Whats On-Demand Manufacturing
Manufacturing

What is On-Demand Manufacturing and Its Impact on The Industry

On-demand manufacturing is not just changing the way products are made, but also transforming the entire manufacturing industry ecosystem, supply chain management, customer relations, and more. It represents a convergence of several digital technologies, each playing a critical role in creating an agile, efficient, and highly adaptable production environment.

In this blog, we delve into the far-reaching impact of on-demand manufacturing across various sectors and how this transformative approach is reshaping traditional supply chains, empowering businesses to thrive in an increasingly dynamic market. By eliminating the need for large-scale inventory, reducing production lead times, and allowing for just-in-time manufacturing, on-demand production is streamlining operations, reducing costs, and minimizing waste.


Understanding On-Demand Manufacturing

What is on-demand manufacturing? On-demand manufacturing, also known as just-in-time manufacturing, is a production strategy where products are made as they are required, rather than being produced in large quantities in advance. This strategy relies heavily on digital technologies such as 3D printing, cloud-based platforms, artificial intelligence (AI), and the Internet of Things (IoT) to enable flexible, efficient, and highly customizable manufacturing processes.

In addition, on-demand manufacturing, also known as just-in-time manufacturing, is a highly responsive and flexible production methodology that leverages the power of digital technologies to produce goods exactly when they're needed, and not in anticipation of demand. This approach hinges on a suite of advanced technologies that facilitate efficient, customizable, and scalable manufacturing processes.

Central to on-demand manufacturing is additive manufacturing, commonly known as 3D printing. This technology enables the production of custom parts swiftly, directly from digital files, significantly reducing lead times and eliminating the need for tooling. This process can accommodate a variety of materials, from plastics and metals to composites, thereby extending the feasibility of on-demand manufacturing to a broad array of products. Check out everything about additive manufacturing and its benefits through our previous blog here.

Moreover, on-demand manufacturing incorporates the use of Internet of Things (IoT) devices for real-time data collection and monitoring, enabling proactive maintenance, streamlined logistics, and precise quality control. Artificial Intelligence (AI) and Machine Learning (ML) are leveraged for sophisticated predictive analytics, which accurately forecast demand, optimize resource allocation, and improve supply chain responsiveness.

In parallel, cloud-based platforms are used for managing orders and facilitating coordination between different stakeholders. They provide a centralized system for handling design files, production schedules, and delivery logistics, all of which are crucial for successful on-demand manufacturing. These platforms can also facilitate real-time communication and updates, ensuring transparency throughout the production process.

Advanced software solutions, such as Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) tools, are pivotal for converting customer requirements into detailed production instructions. These digital design tools allow for the seamless transition from design to production, accommodating complex customization and ensuring accuracy and consistency, making them indispensable in the on-demand manufacturing industry.


History and Development of On-Demand Manufacturing

On-demand manufacturing is not a new concept; in fact, it has roots in the early history of manufacturing. However, the past few decades have seen a significant evolution and advancement of this concept, largely driven by technology and changes in consumer expectations.

  • Pre-Industrial and Industrial Revolution - Prior to the Industrial Revolution, most goods were manufactured on a made-to-order basis, often by skilled craftsmen. This meant that manufacturing was localized and personalized but also relatively slow and expensive. The Industrial Revolution in the 18th and 19th centuries marked a shift towards mass production, where goods were made in large quantities to benefit from economies of scale. The assembly line, introduced by Henry Ford in the early 20th century, further emphasized this shift. Products were made in large volumes, which resulted in lower per-unit costs but also in large inventories.
  • Post World War II - Just In Time Manufacturing - The concept of on-demand manufacturing was revived post World War II by Toyota with their Just-In-Time (JIT) production system. This system was designed to reduce waste and improve efficiency by manufacturing items only when they were needed in the production process. This concept was revolutionary but was limited by the capabilities of technology at the time.
  • Late 20th Century - Advancements in Technology - Technological advancements in the late 20th century began to make on-demand manufacturing more viable. Computer Numerical Control (CNC) technology made it possible to produce customized items quickly and accurately, and the advent of the internet allowed for more efficient order tracking and inventory management.
  • 21st Century - Digital Revolution - The advent of 3D printing technology marked a significant leap for on-demand manufacturing, allowing for the cost-effective production of highly customized products with short lead times. Coupled with advancements in AI and machine learning, manufacturers were now able to predict demand patterns more accurately, further optimizing their production schedules. E-commerce platforms and digital marketplaces also played a crucial role in the rise of on-demand manufacturing in the 21st century, allowing businesses to directly connect with customers, understand their needs better, and deliver personalized products.
  • Today and Beyond - Today, on-demand manufacturing continues to evolve, driven by ongoing advancements in technology and shifts in consumer demand. The rise of Industry 4.0, characterized by smart factories and the internet of things (IoT), is expected to further enhance the capabilities and potential of on-demand manufacturing in the future.


The Impact of On-Demand Manufacturing in the Industry

On-demand manufacturing is transforming the industry in several significant ways. The impacts range from changes in the supply chain and production processes to shifts in customer expectations and the adoption of new technologies. Here are some ways in which on-demand manufacturing is impacting the industry:

  1. Shift in Production Approach - Traditional manufacturing often relies on large batches and economies of scale. In contrast, on-demand manufacturing typically involves producing smaller quantities, tailored to immediate demand. This requires a shift in mindset and production processes, favoring flexibility and responsiveness over volume.
  2. Supply Chain Transformation - The shift to on-demand manufacturing requires a more responsive and agile supply chain. Rather than maintaining large inventories of raw materials and finished products, manufacturers need to source materials quickly and manage production schedules dynamically based on real-time demand.
  3. Increased Use of Technology - On-demand manufacturing relies heavily on advanced technologies such as 3D printing, AI, IoT, and cloud computing. The rise of on-demand manufacturing is therefore driving the adoption of these technologies within the industry.
  4. Customer Expectations - Customers are coming to expect a greater degree of customization and personalization, which on-demand manufacturing can provide. This is changing the way manufacturers interact with their customers and how they design and market their products.
  5. Environmental Impact - By reducing overproduction and waste, on-demand manufacturing can lead to more sustainable practices in the industry. This aligns with a growing emphasis on sustainability among consumers and regulators.
  6. Competitive Scheme - The ability to offer personalized, made-to-order products can give manufacturers a competitive edge. However, it also means that businesses need to stay on top of the latest technologies and customer trends in order to stay competitive.
  7. Job Market Changes - As on-demand manufacturing often requires different skills compared to traditional manufacturing, it may lead to changes in the job market. For example, there may be increased demand for skills related to new technologies such as 3D printing, data analytics, and digital design.
  8. Economic Impact - By reducing the need for large investments in inventory, on-demand manufacturing could lower the barriers to entry in the manufacturing sector. This could potentially lead to increased competition and innovation, with economic implications at both the industry and wider societal levels.


Core Principles of On-Demand Manufacturing

In the context of a manufacturing or business model like on-demand manufacturing, core principles refer to the key characteristics that define the model. These principles guide the implementation and operation of the model, informing decision-making, shaping strategies, and influencing behaviors within the framework of that model. The core principles of on-demand manufacturing revolve around responsiveness, customization, and efficiency. Here are the key concepts:

  1. Just-In-Time Production (JIT) - This is the idea of manufacturing products only when they are needed, instead of keeping large inventories of finished goods or raw materials. This reduces waste and ties up less capital in unsold inventory.
  2. Customization - On-demand manufacturing is often used to produce custom, personalized, or unique items. Instead of creating thousands of identical units, each product is made according to specific customer requirements.
  3. Inventory Management - The principle of on-demand manufacturing is closely tied to effective inventory management. The goal is to have the necessary materials available for production exactly when they are needed - no sooner, no later. This reduces the costs associated with storing large amounts of inventory.
  4. Customer-centric Approach - On-demand manufacturing places the customer at the heart of the process. Products are made to meet specific customer demands, which means companies must be able to capture, process, and respond to customer orders quickly and accurately.
  5. Agile Manufacturing - On-demand manufacturers need to be flexible and responsive, able to adapt quickly to changes in demand or customer preferences. This often requires a high degree of automation and the use of advanced manufacturing technologies like 3D printing and CNC machining.
  6. Efficiency and Sustainability - By reducing waste and using resources more efficiently, on-demand manufacturing is often more sustainable than traditional mass-production methods. This principle aligns with growing consumer and business awareness of the need for environmentally friendly practices.
  7. Technology Integration - The successful implementation of on-demand manufacturing depends on integrating various technologies such as machine learning for demand prediction, robotics for automated manufacturing, and IoT for real-time monitoring and control of the production process.
  8. Quality Assurance - Despite the shift from mass production to individualized, made-to-order production, the importance of maintaining high quality remains a core principle. Quality assurance processes must adapt to ensure that each unique product meets the desired standards.
    In essence, on-demand manufacturing revolves around the ability to respond quickly and effectively to customer needs, enabled by modern technology and lean manufacturing principles.


Technologies Driving On-Demand Manufacturing

The ongoing development of on-demand manufacturing is made possible by a range of advanced technologies. These technologies help streamline production processes, enable customization, enhance efficiency, and ensure high-quality output.

  1. 3D Printing (Additive Manufacturing): This technology enables manufacturers to create products layer by layer from a digital design. It's particularly suited for on-demand manufacturing due to its flexibility, allowing for the production of highly customized and complex products without the need for specific tooling or setup.
  2. CNC Machining: Computer Numerical Control (CNC) machines use digital instructions to automate and control the movements of machining tools. They can produce highly accurate, complex parts quickly and reliably, making them ideal for on-demand manufacturing.
  3. Robotics and Automation: Automated production lines and robotics enable faster production times, consistency in output, and can operate around the clock. They are essential for improving efficiency and reducing lead times in on-demand manufacturing.
  4. Artificial Intelligence (AI) and Machine Learning (ML): AI and ML algorithms can analyze past sales data, customer behavior, and market trends to predict future demand. This predictive ability helps on-demand manufacturers better manage their production schedules and inventory, reducing waste and improving efficiency.
  5. Internet of Things (IoT): IoT devices can monitor and control production processes in real-time, allowing for quick adjustments and optimizing efficiency. They also enable real-time tracking of orders and inventory, providing visibility and control throughout the supply chain.
  6. Cloud Computing: Cloud platforms allow manufacturers to store and analyze vast amounts of data from different sources. This data can be used to improve decision-making, manage inventory, predict demand, and enhance overall operational efficiency.
  7. Digital Twins: Digital twin technology creates virtual replicas of physical systems, allowing manufacturers to simulate and optimize their processes before actual production, which can lead to better product quality and lower costs.
  8. Blockchain: Although still in the early stages of adoption in manufacturing, blockchain has potential for improving supply chain transparency, securing intellectual property rights, and ensuring the traceability of materials and products in on-demand manufacturing.

These technologies, individually and in combination, are enabling the transition to more flexible, efficient, and customer-centric manufacturing models. They are the driving forces behind the shift towards on-demand manufacturing and the realization of its full potential.


Use Cases of IoT Applications in On-Demand Manufacturing

The Internet of Things (IoT) is revolutionizing on-demand manufacturing by connecting machines, people, and processes. It allows real-time data collection and analysis, providing valuable insights to optimize efficiency, predict issues, and streamline operations. Here are several use cases of IoT applications in on-demand manufacturing:

  1. Real-time Monitoring and Predictive Maintenance: IoT sensors installed on manufacturing equipment monitor a variety of parameters such as temperature, pressure, vibration, and more. By continuously collecting and analyzing this data, AI algorithms can identify patterns that precede equipment failure, allowing for proactive maintenance. This drastically reduces unplanned downtime and improves overall operational efficiency - a critical factor in an environment where production is closely aligned with demand.
  2. Logistics and Inventory Management: IoT is also instrumental in streamlining logistics within the on-demand manufacturing context. Sensors and RFID tags can track raw materials and finished products in real-time, providing visibility throughout the supply chain. This data can be used to optimize inventory levels, manage warehouse space, and coordinate delivery schedules, which are especially critical when production is based on immediate demand rather than forecasting.
  3. Quality Control: IoT devices can monitor production processes in real-time, detecting any deviations from predefined parameters that might affect product quality. This allows for immediate corrective action, ensuring consistency and reducing the rate of defects. This is particularly valuable in on-demand manufacturing where the volume of products can be lower, and each product might be unique.
  4. Supply Chain Visibility: IoT can provide end-to-end visibility in the supply chain, from sourcing of raw materials to delivery of the finished product. This can lead to improved logistics, timely delivery, and a better understanding of the entire production process.
  5. Energy Management: IoT sensors can monitor energy consumption of various processes and machines, enabling manufacturers to optimize usage, schedule energy-intensive tasks during off-peak hours, and reduce overall energy costs. In a manufacturing model that potentially deals with smaller margins due to lack of scale, such efficiency improvements can significantly impact profitability.
  6. Production Optimization: By gathering and analyzing data from across the manufacturing process, IoT can help identify bottlenecks and inefficiencies, allowing manufacturers to optimize their processes and improve productivity.
  7. Customization and Personalization: IoT, in conjunction with other technologies like AI and 3D printing, can enable real-time customization of products based on customer requirements. This can range from customizing the design, size, color, or other features of a product, making on-demand manufacturing truly responsive to customer needs.
  8. Safety and Compliance: IoT can also be used to monitor safety conditions in the factory, ensuring compliance with regulations and providing a safer working environment. Sensors can detect harmful gases, extreme temperatures, or unsafe equipment operation, alerting management to potential safety risks.

Overall, IoT is a powerful tool in on-demand manufacturing, enabling a new level of automation, efficiency, and customization.


Conclusion

In a nutshell, the interaction between on-demand manufacturing and Internet of Things (IoT) technology is not only revolutionizing the manufacturing industry but is also reshaping the landscape of supply chain management and customer relationships. A confluence of digital technologies, including IoT, AI, 3D printing, and cloud computing, is at the heart of this transformation, driving the industry towards greater efficiency, agility, and adaptability. These technologies provide a framework for real-time monitoring, predictive maintenance, and supply chain transparency, effectively redefining our perception and management of manufacturing processes.

Additionally, the ability to optimize energy consumption, streamline inventory management, and enable real-time product customization is also realized, thereby fostering a more automated, dynamic, and responsive manufacturing model. This shift is enhancing operational efficiency and reducing costs, all while promoting customer satisfaction through the delivery of more tailored products.

On-demand manufacturing presents substantial potential for increasing sustainability by minimizing waste and overproduction. As we venture into the future, the ongoing evolution of these technologies suggests a continued expansion in the feasibility and efficiency of on-demand manufacturing, promising more breakthroughs and innovative solutions.

In this light, on-demand manufacturing represents a paradigm shift, poised to redefine how products are made, businesses operate, and consumer needs are met, steering the industry towards a more responsive, personalized, and sustainable era.

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3D Printing and IoT
Internet Of Things

What Happens When You Combine 3D Printing and IoT?

You can build a powerful business operation with 3D printing and IoT. It can give your business a huge competitive edge over competitors who resist change. Here are ways your business can benefit from smart 3D printing.


Combining Disruptive Technologies

The combination of disruptive technologies can be the key to a market boom. IoT technology encompasses sensors that receive and transmit data to a server or database in real time. IoT gives a business a wealth of information, usually to analyze internal or external processes. Meanwhile, 3D printing is disruptive because it can generate prototypes and short-run products quickly with zero waste.

Just as combining a computer with the internet was a revolution based on disruptive technologies, combining 3D printing and IoT opens the door to greater efficiency and productivity for a business.


IoT Data Collection Facilitates Customization

Fresh data keeps manufacturers updated on many areas of production, as well as consumer demand. IoT devices can help detect emerging trends in consumer purchasing behavior, which can be useful information for developers to refine products. Data also contributes to customization projects, allowing for specialized models that reflect market segments.

One of the primary advantages of a 3D printer is that it can generate detailed customized products quickly. The product design originates in a computer-assisted design (CAD) software program such as AutoCAD. The software allows for easy editing, making it practical to produce several different versions of a prototype or product.


Designing IoT Devices with 3D Printers

An IoT device includes an interface for human interaction, such as a touch screen or keypad. These controllers are categorized as commercial off-the-shelf (COTS) components and can be added to an IoT device. An IoT device also contains sensors that interact with the environment to collect data. In that sense, IoT devices blend analog with digital elements.

The circuits and components used in IoT devices can be manufactured with 3D print machines. Printing sensors directly on circuit boards is a more efficient process than etching and plating by hand. The 3D printing process is more accurate and takes less time to add COTS components to IoT devices.

An example of a useful customized design that can be made with a 3D printer is a custom antenna for a wireless communications system. Antennas can be designed to optimize signal strength of a specific application based on analysis of IoT data.

Manufacturing designs can be printed from an additive system of integrated 3D printing and IoT sensors to improve the production process. At the moment, this technological mix is emerging and evolving for enhancing low-volume 3D printing.

3d printing

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3D Printing via Wireless Communication

Much of modern technology is being integrated with wireless communication technology, partly for security reasons. Products with embedded RF chips can be tracked to pinpoint their geolocation. A 3D printer can print an active or passive antenna directly on the substrate of a printed circuit board (PCB). This manufacturing process is efficient for LAN, WLAN, SD-WAN and other wireless communication systems.

FR4 is a popular substrate used to build PCBs due to its flame-retardant qualities. The material facilitates both dry and humid conditions, but due to its rigidity, it's difficult to make using a 3D printer. But a printed polymer substrate offers certain advantages over FR4, such as lowering absorptive losses at high frequencies.

Another problem with FR4 is that it's difficult to prototype with rigid circuit boards. Once again, 3D printing on a polymer surface is the superior option. This approach lets you test prototypes must faster so you can accelerate a product launch. Manufacturing IoT devices with a 3D printer is 90 percent faster than relying on a traditional assembly line production process.

At the moment, there are various types of 3D printers designed for different applications. The manufacturing of high-frequency antennas for IoT devices requires an inkjet 3D printer to provide high-resolution printing. Other types of 3D printers may not be suitable for this type of design that must be printed accurately according to size, dimensions, and pad size.


New Possibilities for Combining 3D Printing and IoT

Today a 3D printer can create a multitude of products up to a certain physical size and volume level. Even 3D-printed homes exist now with the help of assemblers. Since it's possible to print electronic circuit components with a 3D printer, there's a wide range of technology that can be improved by this process. Adding in IoT allows real-time monitoring to be part of the production process.

What's missing so far in the 3D printing industry is a framework of consistent standards for additive manufacturing processes. As the industry embraces more consistent standards with a degree of flexibility, it will become more vital in simplying production of sophisticated IoT devices at low volume. It's definitely cost-effective while producing zero waste for making IoT device enclosures that protect the circuitry.

The future of 3D printing technology will certainly involve much more use of the blockchain than today. Blockchain adds a strong layer of cybersecurity and provides timestamps on data transactions that cannot be changed. The combination of several innovative smart technologies is called "Industry 4.0". The main barrier holding back the mass adoption of this new paradigm is cost.

Automation is another area where the merging of IoT and 3D printing will become more powerful as technology improves. IoT sensors can collect data on customer feedback and determine quickly what the right supply level should be to fit demand. An automated 3D printing production process helps resolve high labor costs and shortages.

The most powerful factories of the future will be those that combine a broad range of Industry 4.0 technologies. The challenge for these factories will be to avoid getting sidetracked by irrelevant data. Factories will still require human analysts, aided by AI machine learning software, to evaluate production and quality control processes.


Conclusion

Manufacturing designs can be printed from an additive system of integrated 3D printing and IoT sensors to improve the production process. At the moment, this technological mix is emerging and evolving for enhancing low-volume 3D printing. 

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Additive Manufacturing in Production
3D Printing

Sustainable and Business Benefits of Additive Manufacturing in Production

Additive manufacturing gets its name from adding layers of materials in the production process. Traditionally products have been made from subtractive manufacturing that involves cutting or hollowing materials, which generates waste. Here are reasons why additive manufacturing in production is a much more sustainable solution.


Rise of Additive Manufacturing

The physical fabrication of a 3D object resulting in layered materials stacked together is the basis of additive manufacturing. The process is based on only using the amount of material needed, eliminating production waste. In its early years, this process was mainly used for rapid prototyping, but not mass production. Today, 3D printing is the basis for producing thousands of different products, but still more for short runs.

Additive manufacturing, which is dominated by 3D printing to the point the terms are used interchangeably, has been steadily growing among global producers throughout this century. The market size in terms of U.S. dollars has grown from $4.4 billion in 2013 to $21 billion in 2021, according to Citi Research. Keep in mind the industry only had four major companies in 2000 but now has over 170 different players.

The concept of AM provides a viable solution to cutting production waste that has been traditionally sent to landfills. The buildup of pollutants in landfills elevates the risk of these harmful toxins seeping back into ground water. In recent years, companies have increasingly turned to recyclers to dispose of toxic waste or they've figured out how to repurpose items. With a 3D printer, you can actually make products that generate zero waste while significantly lowering production costs.


Types of 3D Printing Used for Production

A proliferation of 3D printers is emerging in the 2020s. An early type of additive manufacturing for production in the eighties was based on stereolithography (SLA). This method uses liquid resin as the basis for machine parts and prototypes. Early experiments commonly yielded brittle products, but today's 3D printed products are more flexible and durable.

In 1989 came the introduction of fused deposition modeling (FDM), which pushes melted material through a nozzle to create layers of filament. Today the two main categories of 3D printers are the cheaper more common FDM machines for making consumer products and the more advanced SLA printers. Here are some of today's options for 3D printing in production.

Polymer Part Production

Built on stereolithography, polymer part production delivers improved material compared with a few decades ago. The production process involves curing liquid resin into solid objects through a point-to-point layering system.

Digital Light Processing

This process is similar to polymer part production, converting liquid resin into finished products. The difference is this method is capable of generating an entire layer at once.

Metal Part Production

Additive manufacturing options to consider for producing metal products include binder jetting, power bed fusion (PBF) and wire or metal powder solutions. With metal, you'll need to take the extra step of post-print machining for most 3D printers. Binder jetting is a process that applies glue to metal powder as it transforms into dense metal.

Open-Source 3D Printers

Many young entrepreneurs and hobbyists are attracted to participating in open-source 3D printing, in which individuals design their own cost-efficient printers. By 2007 industry leader 3D Systems offered a commercial kit to build a 3D printer for under $10,000.

3d printing

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How 3D Printing Works

Designing a prototype or product begins with a software application such as AutoCAD. This software lets you create a 3D digital model that is then sliced into multiple layers as the model is written in machine code. The 3D printer reads this "G-Code" for producing a physical object.

The most commonly used material in additive manufacturing is ABS plastic because it's soft and can be easily manipulated into any shape. At the same time, it's a durable material. There are various other materials used as filaments in 3D printers such as metal and nylon.

One of the common components in an SLA printer is a light source such as a laser that shines through and heats resin to transform it from a liquid into a solid. The laser precisely cures and hardens areas of resin to form a solid layer.

An FDM printer houses a gun that applies hot glue, based on the programmed design. A motor powers the gun to feed the filament through the heated nozzle as it creates a plastic layer. The gun is designed to move on an X, Y and Z axis to create the proper shape. It's instructed by the computer to apply glue at specific coordinates. The machine uses the glue to draw the design one layer at a time.


Growth of 3D Printing

The 3D printing industry has been initially embraced by industrial producers in the automotive, aerospace, utilities, tech and construction industries. The medical industry has also played a giant role in AM development in the form of equipment, instruments, prosthetics and implants.

Even food producers have gotten involved with additive manufacturing by printing food. Instead of using plastic for the material, 3D printed food is made from edible materials. These items are created with layers, similar to making a pizza. The materials typically start out in liquid or powder form as multiple ingredients are added. One layer might encompass protein, while another consists of vitamins.

The 2030 revenue forecast for 3D printing, according to Grand View Research, is $76.16 billion, which represents 20.8 percent growth from 2022 levels. The metal segment currently accounts for half of revenue from 3D printed products, while polymer is the next largest revenue-generating segment. A future segment to watch for is ceramic, which is poised for significant growth.

Keep in mind the automotive industry still dominates the 3D printing market. Other industries benefitting from AM include dental, jewelry, art and apparel. Companies leading the 3D printer revolution include 3D Systems, Protolabs, FARO Technologies, Materialise, and ExOne. Other major players include GE Additive, Strayasys and Autodesk.


Additive Manufacturing Scenarios in Production

The most practical and productive place for a 3D printer is a manufacturing facility. But these machines are also still very useful for their original purpose of rapid prototyping. Prior to 3D printers, an inventor could spend enormous amounts of time, money and energy on just making and refining different prototypes until arriving at a finished product for commercial use. A 3D printer cuts these costs and makes it easy to edit your model quickly.

In many ways, additive manufacturing is the best solution so far for customizing one-off products, which can be made from multiple materials. Today the maximum number of materials a 3D printer could use to make a product is over a dozen, but certain materials such as paper, wood and rocks are not suitable for 3D printing.

Identifying mistakes quickly in prototypes is part of advancing a product to the next level. A 3D printer can be integrated with machine learning technology for making automated quality control decisions. Just imagine how much time, money and labor this feature alone can save.

MIT startup Inkbit is a pioneer in this technology, designing a precision 3D printer that stores digital replicas of end products. It has developed an AI-based automation system that can instantly correct errors in the production process. Some of the companies Inkbit has made 3D printers for include Amgen, Johnson & Johnson, Novartis and Lockheed Martin.


Investing in a Quality 3D Printer

One of the key issues you should know about when you shop for a 3D printer is that just because these machines are expensive doesn't guarantee they'll do what you expect. Some machines are light-sensitive with low accuracy and other limitations. Certain 3D printers are good for high speed but underperform in other areas. Some machines are more durable than others.

First you need to decide how you're going to use the machine then determine which model best fits your budget and your needs. Is it just for prototyping or do you want to distribute a product? Be sure to look for video reviews of the machines on your wish list.

Closing Thoughts: Additive Manufacturing Can Revolutionize Production
The most advanced 3D printers can make highly detailed products at a fraction of the cost compared with traditional manufacturing processes. Some products that might normally cost $10 to make can be produced for a dollar per unit. Although additive manufacturing technologies are still not practical for high-volume production on large heavy items, certain small items such as machine parts can be mass produced efficiently.

The reason interest is growing among producers in additive manufacturing is that it provides multiple sustainable and profitable solutions. It reduces waste, cuts costs, allows for customization and can accelerate turnaround time.

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Hybrid Manufacturing
3D Printing

Opportunities and Benefits of Hybrid Manufacturing

While additive manufacturing (AM) is game-changing, hybrid manufacturing that includes subtractive processes is even more empowering. This hybrid solution is often used for metal products. Essentially, additive and subtractive processes mixed together amount to combining machining with 3D printing. Here's a deeper look at what hybrid manufacturing can do.


Hybrid Manufacturing Systems

If you decide to invest in a hybrid manufacturing system, the equipment you'll need beyond a 3D printer may include a lathe or mill. In a hybrid manufacturing environment, subtractive tasks can be applied to products after additive layers are created. It's possible to design a hybrid production process of alternating between additive and subtractive elements, if it makes sense. Ultimately, many companies are looking for an all-in-one hybrid 3D printer.

The use of machining typically involves removing material such as polishing metal. Common materials that can be 3D printed and used for hybrid manufacturing include powder from various metals including aluminum, titanium, chrome, copper and stainless steel. In fact, the hybrid system makes it easier to create products mixed with different types of metal.

A typical example of a hybrid process is crafting a product using the additive method then refining with a subtractive finish. Another example includes the production of low-volume machine parts. Some large-scale hybrid processes use injection molding pellets that work well with polymers. The modern hybrid solution usually involves performing additive and subtractive processes on the same machine.


Limitations of Additive Processes

Additive manufacturing clearly is paving the way to greater sustainability simply by eliminating waste in the production process. Many producers gravitate to 3D printers because they are precise about dimensional accuracy. At the same time, a conventional 3D printer cannot do everything certain manufacturers need. It's not a good final solution, for example, when it comes to making metal parts since it can produce rough surfaces.

By adding a subtractive element, the combination of modern and traditional processes generates higher quality metal products that cannot be made otherwise. There are countless products and prototypes that don't require subtractive manufacturing, but some of the most robust industrial parts do require both processes. So no one should dismiss the traditional manufacturing process as outdated, as it still serves important functions in the making of contemporary products.


How Much Are Hybrid Systems in Demand?

The demand for hybrid 3D printers is strong in specific regions of the world. North America dominates the hybrid manufacturing market, accounting for 40 percent market share in 2019. Original equipment manufacturers (OEMs) in the aerospace industry have a growing demand for hybrid 3D printers that make metal parts. Asia Pacific is expected to become the fastest-growing market for these machines in the next decade. Europe will also expand its growth in hybrid manufacturing nearly 15 percent by 2027.


Advantages of Hybrid Manufacturing Systems

There's no reason to view additive and subtractive manufacturing as competing systems when each one offers solutions that can be integrated together. The post-processing of 3D printed parts, for example, often involves a computer numerically controlled (CNC) machining process to ensure greater accuracy. There's less chance of errors when parts are made by the same precision platform.

One of the biggest advantages to hybrid manufacturing systems is that they can accelerate low-volume production schedules for prototypes and certain products. Detailed metal parts can be produced much faster, though, with the hybrid approach. Parts can be printed and machined within a single operation. Mould-making businesses also see more efficient results when including additive processes to form a hybrid solution.

3d printing

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Hybrid manufacturing technology can be a sustainable solution for maintenance and repair work, particularly for designing customized metal parts. It's very useful for repairing degraded parts of large aircraft. The part's precise dimensions can be 3D printed and then refined with even greater precision to fit with another part.

Two key industries that have embraced hybrid manufacturing are automotive and aerospace. Both require what a hybrid solution provides, which is additive processes for complex geometric designs and subtractive processes for higher precision. Another industry in which hybrid manufacturing makes sense is jewelry design.


Options for Available Hybrid Manufacturing Solutions

One of the most effective hybrid solutions on the market for manufacturers is Direct Energy Deposition (DED). This process involves a laser or electron beam melting material as it moves through a nozzle. The part can then be milled in a CNC machine to create a smoother surface. DED is a practical solution for working with large metal shapes.

A leading developer in hybrid manufacturing solutions is Hybrid Manufacturing Technologies. It released its first hybrid deposition and milling system called the AMBIT in 2013. This automated system can be integrated with a CNC machine. DMG MORI is another pioneering firm with its LASERTEC 65 3D hybrid machine.

Imperial Machine & Tool Co. develops hybrid manufacturing solutions for complex 3D printed metal parts that are treated in a CNC machining process to ensure accurate dimensions. The company's hybrid process begins with the design and collaboration phase, as the CAD model must take into account additive and subtractive processes. The completed design is then fed into a 3D printer, which develops the part's layers. After a thermal conditioning phase, the part runs through a finishing process in a multi-axis CNC machine.


Development of New Metal Alloys

A key factor that will expand the market for hybrid manufacturing will be investments in new ways to make metal alloys. These new solutions that blend metals can help improve the quality of shipbuilding. Aluminum alloys are particularly resourceful for the automotive and aerospace industries due to the lightweight and durable quality of aluminum. Hybrid solutions are very useful for adding touches to prototypes, particularly for large-scale aerospace projects.

Titanium is a significant metal used in hybrid manufacturing systems because like aluminum, it's lightweight and strong at the same time. Since it has an excellent weight-to-strength ratio, it works well with aircraft, which achieves greater fuel efficiency with lighter loads. The metal is also resistant to corrosion because it forms passive oxide coating when exposed to air at high temperatures. For these reasons and its versatility, aerospace manufacturers choose titanium to mix with other metals.

An overlooked condition of metal manufacturing is that it cannot rely on just the additive process, since making metal parts typically requires elements of traditional production. Mixing metals is now a key to reducing costs, as scarce metals can be blended with cheaper metals without sacrificing quality. Hybrid printers will be useful for experimenting with different alloys to make prototypes that can be refined by the same machine's subtractive features.


How Hybrid Manufacturing Improves Quality Control

A strong argument for using a hybrid manufacturing system is for the sake of quality control. The additive method puts the proper ingredients together without leaving residue or other waste products behind, while the subtractive process provides a final stage that improves the part's integrity. In order to further ensure quality control, finished parts should be inspected by specialists for evaluation. The choice of appropriate technology and experienced personnel is crucial for a quality control system to empower a business.


Where Hybrid Manufacturing Is Going

Hybrid manufacturing appears to be here to stay, as it's been growing steadily in recent years with the market reaching $80.5 million in 2019. The market is projected to grow 14.8 percent by 2027, according to Grand View Research. Part of this expected growth will be in healthcare, in which hybrid solutions may help reduce the degradation rate for medical implants.

The medical industry will continue to benefit from its adoption of hybrid 3D printers. Optomec introduced a hybrid 3D printer in 2018 for the medical industry. This laser-equipped machine is expected to contribute to the development of dissolvable magnesium medical implants. Universities that study science projects are adopting hybrid manufacturing technology to help develop medical procedures that eliminate second surgery of permanent implants. On a global level, the medical industry currently accounts for about a quarter of the hybrid additive manufacturing market, while aerospace accounts for half.

So where is hybrid manufacturing going? The short answer is outer space and beyond. Two major themes in the future will be AI and automation. Robots building machines sounds like a project in space for satellite communications development. Hybrid 3D printers will play an important role in food production to accommodate space travel. The subtractive process removes certain ingredients while the additive process adds ingredients to optimize nutritional value.

The concept of an all-in-one manufacturing plant is possible, thanks to the combination of additive and subtractive production processes. For some businesses a hybrid 3D printer might be a turnkey solution in their transition toward a digital infrastructure.

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What is 3D Printing
3D Printing

What Is 3D Printing, and How Is It Being Used Today?

The 3D printer is changing business and society in more profound ways than photocopiers in the sixties or home recording equipment in the seventies. It's a revolutionary way to present prototypes or to even manufacture a finished product. Thanks to 3D printing technology, you can create physical objects from digital files.


Evolution of 3D Printing

The first documentation of what shaped the 3D printing concept came from a 1945 short story called "Things Pass By" by science fiction author Murray Leinster. He called it a "construction machine" and described it as efficient and flexible with the capability of producing machine parts more cheaply than any other method. The end product based on scanned drawings was made of plastic.

The first patent for 3D printing was secured in 1986 by Charles Hull, who co-founded 3D Systems Corporation. The company issued its first commercial 3D system in 1988. Other types of 3D printing machines soon followed. Early 3D printing was used for industrial purposes, typically for prototyping new inventions.

By the 2000s, the term "additive manufacturing" gained attention as an alternative production process to "subtractive manufacturing." While subtractive manufacturing removes material, such as hollowing out a piece of metal, additive manufacturing, in which 3D printing is a subset, builds products by adding material layers.


How 3D Printing Works

Light shining through a container of resin forms the basis of how 3D printing works. Materials used in the production process include plastics, liquids, and powder. These components allow for making a wide range of products from tools to appliances, furniture, and even food.

One of the various methods of 3D printing is called "stereolithography" (SLA), which was introduced by Charles Hull in 1986. This method uses photopolymer resin to create object layers. When UV light from a laser beams through the liquid resin, it creates a chemical reaction that hardens the resin into durable plastic. The object's layers are created one at a time through a tracing process.

3d printing

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Continuous liquid interface production (CLIP) is among the fastest 3D printing processes, based on digital light synthesis technology, in which LED light projects UV images to resin. Another 3D printing method is called "digital light processing" (DLP), which is similar to SLA but uses different light sources such as arc lamps.

Once you create a printable file in a CAD program, you can store it in a virtual library. From there, you can export the CAD or STL file to a 3D printer through USB, SD, or Wi-Fi. The files can be easily edited at any time. The next step is slicing, which prepares the file for a 3D printer. This step involves slicing the file into hundreds or thousands of layers using slicing software.

Turnaround time for printing an object is a matter of hours. Not only do 3D printers speed up production for a prototype, but they also eliminate the need for other expensive tools and molds. These modern machines can further be used for short-run production. But trying to mass-produce items with today's 3D printers has limitations and diminishing returns.


Today's 3D Printing Industry

Current 3D printing is used for both one-off prototyping and for limited production, still mainly in the industrial realm. According to Acumen Research and Consulting, the global 3D printing market will reach $41 billion by 2026.

Today, various industries use this technology as part of a major digital transformation to make production more efficient. Here are some of the ways it's now being used in making products:

  • Automotive and Aviation - engines and other parts
  • Construction - buildings can be prefabricated
  • Dental - artificial teeth and crowns
  • Education - creation of open-source scientific tools
  • Fashion - shoes and apparel
  • IT - formation of digital twins
  • Jewelry - detailed, customized rings
  • Medical - prosthetics
  • Military - firearms
  • Pharma - formulations for tableting

Countless consumer products can now be manufactured with 3D printers. These machines are particularly useful for industries that offer custom solutions. Original Equipment Manufacturers (OEMs) can use 3D printers to make proprietary machines, parts, and tools.

A major advancement for 3D printers has been in healthcare, as the technology can provide implants. During the past decade, 3D printed implants have accounted for over 100,000 hip replacements. A more subtle healthcare milestone has been the use of hidden 3D-printed hearing aids. Prior to this century, hearing aids were much more complex to create, going through multiple manual processes.


How 3D Printing Contributes to Sustainability

One of the main reasons 3D printing is considered a sustainable manufacturing solution is because it reduces waste. It only uses the right amount of material necessary to create a product, whereas traditional methods involve generating a certain percentage of wasted material. A 3D printer can also reduce the amount of energy used in manufacturing since it only uses power to a certain threshold.

The fact that a 3D printer can serve a local community elevates its sustainability profile even more. Local production reduces the need for long-distance transportation, which typically relies on burning fossil fuels. Due to global supply chain congestion with rising fuel and storage costs, it's much more sustainable for communities to adopt local 3D printing.


Learning to Use a 3D Printer

A common way to enter 3D printing is to learn computer-assisted design (CAD) software, which is used by architects, designers, engineers, and manufacturers. Universities offer courses in graphic design and CAD software, which can be applied to 3D printing. An easier way to get started is with free Tinkercad software, which is browser-based, so you don't have to install it on your device.


Future Concerns of 3D Printing

As 3D printing evolves, various challenges surround its adoption. Intellectual property protection is a major issue since products can be duplicated by a 3D printer. This activity can cut into the profits of a manufacturer, which may try to sue for infringement. Another concern is the expensive cost of a 3D printer, but a solution is to outsource to a third-party firm that specializes in 3D printing.

There are other issues that manufacturers should consider before investing in 3D printing technology. One drawback is that it doesn't reduce the cost of individual units when they are mass-produced, making large volumes somewhat impractical. Larger items require post-processing such as removing support material and applying finishing, which potentially slows down production.

Finally, some people worry that emphasis on 3D printing will reduce manufacturing jobs. This fear has been growing throughout the industrial age as machines keep appearing that handle human tasks. But there will still be a need for quality control specialists to evaluate finished products to ensure they are safe and accurately produced before selling them on the market.


Conclusion

Key advantages to 3D printing include manufacturing lightweight yet durable products in a flexible manner without wasting materials. Overall, the process saves time, money, and energy compared to traditional production methods. Ultimately, the process can be automated, which speeds up production and cuts labor costs. It's also an environmentally-friendly solution as it helps pave the way toward greener manufacturing.

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