3D printing, also known as additive manufacturing or AM for short, is a process that creates three-dimensional objects by building them up layer by layer. In recent years, the technology has advanced to the point where it’s possible to 3D print metal parts with high accuracy and precision. This development has opened up a variety of new use cases and benefits for engineers and companies in a wide range of industries.
Here are some key benefits of Metal Additive Manufacturing:
1. One major benefit of 3D printing metal parts is that it allows for greater design freedom. Traditional manufacturing methods, such as machining or casting, can be quite restrictive in terms of the shapes that can be achieved. With 3D printing, however, complex, highly detailed, and intricate designs can be easily realized, which can be particularly useful for aerospace, biomedical, and automotive engineering applications.
2. Another benefit of 3D printing metal parts is that it can greatly reduce lead times and costs. Traditional manufacturing methods often require expensive tooling and molds, which can take a long time to create. With 3D printing, however, parts can be produced on-demand and in-house, which can significantly speed up the production process and decrease costs.
3. 3D printing metal parts can also provide other advantages such as reducing material waste, customizing parts, and producing low volume, high-value items. It allows prototyping parts and testing them faster, having the ability to iterate quickly until the final design is achieved.
Engineering companies have been utilizing Metal AM’s key benefits to improve manufacturing processes and eventually produce better and more efficient components.
- In aerospace engineering, companies such as GE Aviation have been using 3D printing to produce complex metal parts for jet engines, such as fuel nozzles. The fuel nozzles in GE’s LEAP engine, for example, are produced using a 3D printing technique known as direct energy deposition, which allows for very precise control over the shape and structure of the part. This has led to a significant reduction in the weight of the nozzle, as well as an increase in its durability and performance.
- In biomedical engineering, companies such as Oxford Performance Materials (OPM) have been using 3D printing to produce custom-made spinal implants. These implants are created using a process known as selective laser melting (SLM), which allows for the production of highly precise, complex structures. OPM’s spinal implants can be customized to fit a patient’s unique anatomy, which can greatly improve the success rate of the surgery and reduce recovery time.
- In the automotive industry, companies such as Local Motors and Divergent Microfactories are using 3D printing technology to produce lightweight, strong and cost-effective parts for cars and other vehicles. The 3D printing process allows for the creation of complex, customized parts that can be produced on-demand and in-house, which can greatly speed up the production process and reduce costs.
3D printing metal parts has proven to be a very promising technology for engineers and companies in a wide range of industries. It allows for greater design freedom, can significantly reduce lead times and costs, and offers several other advantages. Aerospace, biomedical and automotive industries are among the key industries where this technology is making a big impact. As the technology continues to evolve, we can expect to see even more use cases and benefits in the future.
While there are many benefits to 3D printing metal parts for engineering, there are also some key drawbacks that should be considered.
1. 3D printing metal parts can be more expensive than traditional manufacturing methods, especially in terms of equipment, material and post processing costs.
2. Metal AM technology is still relatively new and not yet fully mature, which can make it difficult to achieve the same level of precision and accuracy as traditional methods. This can be a particular issue for industries such as aerospace and medical, where high precision is critical for safety and performance. Furthermore, depending on the process and the material used, some print might require post-processing step such as heat treatment which adds another level of complexity and time.
3. Not all metals can be 3D printed, because the process rely on powders and most of the metals don’t come in powder form. This can limit the types of materials that can be used and affect the final properties of the part. The cost of producing powders, turning metal ingots into powder is an expensive process as well and can potentially add to the cost of production of metal AM parts.
4. It’s also important to note that while 3D printing allows for greater design freedom and can produce highly detailed and complex parts, it’s not always the best choice for a particular application. In some cases, traditional manufacturing methods may still be the most cost-effective. or efficient choice.
5. Finally, there’s a lack of standards for 3D printing metal parts, which can lead to variability and quality control issues. The industry is still developing in terms of standards, regulations, and certifications.
Overall, while 3D printing metal parts has many benefits and is a promising technology for engineering, it’s important to carefully consider the potential cons and weigh them against the benefits for each specific application.
“3D Printing is not just a new technology, it’s a new way of thinking”
Chuck Hull, inventor of 3D Printing
As the technology of metal 3D printing continues to evolve, engineering companies are looking for ways to adopt this technology and leverage its benefits in their operations.
So how can companies who want to adopt AM incorporate this into their work flow? Here are three key strategies that engineering companies can apply:
- Design for Additive Manufacturing (DfAM): This strategy involves designing parts specifically for 3D printing, taking into account the unique capabilities and constraints of the technology. This can involve using topology optimization to create lightweight, structurally efficient parts, or using lattice structures to create parts with porous internal geometries. DfAM can help to ensure that parts are optimized for 3D printing and that the full potential of the technology is leveraged.
- Invest in the right equipment and material: With a variety of metal 3D printing processes and materials available, companies should invest in the right equipment and materials that align with their specific needs. It’s important to select the right technology based on the size of the parts, the volume of production, the quality of the surface finish and final properties required, and the budget availability.
- Compliance with AM Regulations: Adopting metal 3D printing also requires compliance with relevant regulations and industry standards. Engineering companies need to ensure that their 3D printed parts meet the same safety and quality standards as those produced using traditional methods. This can include obtaining certifications and approvals from relevant regulatory bodies, as well as implementing internal quality control procedures. Furthermore, companies should keep up with the regulations and changes in the field as the regulations are still evolving and changing.
By implementing these strategies, engineering companies can effectively adopt metal 3D printing and realize its benefits while minimizing the risks and challenges associated with the technology.
Here are some key resources that would be useful when adopting AM into your workflow:
- For learning more about design for additive manufacturing (DfAM) you can refer to the book “Design for Additive Manufacturing: Concepts, Methods, and Tools” by Michael Krystek
- For learning more about the different metal 3D printing processes and materials you can refer to the “Handbook of Metal 3D Printing” by J. Paul Bryden
- For learning more about additive manufacturing regulations, certifications and standards, you can refer to the ASTM International’s Additive Manufacturing Center of Excellence (AMCoE) which provides a wide range of information and resources related to AM regulations, certifications, and standards.
