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Which Additive Manufacturing Process Is Right for You?

Bhagyashri Kambale | December 06, 2021
ADDITIVE-MANUFACTURING-PROCESS-MIN
Additive Manufacturing (AM) uses computer-aided design (CAD) or 3D object scanners to create accurate geometric features. In contrast to traditional manufacturing, which frequently involves milling or other processes to eliminate superfluous material, these are produced layer by layer, as with a 3D printing process.

The global additive manufacturing market is expected to grow at a 14.42 percent annual rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2028, according to reports and data. Overall, the worldwide 3D printing industry is gaining traction due to various reasons, some of which are listed below.

  • Significantly, greater resolution
  • Reduced manufacturing costs as a result of recent technology breakthroughs
  • Ease of creating customised goods
  • Increasing possibilities for printing with diverse materials
  • Funding by the government for 3D printing ventures

Additive manufacturing is available or may be implemented in various procedures, which is the primary objective of this article. First, we'll look at the seven additive manufacturing processes and which one is the best to use. So let us begin.

“Don’t be afraid to go outside of your industry to learn best practices. There might be something that surprises you or inspires you to try in your line of work.”

– Emily Desimone, Director of Global Marketing at SLM Solutions

Additive Manufacturing Processes

There are numerous diverse additive manufacturing processes, each with its own set of standards. Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements.



Material Jetting

This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation.


VAT Photo Polymerization

This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories.


Binder Jetting

Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object.


Material Extrusion

S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object.


Powder Bed Fusion

Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering.


Sheet Lamination

Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer.


Directed Energy Deposition

Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate.


Which Additive Manufacturing Process is best? Why?

Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified.

The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes.

Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies.

Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament).


How BASF is Using Additive Manufacturing


BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio.

The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others.

BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM.

BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year.

BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers.

Final Words


All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output.


FAQs

 

What are the benefits of additive manufacturing?

AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability.

What is the major challenge in additive manufacturing?

Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing.

What are the steps of additive manufacturing?

The additive manufacturing steps are divided into four steps as below,
  • Step1 - Design a model with CAD software
  • Step2 -Pre-processing
  • Step3 -Printing
  • Step4 - Post-processing

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Additionally, it eliminates andsubstitutes inefficient jobs within processes, significantly increasing their efficiency. This efficiency is translated into time savings, which results in a substantially more cost-effective manufacturing process. Decentralized Production Manufacturing digital transformation allows organizations to supervise manufacturing remotely, allowing production to continue uninterrupted. In rare cases like Covid-19, digitalized businesses have not had to cease or even slow down production. These systems can work without interruptions for much longer than any worker. Digitalization also boosts methodology flexibility and reactivity. For example, if a production plant has a problem, an automatic alert is generated, and the issue is resolved regardless of the day, time, or presence. Improved Operational Efficiency Smart product connectivity allows devices to connect and communicate with each other (M2M). This connectivity enables decentralized decision-making. Many duties no longer require an employee to be physically present. New manufacturing and production models minimize boring, risky activities while increasing accuracy, efficiency, and responsiveness. Transforming businesses through digital means making better decisions based on real-time data. Training, changes, and repairs are no longer issues due to reduced frequency and automation. New Business Opportunities New digital technologies enable the manufacture of previously unviable products and services, generating new revenue streams. Also, new services (innovation or reorientation) are launched considerably faster. Companies may utilize big data and AI to experiment, anticipate trends, and predict about new advancements. These technologies can help organizations become more eco-friendly and create products that are less detrimental to our environment. Attracts New Talent Professionals with fundamental talents in this complicated and disruptive environment are drawn to digitalizedorganizations that are up-to-date with trends and processes. Also, if the change is managed well, it will lead to higher profitability, increasing employee satisfaction. Human motivation, along with excellent digital technologies, will reflect in the company's production and profitability. Dusseldorf@Germany: The Deloitte Digital Factory The digital factory in Dusseldorf provides a flexible setting for innovative workshops and training, bringing together the old and new worlds of supply chain and industrial operations to provide a seamless experience. Specific use case examples, as well as the digital solutions sector, will motivate and encourage businesses to get on their digital transformation journeys, making use of the most up-to-date technologies in the process. 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Digitalization is the use of digital technologies to collect data, identify patterns, and make better business decisions. How digital technologies are applied in manufacturing? Digital manufacturing technologies enable the integration of systems and processes across all stages of production, from design to production and beyond.

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Article | March 22, 2022

Manufacturing analytics, or real-time manufacturing analytics, is the process of collecting, cleansing, and analyzing data from machines to forecast their future use, prevent failures, forecast maintenance requirements, and identify areas for improvement. “The goal is to turn the data into information and information into insight.” - Carly Fiorina, ex CEO of Hewlett-Packard Manufacturing data incorporates all structured and unstructured information collected manually or through software from machines and humans throughout the manufacturing process, up to the point at which a product is launched to the market. In this article, we will look at the use cases of data analysis in manufacturing and some of the start-ups from the U.S. that are helping manufacturers gather their real-time manufacturing analytics. Data Analysis in Manufacturing: Use Case Analytics Demand Forecasting Forecasting demand is highly dependent on historical data on supply levels, material costs, purchase trends, and customer behavior. Manufacturers can use analytics to accomplish the following: Define the products to be manufactured in a time frame Define products that are no longer in stock Determine the quantity of products to be manufactured Forecast sales prospects Inventory Management Forecasting demand enables manufacturers to manage inventory, purchase materials, and optimize storage capacity based on data. Additionally, manufacturing industry data analysis provides insight into: The sales-to-inventory ratio indicates the average inventory value over net sales. Days in inventory refers to the time a manufacturer retains before selling a product. Gross margin return on inventory (GMROI) is a term that refers to the amount of gross margin a manufacturer receives for each dollar invested in inventory. Maintenance Optimization Data collected from various manufacturing machines, tools, and devices, as well as information about operations and the gears required for the machines, can be analyzed to: Predict when a machine will require maintenance based on the amount of time and the operations in which it has been used. Identify and resolve operational anomalies caused by or will result in machine failure. Prevent downtime by scheduling machine breakdowns, repairs, and replacements in advance. Price Optimization Utilizing analytics can assist manufacturers in determining the actual cost of a product based on the costs of materials, labor, machines, and tools used or purchased during the manufacturing process. Additionally, manufacturers can optimize prices based on data about competitors, market trends, consumer behavior, and purchase history. Additionally, analytics can assist in setting dynamic prices that are determined by demand, supply, competition, and subsidiary product prices. Analytics for Manufacturing as a Service: Three U.S.-based Startups Uptake Uptake offers predictive analytics solutions powered by artificial intelligence for various industries. It provides a compass, which allows organizations to optimize work orders and scout. This allows users to analyze data and custom alerts and radar to get failure and anomaly detection solutions. Failure prediction, noise filtering, situational analytics, and detecting changes in operational behavior are just a few of the features that these systems offer to their customers today. The product, by Uptake, is intended for use in various industries like mining, construction, fleet management, manufacturing, aviation, government, and oil and gas. Seeq Seeq is a leading provider of industrial data analytics solutions. Its big data analysis solutions help in the analysis and comprehension of industrial process data (IPD) more effectively and quickly than typical alternatives. Reduced analysis time, quicker relationship discovery, ERP and other system connectivity, support for business intelligence (BI) tools such as Excel, Tableau, SAS, and MATLAB, and collaboration support are some of the features. Sight Machine Sight Machine provides a platform for manufacturing applications that utilize digital twins. It provides solutions for continually analyzing images captured by industrial cameras, sensor data, and data from manufacturing systems to improve product quality and operations. It provides real-time visibility and actionable data for every part, machine, line, and plant manufacturing process. Its clientele includes Nike, Sony, Nissan, and Google, to name a few. Final Word Big data analytics in manufacturing assists businesses in identifying the parameters that have a direct effect on production. Additionally, modifying the target process helped businesses increase productivity by 50%. McKinsey estimates that when analytics are used in design-to-value workflows and projects, manufacturers' gross margins can increase by as much as 40%. Manufacturing analytics can help with design-to-value, supply chain management, and after-sales support. Real-time manufacturing analytics enables manufacturers to optimize their overall production. FAQ Why is data critical in manufacturing? Big data helps manufacturers understand their customers' needs and wants better. To launch a new product or upgrade an old one, data is required to make it appealing to customers and assess the risks of competition. What is production analysis? Production analysis visualizes production output and helps assess production losses and associated costs. What is predictive manufacturing? Predictive manufacturing uses descriptive analytics and data visualization to provide a real-time perspective of asset health and reliability performance.

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Rise in Adoption of Advanced Connecting Technology Boost the Demand for Smart Locks

Article | March 2, 2022

Rise in security and privacy concerns and the growing trend of IoT and automation drive the growth of smart surveillance and home security systems. The development of smart locks has enhanced locking systems with improved security. With the emergence of new connected technologies in the market, the demand for advancements in smart locks also increases. Due to this, market players are investing in continual R&D for developing top-notch smart locks, thus meeting the consumers' rising demand and securing their footprint in the industry. Demand for the smart lock is high in residential, commercial, and government sectors Smart locks are convenient to use and provide improved security to the user. From the residential to the commercial sector, the acceptance of smart locks is increasing gradually. Increase in standard of living in urban areas and disposable incomes drives the demand for smart locks in emerging nations. In addition, the easy availability of the internet and improved use of smartphones aid the acceptance of smart locks in residential sectors. The integration of smart locks with larger security systems provides improved protection. Due to this, the demand for smart locks is high commercial sector to provide reliable authentication and security procedures. The smart lock technology is widely used in hospitals, office buildings, banks, and other sectors for a variety of purposes such as network access, workstation access, and physical access. Smart locks are ideal for bolstering the physical security of the building and space. Technology plays a vital role in the government sector. Increase in security and safety concerns of personal and information assets has enhanced the adoption and implementation of smart lock technology in the government sector. Smart locks are used by multiple government agencies and forensics departments, specifically at sensitive information stations, for staff authentication and other security purposes. The market has a range of smart locks with hundreds of features. Technology in smart locks has come a long way. Presently, the market has smart locks with various operational modes such as WiFi, bluetooth, fingerprint, voice assistants and commands, and biometrics. However, there is still a long way to go, and market players are working on new technologies in smart locks. The latest and unique technology in smart locks provides lucrative opportunities for market growth. In addition, increased government investments in smart city projects in developing nations assist the market growth. According to Allied Market Research, the global smart lock market is anticipated to grow at a significant CAGR of 16.4% from 2017 to 2023. New launches and the latest technology in smart locks Market players are adopting strategic collaboration to innovate advanced lock systems with emerging technologies and market expansion. Kaadas, a leading provider of digital smart locks joined hands with Lamborghini to develop smart facial-recognition door locks. Kaadas recently introduced its high-tech and exclusive collection of smart facial-recognition door locks, which uses 3D structured light technology. The advanced 3D recognition technology offers infinitesimal accuracy for face recognition for biometric authentication and door unlocking. The novel Kaadas- Lamborghini facial recognition lock provides improved security for home and office buildings. The 3D recognition technology extracts exact facial features and bone structure for developing the 3D model and doesn’t support door unlocking with videos or photographs. Along with a 3D facial recognition system, the smart digital lock also provides advanced features including PIN code, mechanical override key, fingerprint biometrics, and encrypted CPU card for door unlocking. The facial recognition lock also supports automatic locking of the doors once closed. This high-tech lock can be a game-changer in the smart locks market. Smartphones have become an integral part of today’s lifestyle. With the growing technological advancements in IoT and remote control devices, operating smart devices and systems with smartphones has become easy. Market players are developing advanced and efficient smart locks to meet the growing customer demands. Schlage’s latest Encode Plus Smart WiFi Deadbolt is the first smart lock that works with Apple home keys. Encode Plus Smart lock works with Apple wallet and can be accessed with Apple Watch, iPhone, and home kit. It also offers other features to the customers such as remote controlling with applications, emergency alerts, activity details, and other advanced features which a user expects in a smart lock. The smart lock is also well-suited to Google Assistants and Alexa, and it will be available in the market later this spring. Covid-19 Scenario The outbreak of covid-19 impacted the global smart lock market as consumer spending on nonessential products decreased during the pandemic. However, the world is getting back to normalcy. Also, the inclination towards digitalization and automation has increased among people. The market is expected to witness significant growth in the coming years with the latest advancements in smart lock technologies. The market will recoup soon.

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How to Find a Suitable Contract Manufacturing Partner?

Article | December 10, 2021

The benefits of contract manufacturing are triggering manufacturers to utilize it as a strategy to speed up production and increase revenue. According to BCC Research, the worldwide contract manufacturing industry should increase from $2.0 trillion in 2018 to $2.7 trillion in 2023, a 6.7% CAGR. Given the growing demand, contract manufacturing has a long way to go in innovating new solutions for manufacturers. As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity. – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca Let us look at the benefits and concept of contract manufacturing, often known as manufacturing partners in some circles. Contract Manufacturing: Concept and Benefits Concept Contract manufacturing is a business model in which a company agreeswith a contract manufacturer to make components or finished goods based on the hiring company's design. In short, it is a business model in which one company hires another company to manufacture components or goods for them or their products. Benefits The following are some of the primary advantages of contract manufacturing that attract manufacturers to adopt this concept and find a trusted supplier to manufacture any product or part of their product without much difficulty. Cost Efficiency: In contract manufacturing, companies do not have to pay for the facility, equipment, or labor needed. Resource Allocations: The money and resources saved through contract manufacturing can be redirected towards other company operations. Faster Lead Times: Hiring a contract manufacturer reduces manufacturing time. This improves market speed, delivery time, and customer service. Quality Control: Contract manufacturers are likely to have their own quality control processes in place, which allow them to spot counterfeit or damaged products early on. Advanced Skill Sets: Companies can benefit from the skills they may not possess, but the contract manufacturer does. Contract Manufacturing Examples Here are some examples of contract manufacturing companies that offer manufacturing services to other businesses and work on full-service outside manufacturing projects. Example 1: Kimball Electronics Group Kimball Electronics Group provides a comprehensive range of electronics manufacturing services, including engineering, prototyping, testing, electronic data interchange (EDI), new product introduction, and repair depot services. Soldering, assembly, reflow, de-paneling, flux application, inspection, screen printing, testing, and rework are all processes used in their manufacturing. Example 2: Scapa Healthcare Scapa Healthcare, headquartered in Knoxville, Tennessee, provides contract manufacturing services for medical and cosmetic products. Their portfolio of products includes sunscreen, silicone medical adhesives, and innovative materials. Additionally, the organization provides development, packaging, and logistics services. Things to Consider While Selecting a Contract Manufacturing (CM) Partner You need to know how to identify the ideal contract manufacturer for your business to accelerate production and produce high-quality items. Below, we've listed some of the most important things to keep in mind while looking for an outsourced manufacturing partner for your company. Competency Understanding a contract manufacturer's (CM) capabilities in terms of logistics and fulfillment is critical. Is your potential CM able to meet shifting product demands? How to use the CM's services? You may need one or more services from CM for your product, so always examine their capabilities or develop a list of their services and see which ones are valuable for you. Knowledge or Prerequisite A qualified, experienced, subject matter expert CM always correctly understands the requirements and delivers the services as per expectations and within the time frame specified in your production schedule. Always inquire about their qualifications or certificates in the places where your product will be manufactured. Compliance Any contract manufacturing plan must have an agreement or compliance clause. Always inquire about the compliance procedure and thoroughly understand the terms and claws to avoid future issues. Workforces Verify your possible contract manufacturer's personnel count. Is it easy to talk to them? Is labor skilled enough to meet the product's goals? It is critical for large-scale production and production, requiring swift responses. Any work force shortage might cause production delays. Gear & Expertise Check for machines and equipment as well as human labor in your possible CM. Many CM lease equipment to complete a project. So always check how the CM will organize the essential equipment for your project. Expertise in using the equipment is also necessary. Verify which machines were used and whether or not professionals were involved. Whereabouts The CM's location is the main factor to check. Because the CM may have numerous plants, knowing which plant is assigned to your product is essential to knowing every aspect of its production. Also, the assembly location must allow you to visit and inspect the manufacturing between cycles. Business Stability Finding a reliable contract manufacturer with solid financial backing and market roots is essential to avoid market scams. However, you must also analyze and solve risk factors like equipment failure, supplier capacity, and unreasonable expectations. Selection Myths of Contract Manufacturing Partner Once you've produced a list of shortlisted contract manufacturing partners who meet all of the criteria described in the preceding heading, you can proceed by following the steps below to select the best contract manufacturing partner. Look for Who is Willing to Invest in Your Business Incorrect. The objective is to find a vendor prepared to manufacture at a loss. A contract manufacturer's strength is that they can stay competitive and make a profit for both parties. Focus on Tier 1 CM Partners from the Market This one is indeed not acceptable. Tier 1 is a financial phrase used to separate large corporations from smaller ones. You want a contract manufacturer who understands your business and your needs. Don't worry about the manufacturing partner's size. Go Ahead with the One Who Offers the Best Services at the Lowest Price Trying to get the cheapest quote isn't always the best idea. You should get a quote from your contract manufacturing partner, but the quote may not always reveal the complete story. Cost per unit frequently captures approximately 75% of total supply chain cost. Some contract manufacturers charge the OEM the remaining 25%. Consider the complete picture while selecting a CM partner. Final Words Manufacturers use contract manufacturing to meet their commercial goals. Therefore, contract manufacturing is a win-win situation for both industrialists and contract manufacturers. Finding the proper contract manufacturing partner for your company is not straightforward, but our brief guide can help you identify the right manufacturing partner. FAQ What makes a good contract manufacturer? The most significant contract manufacturing firms are more than just supply chain partners. They recognize and treat your items as if they were their own, are meticulous in their operations, and are concerned with quality and capital. What differentiates contract manufacturing from outsourcing? A contract is a legally binding arrangement. It involves two or more parties. For example, outsourcing is outsourcing some tasks to an outside organization under a contract agreed upon by both parties. What's the difference between contract manufacturing and licensing? Contract manufacturing only outsources production phases, while licensing is far more complex. In return for fees, a corporation sells the right to utilize its intellectual property to another company. Licenses are like franchises. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What makes a good contract manufacturer?", "acceptedAnswer": { "@type": "Answer", "text": "The most significant contract manufacturing firms are more than just supply chain partners. They recognize and treat your items as if they were their own, are meticulous in their operations, and are concerned with quality and capital." } },{ "@type": "Question", "name": "What differentiates contract manufacturing from outsourcing?", "acceptedAnswer": { "@type": "Answer", "text": "A contract is a legally binding arrangement. It involves two or more parties. For example, outsourcing is outsourcing some tasks to an outside organization under a contract agreed upon by both parties." } },{ "@type": "Question", "name": "What's the difference between contract manufacturing and licensing?", "acceptedAnswer": { "@type": "Answer", "text": "Contract manufacturing only outsources production phases, while licensing is far more complex. In return for fees, a corporation sells the right to utilize its intellectual property to another company. Licenses are like franchises." } }] }

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