A guide to Additive Manufacturing – is it right for you?
2024-11-26
6 min read
Advances in 3D printing machines and a wide range of printing materials have transformed the manufacturing industry. In fact, various sectors are already reaping the advantages of additive manufacturing (AM).
In truth, many manufacturers have dabbled with AM as a means of producing final products directly. However, the large-scale adoption of this approach still remains limited. In this blog, we'll explore the key benefits and drawbacks of AM, helping you to make informed decisions for your business.
What is Additive Manufacturing (AM)
Additive manufacturing (AM), also known as 3D printing machines, is a groundbreaking printing process for creating 3D objects. Unlike traditional manufacturing methods that remove material (subtractive), AM builds objects layer-by-layer from a digital design. This allows for the creation of complex shapes and intricate designs that wouldn't be possible with conventional techniques. AM uses various materials like plastics, metals, and even ceramics to create working prototypes and end-use parts.
The global adoption of AM
Research by Spherical Insights suggests that additive manufacturing, after more than 40 years of development, is becoming more mainstream. Forecasts indicate that the worldwide additive manufacturing industry will expand from $19.97B in 2023 to $143.3B in 2033 [1]. This is a CAGR (Compound Annual Growth Rate) of 21.78%. However, just because manufacturing is in the name, this does not mean AM is useful to all manufacturers.
Implementing AM technology to simply switch existing component creations from conventional manufacturing methods is rarely advantageous. AM offers its largest benefit when components are tweaked and redesigned. However, this benefit is limited due to the high cost of the technology and compatible materials. For example, creating hollowed space to make components lighter is much easier to achieve using AM than with conventional means that would require extra, complex steps.
In addition, manufacturers often struggle to find a skilled workforce capable of applying 3D printing to real-world production. This is largely due to the somewhat new nature of the technology. This limited skilled workforce is just one reason why manufacturers need to carefully evaluate which of their applications would most benefit from AM.
Advantages of Additive Manufacturing
1) Reducing energy consumption in manufacturing industries
Among the numerous benefits of AM, is the chance to reduce energy consumption by up to 25 per cent [2]. AM processes have the advantage of being more targeted in their energy use. They can focus solely on the material being built upon layer by layer.
As energy prices continue to climb across all sectors, AM offers a great chance for manufacturers to achieve cost savings. As well as, the opportunity to become more environmentally friendly.
While the decrease in energy usage and waste is noteworthy, manufacturers are unable to completely benefit from it due to the restrictions of producing end-use parts on a big enough scale.
2) Reducing waste
Beyond its potential for energy savings, there are other major environmental and economic advantages of additive manufacturing. A dramatic reduction in waste and material costs.
AM's layer-by-layer construction approach reduces material waste compared to traditional subtractive manufacturing methods. These methods involve removing material from a solid block to achieve the desired shape. According to studies, AM has the potential to achieve waste reduction of up to 90 percent [2]. This, in turn, can lead to a massive decrease in raw material consumption.
3) Streamlining supply and production
Environmental benefits are not the only advantages of additive manufacturing implementation. The technology is alleged to help make the factory floor more flexible and efficient.
AM allows companies to print components as needed. This is in contrast to traditional manufacturing, which typically involves large production runs and pre-determined inventory levels. This lowers the risk of overproduction and lessens the need for extensive storage space for finished goods or raw materials.
Disadvantages of Additive Manufacturing
1) Higher production costs for large volumes
Industrial 3D printers have a huge initial start-up cost. This is anywhere from five thousand to hundreds of thousands in US dollars for just one machine.
Alongside this, in 2011, Atzeni and Salmi conducted a study that revealed interesting findings. They discovered that the material costs for a specific metal part, when manufactured using traditional methods, amounted to €2.59 per part. However, the cost of the same part using selective laser sintering in AM skyrocketed to €25.81 per part [3].
This means it would cost ten times more for manufacturers to use AM instead of traditional techniques. However, it is important to note that the material costs have likely decreased since this study was published. Also, the wider range of available materials might include cheaper options. However, despite these factors, the cost gap between AM and traditional methods still remains.
If a plant's main goal is to reduce energy consumption, they may want to consider a more cost-effective alternative. One option could be to rethink their energy source, such as by installing solar panels.
The cost of solar panels in the UK for 6kW panel systems can range from £9,500 to £10,500 for 24 panels, which covers 43 m² of roof space. Although, when sustainability is the priority, implementing solar panels might offer a faster return on investment (ROI). As well as, offering benefits that can be seen across the factory.
While the environmental benefits of waste reduction are undeniable, the cost benefits are left to be desired. Manufacturers could still enhance their environmental consciousness and reduce material costs by adopting waste reduction methods. One such method is closed-loop manufacturing, which involves reusing materials used in production.
2) Slower production speed
AM technology is currently limited by its time and complexity constraints. Manufacturers may find AM technology largely beneficial for creating prototypes. Or, only useful in fields such as aerospace and medicine, where design manipulation is needed. With this factor taken into account, it would be far more beneficial for manufacturers to find other methods of energy cost reduction to save on costs.
The slower speed of production also might cause manufacturers to have the opposite problem of streamlined supply and production. This is where overstocking is avoided, but the plant struggles to fulfil orders. The printing process for 3D objects might take anywhere from thirty minutes to several days. The larger and more complex the part, the longer it takes.
3) Limited material selection
Currently, additive manufacturing offers a smaller selection of materials compared to traditional manufacturing techniques. This can be a significant limitation for certain applications. Construction, for instance, heavily relies on readily available and cost-effective materials such as concrete and steel. However, these materials are not yet widely available in AM processes.
Research and development are constantly advancing, leading to a predicted growth in the range of materials compatible with AM. However, at present, the limited selection of materials can pose constraints on the efficient use of AM in various applications.
Is AM right for you? - Applications of Additive Manufacturing
While AM has many beneficial qualities, the technology is still in the early stages of usefulness to the general manufacturing industry. Until progress is made in the speed of the process and the cost of materials, other production methods might be better suited to applications where low-cost, time-efficient production is needed.
On the other hand, the wider manufacturing industry might not benefit from this technology anytime soon. However, sectors such as aerospace, medical, and energy have already seen the benefits of AM. AM technology might not be what manufacturers currently need, but with progress, this will likely change.
To learn more about specific applications, materials, and advancements in additive manufacturing, explore our knowledge hub!
Sources:
[2] https://www.energy.gov/sites/prod/files/2014/05/f15/energy-nam.pdf
[3] Atzeni, E, Iuliano, L, & Salmi, A. (2011) On the competitiveness of additive manufacturing for the production of metal parts. In AMST’11–Advanced Manufacturing Systems and Technology (pp. 351-362). Arti Grafiche Friulane.
