Key Takeaways
- Additive manufacturing has become a viable option for serial production due to advancements in machine reliability, materials, post-processing, and economics.
- Modern powder bed fusion technologies can produce parts with standardized mechanical properties and surface finishes.
- Additive manufacturing offers greater flexibility and faster production times compared to traditional methods like injection molding.
- The technology has improved to the point where it can meet functional performance requirements for most industrial applications.
Introduction to Additive Manufacturing in Production
For years, additive manufacturing was primarily used for prototyping due to its ability to produce parts quickly and without the need for tooling. However, the technology has advanced to the point where it is now a viable option for serial production. The improvements in machine reliability, materials qualification, post-processing capability, and economics have made additive manufacturing a competitive option for production lines.
Overcoming the Repeatability Problem
One of the main objections to using additive manufacturing in production was the lack of consistency in part production. However, modern powder bed fusion technologies have addressed this issue, delivering standardized mechanical properties and surface finishes across entire batches. While the surface quality may not be identical to injection molding, it meets the functional performance requirements for most industrial applications.
Comparison of Additive Manufacturing and Traditional Methods
| Technology | Production Time | Tooling Lead Time | Upfront Costs |
|---|---|---|---|
| Additive Manufacturing | Weeks | 0-2 weeks | $0 - $10,000 |
| Injection Molding | Months | 12 weeks | $10,000 - $50,000 |
Speed and Capital Efficiency
Additive manufacturing offers greater flexibility and faster production times compared to traditional methods like injection molding. With tooling lead times of up to 12 weeks and upfront mold costs that can run to tens of thousands of dollars, injection molding is optimized for high-volume, stable production runs. However, modern manufacturing requirements are increasingly characterized by smaller batch sizes, faster production cycles, and greater design flexibility, making additive manufacturing a more suitable option.
Bottom Line
Additive manufacturing has finally earned its place on the production line due to significant advancements in technology, materials, and economics. With its ability to produce parts with standardized mechanical properties and surface finishes, additive manufacturing offers a competitive option for production lines. As the technology continues to improve, it is likely to play an increasingly important role in modern manufacturing, offering greater flexibility, faster production times, and reduced costs.