COVER STORY ADVERTISEMENT FEATURE
Right: The design possibilities presented by 3D printing have the potential to impact on almost any industry. Designs that would have been impossible with
conventional production methods now allow businesses to entirely rethink their products with organic shapes and complex geometries. The potential for innovation, as well as economic efficiency, is huge
INDUSTRIALISATION OF 3D PRINTING As the industrial revolution taught us more than two hundred years ago, it is easier to solve such problems within the framework of a manufacturing company. Industrial 3D printers supported by professional teams of engineers and operators can work together with OEMs and entrepreneurs to achieve the reliability, repeatability and economies of scale commonly associated with mass production facilities. Production AM systems have the ability
to simultaneously manufacture tens, hundreds or thousands of individual components irrespective of whether the parts are all identical or all unique. Does this mean that the per-part cost to make one part would be the same as 1000 parts? Not quite, as there is an element of setup cost for each unique part – whether that be in checking orientation of the part for printing, sorting the parts after production or just in paperwork. However scale does have a significant impact on cost even if the mass production is aggregated from many projects or customers. With the high capital outlay for
Initial attempts with various technologies led to the selection of the HP Multi Jet Fusion 3D printer as the technology of choice for Bowman’s own production parts
production 3D printers any time the equipment is sat idle has a significant impact on amortised costs. To drive costs down, higher volumes of different parts allows parts to be packed more densely as they are built resulting in less waste and higher productivity at the same time. Once scaled up to the point of running multiple production printers, the efficiencies further increase as post processing equipment and staff requirements are minimally affected by the higher throughput. For this level of 3D printer the barrier to ownership is not only the capital outlay,
staffing requirements or space needed but rather the need to achieve the high volumes of required throughput to make the venture competitive against outsourcing printing services which is starting to become the ‘norm’. The advantages of AM
are clearly too great to pass by unnoticed, but the costs and challenges are enough to prevent many from taking the plunge. This has created an environment in which early adopters are starting to see the rewards. An increasing number of OEMs and entrepreneurs are deciding that the best route forward is to outsource their manufacturing requirements to more established players. Money can be spent on research and design innovation, while those with experience within the industry develop the manufacturing side; a natural division of labour that will reap rewards for all sides. Bowman International entered the
world of 3D printing on the back of designing a revolutionary new split- bearing design which utilises patented 3D printed bearing cages and seals to produce a true market leading product. At the time (2016), there were few additive manufacturers in the market with the capacity, quality controls and processing rigour necessary to produce industrial parts, so an AM division was established, Bowman Additive Production (BAP). After three years of trials, research and
development, Bowman is establishing a foundation of knowledge and experience that make it an industry leader. Initial
attempts with various technologies led to the selection of the HP Multi Jet Fusion 3D printer as the technology of choice for Bowman’s own production parts. The printer manufacturer, HP, has focused on developing printers specifically aimed at larger scale production matching Bowman’s requirements and ambitions. These machines produced parts with exceptional isotropic properties and boast unrivalled productivity, while the technology continues to be developed towards favouring efficient mass production. Having chosen HP’s MJF solution,
Bowman is focussed on refining its automated post-processing, improving production efficiency, and offering its full range of subcontract AM services to companies that wish to explore and outsource their own additive production. For most manufacturers, the
establishment of an additive arm is not economically viable, while many 3D print bureaus can’t fulfil the desired quality controls and part consistency necessary for production parts. This is where Bowman has found its niche. We believe the future of 3D printing is to be found in mass production of end-use parts in the same way Bowman is doing itself. From a broader perspective, there is
doubtless potential for an increasingly self-reliant post-Brexit Britain to turn to manufacturing on a scale unseen for decades. High-end manufacturing utilising AM is sure to be a significant player in future of the UK economy. We are pleased to be forerunners in this regard.
Bowman Additive Production
sales@bowmanap.com T: 01235 462517
www.bowmanap.com
DESIGN SOLUTIONS | NOVEMBER 2019 7
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