AM Production Basics

AM represents a significant shift in the manufacturing paradigm. By moving beyond its prototyping origins, AM is becoming a cornerstone for innovative production strategies across various industries, each leveraging its unique capabilities to address specific challenges and opportunities.

There are several key advantages that AM offers from a production standpoint, including:

• Complex Geometries: AM allows for the creation of intricate designs that would be challenging or even impossible with traditional methods. This capability can lead to parts with optimized performance, lighter weights, or integrated functionalities.

• Customization: AM offers the flexibility to produce customized or personalized parts without the need for retooling, making it perfect for industries like medical implants or bespoke consumer goods.

• Supply Chain Simplification: By producing parts on-demand, AM can reduce the need for extensive inventories and streamline supply chains.

• Material Efficiency: Many AM processes only use the material needed to create the part, reducing waste.

• Rapid Iteration: Changes in design can be quickly implemented and produced, allowing for continuous improvement even during production stages.

However, there are also challenges to utilizing AM processes for producing parts, which include:

• Scale & Speed: While AM is highly versatile, it may not always match the speed of traditional manufacturing methods, especially for high-volume runs.

• Material Choices: While the range of AM materials has expanded greatly, it may still be limited compared to traditional processes.

• Post-Processing: Many AM parts require significant post-processing to achieve desired surface finishes or mechanical properties.

• Quality Control: As with all manufacturing, ensuring consistent quality is paramount, and AM has its unique set of QC challenges.

When considering AM for production, the selection of the right material is not solely based on the immediate needs of the part but also on the environmental conditions it will face. Being mindful of these considerations ensures the durability, functionality, and longevity of the AM-produced parts. These considerations include:

• UV Exposure:

  • Description: Prolonged exposure to ultraviolet (UV) radiation can degrade many materials, leading to color fading, reduced mechanical strength, and compromised structural integrity.

  • AM Materials: Certain photopolymers, like those used in SLA or DLP printing, might be more susceptible to UV degradation. UV-stabilized or UV-resistant materials have been developed to counteract this effect.

  • Applications: Outdoor products, dashboard components in vehicles, or any parts directly exposed to sunlight.

• Weather/Elements:

  • Description: This includes a wide range of environmental factors such as temperature fluctuations, moisture, and prolonged exposure to the elements.

  • AM Materials: Polymers like ABS, ASA, and specific grades of nylon (PA) have demonstrated better resistance to weathering. Metal-based AM materials like stainless steel, titanium, and Inconel can also withstand challenging outdoor conditions.

  • Applications: Outdoor fixtures, automotive parts, marine components, and more.

• Chemical Interactions:

  • Description: Parts may come in contact with various chemicals, solvents, or reactive agents, potentially leading to material degradation or failure.

  • AM Materials: PEEK and PEKK are examples of high-performance thermoplastics known for their chemical resistance. For metal AM, materials like titanium and Inconel resist many corrosive environments.

  • Applications: Chemical industry components, fuel tanks, medical implants, and other environments with potential chemical exposure.

• Physical Interactions:

  • Wear: Consideration for parts that experience constant friction or abrasive forces. Materials with high wear resistance, like certain metal alloys or carbon-fiber filled polymers, are preferred.

  • Compression: Materials with high compressive strength, often metals or engineering-grade polymers, are chosen for applications like mounts or load-bearing structures.

  • Tension: For parts that need to withstand pulling forces, materials with high tensile strength, such as certain metallic alloys or high-strength polymers, are optimal.

  • Bending & Flexing: Flexural strength and elasticity are vital for parts that need to bend without breaking. Materials like TPU or flexible nylons are often used in AM for such applications.

  • Material (In)Compatibility:

    • Description: This involves understanding how the chosen material might react when in contact with other materials or biological systems. Unwanted reactions can lead to corrosion, accelerated degradation, or health risks in biological environments.

    • Corrosion: Certain metals might corrode when in contact with specific chemicals or even other metals. For instance, galvanic corrosion can occur when two dissimilar metals are in contact in the presence of an electrolyte. Material choices for AM need to consider the broader environment and other components the printed part will interface with.

    • Material Interactions: Some materials might have detrimental effects on each other. For instance, certain rubbers or plastics might degrade faster when in contact with specific solvents or oils. In multi-material designs, understanding the long-term interactions between those materials is crucial.

    • Biocompatible Applications: For medical implants or devices that interface with the human body, materials must be biocompatible, meaning they do not induce an immune response. Titanium, for instance, is often used in AM for medical implants due to its excellent biocompatibility. Similarly, specific resins used in dental AM applications are formulated to be biocompatible.

    • Applications: Implants, wearable devices, multi-material machinery components, and any environment where the AM material might come in contact with other substances or biological systems.

certain additive processes reducing the traditional manufacturing constraints related to batch size. example: SLA cures one layer at a time, regardless of amount of material to be cured in the layer, meaning multiple parts can be printed in the same amount of time as a single part. however, the issue of failed prints wasting additional material is still a "pro" of one-piece-flow vs batching

reducing the number of human interactions/interventions

customer lead time

• Batch Size Flexibility in AM:

  • Description: Unlike traditional manufacturing, certain AM processes offer the ability to reduce constraints related to batch sizes, meaning parts can be produced individually or in batches without significant time variance.

  • SLA Example: Stereolithography (SLA) cures resin layer-by-layer with UV light. Regardless of how much of the layer is occupied by material, the time it takes to cure a layer remains relatively constant. This means multiple parts can be printed simultaneously in almost the same duration as printing a single part.

  • Consideration: However, while batching multiple parts can be efficient, it brings a potential risk. If a print failure occurs, it can affect all parts in that batch, leading to greater material wastage compared to printing parts individually.

• Reducing Human Interactions:

  • Description: One of the significant benefits of AM in a production setting is the reduction in manual labor and interventions. Once set up, many AM machines can run autonomously, reducing potential errors and improving production efficiency. Additionally, the capability of AM to consolidate multiple components into a single printed part greatly reduces overall manual labor.

  • Machine Autonomy: Many AM machines, once set up, can operate autonomously. Fewer human interventions mean consistent production quality and reduced risks associated with manual handling. With advancements in machine learning and sensors, AM machines can even self-correct or adjust parameters in real-time, further diminishing the need for human oversight.

  • Part Consolidation Benefits:

    • Fewer Assembly Steps: By merging multiple components into one, the need for assembling multiple parts is eliminated or greatly reduced. This translates to less time spent on manual assembly, fewer assembly errors, and overall reduced labor costs.

    • Reduced Inventory: Fewer unique parts mean a reduction in inventory management complexity and storage costs.

    • Enhanced Product Performance: Consolidated designs can lead to parts with fewer weak points (like joints or seams), potentially enhancing the durability and reliability of the final product.

  • Impact on Labor: The holistic result of these advantages is a considerable reduction in the manual labor associated with the production process – from initial part creation to the final assembly of the product.