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There has been an undeniable surge of assertions that additive technologies are ready for production applications across the additive manufacturing (AM) and 3D printing sector. This can largely and correctly be attributed to the industry's evolution. As AM technologies have continued to mature over the last four decades, they have shifted beyond their traditional niche of prototyping and into the domain of production. As an industry leader, at Stratasys we believe we are currently in a transition period that has been — and continues to be — fuelled by combined advancements in machine capabilities, material properties, and software to deliver higher volumes of end-use quality parts with cost efficiencies built in. 

Indeed, a number of AM technologies have been demonstrably proven as a viable method for producing end-use parts. We can testify to this as we work in partnership with an increasing number of clients to meet their needs in this area. However, we also understand that we are actually still in the early stages of the transition we are talking about here in this article. Utilizing additive processes to manufacture end-use parts is a positive sign of progress, yet it is not the same as using AM in a true production environment, producing medium to high volumes of qualified parts, reliably and repeatedly for demanding applications. While there are today some visible applications that do represent production using AM, they remain a minority. The good news is that we are heading in the right direction as we witness more companies undertaking the transition to AM for production applications at increasing volumes. 

This has long been the goal – producing end use parts in increasing volumes, rather than the one-off or very low volumes of parts that additive manufacturing is traditionally associated with. Cost-per-part has always been a difficult barrier to adoption to overcome — the economics must make sense for higher volumes of parts in the range between 1 and tens of thousands, before injection moulding then takes over. Overcoming this barrier has required a holistic approach. 

The evolution of the various AM hardware and software technologies, together with material development is enabling the increased viability of AM for much higher volume production. Some of the key factors driving this transition include higher performance materials; end-to-end process optimisation, including post processing; improved productivity and efficiency rates; and improved yield, process reliability and repeatability. 

Process & System Capabilities

The ability to handle higher volumes of parts is an unmistakable trait of AM production systems together with high quality, reliable and repeatable output. It's about harnessing the power of advanced machinery and technologies to undertake larger-scale projects, ensuring that precision and speed are not compromised. Thus, such systems can weave seamlessly between intricate custom jobs, batch production and extended production runs in ways that traditional manufacturing systems can’t.

However, as has always been the case since the origin of additive technologies, no single process fits all requirements. This is why Stratasys has focused on developing and expanding its range of processes and the systems that deliver them to meet the demands of its industrial customers. In this way our P3, industrial FDM and SAF processes cover the broad spectrum of capabilities for production applications of AM addressing the requirements for speed, part volumes, quality output and mechanical properties.

A Holistic Approach

However, and this is really important, improved AM hardware, in isolation, will never make production applications viable. At Stratasys we recognised this early on and as a result we have come at the technologies in a holistic way. This transition to direct production with AM is taking place because the hardware AND the software AND the materials available have all evolved to a level that can deliver comprehensive and competitive production solutions for key applications. 
 
Application performance is a critical issue for end use parts, and it is a driver for the increased growth we are witnessing via the breadth of rapid, validated engineering grade materials that we have added and continue to add to our portfolio. 
 

End-to-End

With AM every phase of the manufacturing process chain, from initial design consultation to final post-processing, can be optimized for efficiency, quality, and cost-effectiveness. 
 
Design and system optimization is as important for the overall outcome of AM for production as the hardware and the materials. Understanding this, Stratasys has developed a suite of software solutions to support the AM workflow. It focuses on an open and connected platform that streamlines the additive manufacturing process. Providing an accessible and user-friendly interface, GrabCAD supports simplified print preparation with features that allows previewing and adjustments/corrections to 3D models ahead of printing. A professional version also allows management workflows with additional features that include access controls, job management tools, and traceability for printed parts. 
 

Opportunities for Added Value

It is often the case, when talking to people that we often think about and discuss AM for production in terms of the challenges that we have to overcome to achieve it. Volumes, costs and quality are all important issues, as outlined above, that are frequently raised. However, often overlooked in this conversation are the benefits of integrating AM production strategies and the added value that an AM approach brings. 
  • Flexibility can be seriously underrated in terms of the value that it can bring to a business. Specifically in this regard, additive technologies do not require production tooling, which can eliminate long lead times and significant cost constraints associated with it and enable a more agile approach. Parts can be produced on-demand which introduces further cost savings on inventory and storage along with greater flexibility.
  • Complexity: Additive processes excel and are indeed unique when it comes to producing complex parts. The layer-by-layer nature of AM methods allow for the production of intricate geometries without being limited by what a machine can or cannot carve or drill. This means that complex internal features, lattices, and channels can be produced in a single process. In addition, parts can be optimized for their specific function and can be designed with features that improve performance. 
  • Customisation: Additive processes are scalable for making custom and mid-volume production economically viable, and higher volume production more efficient than traditional processes. This is enabling growth for mass customization applications. 

Vertical Integration into Production

As we continue to evolve the technologies and demonstrate their capabilities as well as highlighting the business benefits and added value that AM processes offer, Stratasys can bear witness to many companies that are keen to position themselves at the forefront of this transition into production that we are going through. Demand for agile, customisable, and efficient production solutions is growing across many sectors, including but not limited to medical, dental, aerospace, energy and transport.
 
Here are just a few applications that provide testament:

TE Connectivity

TE Connectivity is a world leader in the production of connectors and sensors, manufacturing 192 billion parts annually for its global customer base. The company was an early adopter of 3D printing technologies and had been beta testing the Origin One system, featuring the P3 process, since 2018. The additive manufacturing group at TE recognized the potential for the technology and material offerings:
TE Connectivity

Stratasys has been a great partner in helping us optimize accuracy and repeatability for connectors that require ± 50 micron accuracy, and demonstrating the possibilities of using AM to produce part volumes in the tens thousands. Today, we’re seeing the hardware, the software, and the materials from Stratasys really come together to begin making production scale a reality for us. We believe this helps make TE Connectivity a more agile and cost-effective partner for many of the world’s leading OEMs.

Lockheed Martin

If space is the final frontier, then human travel in to deep space, beyond the Moon, is the ultimate frontier. NASA’s Orion program intends to do just that. The conditions of deep space require a multi-mission approach with rigorous parts testing and the construction of a new spacecraft for each mission. This ensures both the integrity of the parts but also poses a challenge for Lockheed Martin, prime contractor for the Orion vehicle: repeatability.

satellite-3d-printed-part-lockheed-martin

We’ve been able to see orders of magnitude savings both in cost and schedule on all of these parts because the part builds are very consistent, the material properties are well understood, and the build parameters are becoming better understood.

Roush Performance

Founded by motorsport legend Jack Roush, Roush Performance develops aftermarket style and performance improvements for OEM vehicles like the Ford Mustang and F-150 pickup truck and upgrade packages for other select vehicles.

Instead of injection molding, Roush engineers 3D printed the mounts with SAF™ technology using the H350™ printer. This powderbed process provided sufficient throughput over several build cycles to make several thousand parts for the entire production run of F-150 vehicles. 

roush

Nissan Nismo

Origin One system helped take flexible production to the track for Nissan Nismo.
Nissan Racing Car

The elastomer materials we produced with Origin One, were a great benefit to our team. The comfort of the handles and durability of IND 402 was a good fit for our needs and we realized the evolution of the new technology.

There are many more examples available as case studies on the Stratasys website. It is likely that many more applications of additive technologies transitioning into production environments will emerge over the coming months and years. Stratasys technologies will continue to lead the way.