2024-11-11 17:43:00
The AM world has already packed its bags for Formnext. Anyone who is serious about 3D printing should visit the fair in Frankfurt. However, 3D printing is not high on the agenda in many companies. You won’t find those companies in Frankfurt. Why not? Is the technology too difficult? Is additive manufacturing not yet Chef Sache? And: don’t we desperately need the technology if we want to become circular and less dependent on countries outside Europe for raw materials?
Parts on Demand threw a few weeks ago during the 10e birthday party kicks the bucket with a panel discussion. The audience were mainly people who no longer need to be convinced of the added value of 3D printing. But how do you get the rest? “How do we bring 3D thinking to the fore,” discussion leader Janet Koren asked the panel. 3D offers advantages, solves problems, innovates, but it is not yet at the front of engineers’ toolbox.
3D design is really a profession in itself
Generation thing?
And then things immediately go wrong. “You have to make the choice for 3D printing at an early stage; you then have to approach the design process differently,” says Bas Roelofs, engineer and 3D specialist at Machinefabriek Geurtsen. This is one of the manufacturing companies that does embrace 3D printing. Machinefabriek Geurtsen, which builds and sells automation solutions for production processes, even 3D prints the concepts to convince the customer during the sales process. Is Geurtsen a white raven? Anne van den Dool, Parts on Demand, notices in practice that companies often knock on the door the first time because of an obsolete part. “When they see what is possible, they take next steps. It is often due to prejudices.” Isn’t it a generational thing, asks Mindel van Gijzel, Partner Program Manager at ABB. Certainly, thinks Bas Roelofs. ‘When laser cutting came along and you finished a product with laser cutting and edging, you saw the same thing as with 3D printing. It was difficult to involve the older generation.”
Will there be a change?
Herman van Bolhuis, director of 3D Makers Zone, has noticed a change, especially when it comes to 3D metal printing. When the first group of companies discovered that the business case was difficult to find, they ignored the technology for seven years. “That has delayed the market for years. But the quality of the machines is improving, the software. Now we see a second generation of parties that are looking for a future in 3D metal printing, they really have different questions,” says the AM evangelist.
Why not design in 3D
Herman van Bolhuis also attributes the low acceptance rate to the designers, who are quite stubborn. “3D design is really a profession in itself.” Precisely for that reason, guidelines and knowledge surrounding 3D printing that PWR Pack International has built up are shared internally with new employees. The robot integrator for food packaging lines already uses 3D printing extensively to build lighter grippers. The traditionally milled and turned end of arm tooling for a robot is often too heavy. Through the search for lighter and stronger, the company ended up with 3D printing, explains Michiel van Valkengoed, engineering manager at PWR Pack International.
Material integral part
René Tamboer, program manager for digitalization of the manufacturing industry at TU Delft, understands why things are going slowly. “The industry relies on traditional materials. But with 3D printing, the material is an integral part of the design and the process. The freedom the engineer has makes it difficult to implement in a traditional company.” People are not yet trained for it. And they must dare to let go of the traditional.
Management must support 3D printing from a vision
The management must bear it
Additive manufacturing is not a Chef Sache in most companies. It’s up to the engineers. A department buys a simple FFF printer, is disappointed and writes off 3D printing. “Too bad,” says Mindel van Gijzel of ABB. In her opinion, 3D printing should be supported by management. Later in the discussion she mentions Kaak as an example. The manufacturer of bread baking lines was one of the first to do so a few years ago and is now investing again in AM technology, an ABB robot with Meltio AM technology. “Maybe not always profitable, but there is a vision behind it. If AM was not supported by the management, this would never have happened.” Amber Fiechter, business development manager at FME, agrees with this. If management carries it, the engineer has more freedom to search and talk. The FME is trying to create awareness of this with the Additive Manufacturing Network.
A new one for every two departing employees
Herman van Bolhuis also welcomes it when 3D printing comes onto the board. From the 3D Makers Zone they try to convince at that level, with arguments that are not directly related to the technology but do directly affect management. “For every two employees who leave, at most one will return. So you have to work on higher labor productivity and that is possible with digital technology, says Van Bolhuis. He expects this to be the theme in the industry for the next ten years. Moreover, keep an eye on China, warns Mindel van Gijzel. “We really have a challenge when you see how fast everything is moving in China. They work extremely well. We are lagging behind in terms of innovation. We therefore need to work together more.”
I am working on circularity; market products as a service and take them back
New round, new opportunities
The manufacturing industry will increasingly have to deal with legislation in the field of circularity in the coming years. And there will be a repair directive from Brussels. Can legislation help 3D thinking? The experts on the panel are not yet convinced. Herman van Bolhuis points out that practice is often slightly different. “Circular pellets are not all equally good.” And Kris Binon, AM consultant at software developer AMIS, thinks that you first have to design differently. Traditionally, the industry makes products consisting of multiple materials. That makes recycling difficult. If you are going to 3D print with one material, circularity could help. René Tamboer is more positive about the theme of circularity. The demand for titanium is becoming enormous, but the material is not always easy to obtain. “If you can keep the material running at a certain level, that’s good.”
It is not profitable
He believes that the industry should think more about this. Just like designing more repairable products. But then a solution must be found to produce cheaper, says Mindel van Gijzel. “Customers want it but they can’t sell it because it is not profitable. We really need to work together to produce cheaper.” Herman van Bolhuis thinks that this currently niche application will certainly grow in a number of years.
Less material, circular, local
He is convinced that digitalization and circularity is the direction in which we should think in Europe. In terms of raw materials, Europe must take a much more conservative course. “You have to be concerned with reusing materials; market products as a service and take them back.” René Tamboer even dares to say that you have no future as a manufacturing company if you don’t go along. Design for AM in relation to fewer materials, circular and local production: that is the future. “If you don’t go along with that, you can shake things up in a few years.”
TU Delft is joining forces with it AM Network of FME organize a series of master classes on 3D printing in the Digital Innovation Hub.
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What are the key benefits of integrating 3D printing into sustainability efforts within manufacturing?
D for sustainability and cost management.” He emphasizes the potential for 3D printing to contribute to circular economy principles by allowing for the design of parts that can be easily disassembled or recycled.
**Designing for 3D Printing**
The discussion highlights that designing for 3D printing requires a fundamental shift in mindset for engineers and designers. Many are still accustomed to traditional manufacturing processes and materials, which do not lend themselves well to the capabilities of additive manufacturing. For instance, the flexibility and design freedom that 3D printing offers—such as complex geometries and optimized structures—are often underutilized due to a lack of understanding or willingness to change.
**Management’s Role in Adoption**
A key takeaway is the critical role of management in fostering an innovative culture that embraces additive manufacturing. Without support from leadership, engineers may be limited in their experimentation and exploration of 3D printing technologies. Investing in training and providing resources can empower teams to integrate 3D printing into their workflows more effectively. Companies that have seen success, like Kaak, demonstrate how a clear vision and persistent investment can yield significant returns, despite potential challenges in immediate profitability.
**Looking Ahead**
As the industry faces growing pressure for sustainability and innovation, the necessity of adopting advanced manufacturing technologies like 3D printing becomes more pronounced. Strategies that promote a circular economy, backed by robust management support and workforce training, will likely be crucial for companies aiming to stay competitive. The evolving landscape also requires vigilance against global competitors, particularly countries like China, which continue to advance rapidly in technology adoption and innovation.
embracing 3D printing in manufacturing is not just about the technology itself; it’s about rethinking design processes, cultivating a conducive organizational culture, and aligning with broader economic and environmental goals. Companies that navigate these challenges successfully may well position themselves at the forefront of the next industrial revolution.
