
What are the techniques for designing for additive manufacturing?
When choosing the design technique(s) to use, it is important to consider how the part will be used and what role it will play. In fact, topology optimization and generative design are often related. The of generative design is to create a design that can meet performance requirements better, faster, and with reduced weight, using computational methods and existing resources. Topology optimization is a proven generative design method that focuses on optimizing material distribution using reliable numerical methods. In many cases, the optimized shapes obtained through topology optimization cannot be manufactured using traditional processes.
Every manufacturing process has its own design techniques: parts that are to be machined are designed differently than those that are to be 3D printed. Additive manufacturing uses unique design rules and tools to create optimized designs that are ready for 3D printing. These design solutions are developed with the goal of optimizing the cost, reliability, and other aspects of the product’s life cycle as much as possible.
Additive manufacturing brings these innovative, generative designs to life by printing materials layer by layer. These optimized product designs can significantly reduce waste, material usage, and product weight, which has a significant impact on product manufacturing costs and practical performance.
By combining additive manufacturing and generative design, the overall cost of prototyping can also be significantly reduced. Using an on-site 3D printer, product designers can quickly produce a prototype optimized with generative design. Rapid prototyping also impacts subsequent steps in the process. It allows manufacturers to bring their products to market faster than ever before and meet the demands of ever-shortening lead times.
Manufacturers will need an additive manufacturing strategy to keep up with mass customization trends and competitive challenges. Combined with the digital design process, additive manufacturing provides an opportunity for the spread of innovative technologies and can facilitate collaboration between different roles. Additive manufacturing will revolutionize the physical production line, while the digital process will be able to extend its broad impact to all operations.
FDM and PolyJet technology from 3D printing pioneers
Being a member of the family that invented FDM technology means that we are supported by Stratasys’ strong commitment to research and development. VARINEX Zrt. has 25 years of experience in the field of 3D printing services, i.e. contract printing. Our engineering colleagues, who use FDM and PolyJet technologies on a daily basis, are able to fulfill customer orders at the highest level. The experience gained from contract printing tens of thousands of different parts per year ensures the right choice between FDM and PolyJet technology for the given application area.
Before starting a project, contact our expert engineering colleagues 3dp@varinex.hu !