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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How can management effectively support the integration of additive manufacturing into engineering practices?
D for the circular economy. 3D printing has the potential to help reduce waste and reliance on raw materials by enabling companies to produce parts and products on demand, thus minimizing inventory and excess production.”
**The Role of Education and Training**
One of the major barriers to the adoption of 3D printing in many organizations is the lack of knowledge and training among designers and engineers. As René Tamboer noted, traditional manufacturing relies heavily on established materials and methods, making it challenging for professionals to shift their mindset to embrace the unique opportunities that 3D printing offers. Organizations need to invest in training programs that educate employees on 3D design principles and additive manufacturing processes. This investment in human resources will ultimately lead to greater innovation and adoption of 3D technology.
**Management’s Role in Adoption**
For 3D printing to become a core part of engineering practices, it requires strong support from management. As highlighted by Mindel van Gijzel and Amber Fiechter, leaders already using additive manufacturing are setting an example. Support from management allows engineers to explore new concepts and take calculated risks without fear of backlash for failures. This can foster a culture of innovation where additive manufacturing becomes part of strategic planning and product development rather than an afterthought.
**Collaborative Innovation**
The panel discussed the need for collaboration within the industry and across sectors to push 3D thinking to the forefront. The demand for more efficient, flexible, and sustainable manufacturing processes underlines the importance of sharing knowledge and practices between companies. As organizations champion the use of additive manufacturing, they can collectively address challenges such as scaling production, improving material properties, and ensuring compliance with upcoming regulations.
**Conclusion**
Incorporating 3D printing and additive manufacturing into the industry is not simply about adopting a new technology; it requires a cultural shift in thinking, design, and production processes. By fostering an environment where engineers are encouraged to innovate, supported by management, and educated on new technologies, companies can advance their capabilities in 3D printing. Furthermore, as Europe seeks circular economic solutions amid global material shortages, adopting additive manufacturing may not only meet these challenges but also position organizations as leaders in sustainable innovation. With proactive engagement from all stakeholders, the transition towards more widespread use of 3D printing can become a reality.