3D PRINTING/ADDITIVE MANUFACTURING 3D PRINTING: MOVING
MANUFACTURING TOWARDS MASS CUSTOMISATION
As additive manufacturing gets faster and the choice of materials grows, many see it as the first-choice production method for design engineers seeking greater agility to meet new
market demands. Andrea Landoni, global product manager for Protolabs, explores a new era of mass customisation for the technology
N
ot only does 3D printing offer designers almost infinite design flexibility, but
because there is no tooling or set- up, it is ideal for rapid prototyping. The development of more materials, new technologies and better finishes means it can also be used to produce customised and personalised parts, as well as small batches of end-use parts. Until recently, the speed
of production for larger runs meant that most manufacturers sought other technologies, such as injection moulding, for mass production. Things, however, have changed. New 3D printing technologies, such as Digital Light Synthesis using production-grade materials like EPX 82, are radically changing the speed of manufacture. In one example, the batch production of 28 units was four times faster than using stereolithography, and time savings are even greater for taller parts.
CUSTOMISATION AT SCALE When tens of thousands of parts need to be produced rapidly, other technologies, such as injection moulding, are still the first choice for many. But additive manufacturing is closing the gap for those who look towards just-in- time manufacturing or mass customisation to give the end user more choice. Manufacturers are accelerating their speed
to market from initial design. This places more pressure on engineers to design parts and products that their companies can produce using their chosen technology. Tools such as AI help this speed by, for example, checking that a design is possible but products still need testing before launch. This is where 3D printing makes a huge
difference. It can produce parts in a day or less, which you can then test and validate.
business fabrication time. Because moulds or fixed tooling are not needed, every part you design can be unique and cost-effective to produce. This gives your customer more choices at a reasonable price per part and higher margins for your business. Even when the product is finished, if market
feedback suggests that it needs further modification after launch, 3D printing allows you to quickly resolve any issues without the time or cost of retooling.
COST-EFFECTIVE CUSTOMISATION If there is no tooling, instead of mass-producing identical items, you can now produce customised parts on demand, opening a whole new era for individualisation at scale. We have already seen this in the
New 3D printing technologies are radically changing the speed of manufacture
It also allows you to quickly trial different product variations. Even after the testing and validation process,
because moulds and fixed tooling are not needed, additive manufacturing is faster to produce parts initially and can be a key means of meeting production line demand for parts. For additive manufacturing, you can upload a CAD file and generally leave the equipment to produce it. In addition, there is no need to hold expensive
inventory, you simply produce parts to meet the demands of the production line. Moving from testing to production, using 3D printing has obvious time-saving benefits, especially for just-in-time manufacturing. For the designer, it allows you to realise previously impossible designs through to production. Furthermore, the benefits for some industries – like aerospace and automotive – in realising lightweight components are huge. This design freedom also means
you can design and produce a single component or part with multiple features instead of producing a number of parts for assembly, saving your
FEBRUARY 2025 DESIGN SOLUTIONS 41
medical industry. Based on scans, prosthetics are now produced that exactly meet the needs of the patient, and 3D-printed crowns and dental implants are commonplace. While most of the industry is not geared up for individual personalisation, with 3D printers getting faster and with more material choices available, you can still meet the needs of ever-shrinking market segments and offer customer choice at a reasonable cost. This can set those seeking to
differentiate themselves and earn higher margins apart. Additive manufacturing allows you to not only test the market for these segments but also cost-effectively meet their needs faster than ever before. With more materials becoming available for 3D printing in better finishes, and the speed of production increasing, the technology is opening up enormous advantages for manufacturers looking to get to market quickly and better meet their customer’s needs at a cost-effective price.
Protolabs
www.protolabs.com/en-gb/
FEATURE
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