Actual approaches

The decision to adopt 3D printing in a workflow is often not so much borne of the idea that “I want to 3D print this!” but, rather, stems from a manufacturing problem that requires a solution.

Understanding your needs, your challenges, your validation processes, and – vitally – what qualities a single solution would need to offer to produce what you need, when you need, and at the cost you (and your customers) need it is the first step. From there, if 3D printing seems to be a fit, you’ll often find it by narrowing down your own parameters.

For example, do you have a high-value, low-volume project using an expensive material that you’d like to redesign, lightweight, and optimize? Sounds perfect for 3D printing, and those parameters will guide you to the right combination of software, hardware, and materials.

If, though, you need a lot of the same thing made – don’t 3D print it just because you can. Traditional high-volume manufacturing processes like injection molding are still often the best fit. Sometimes 3D printing may fit as a bridge process while a traditional technique ramps up, but don’t look for 3D printing to be your end-all-be-all every time.

Actual approaches

There simply isn’t a one-size-fits-all solution anywhere in manufacturing. For some businesses, in-house makes more sense than outsourcing ever will. With experienced teams, investing in owned operations that keep intellectual property and supply chain close in hand is the only logical way to proceed. Point-of-care 3D printing, for example, needs to be done at the point of care.

Teams looking at the capabilities of million-dollar machines but lacking footprint/budget/enough work to move toward ROI, though, may be wise to work with those service companies that already have that expensive equipment available to them. Take stock of what you actually need to accomplish and whether it makes sense to engage those who already have both installations and know-how. Increasing numbers of service bureaus are highlighting their validation processes, too, from ISO to ITAR to clean room facilities.

Actual approaches

We’re back to DfAM here. 3D printing isn’t a new way of making a wheel; it reinvents the wheel.

Take the time to step back, evaluate what you’re doing, what it needs to do, and whether it makes sense to step into areas like topology optimization, generative design, or other advanced design processes that appropriately apply new capabilities, new physics, and new geometries via new ways of making. A design file for a CNC-made part is just that; it shouldn’t be a 1:1 move to a new platform. You’ll get better results using a file designed for the manufacturing process you’re using.

Actual approaches

Intellectual property is precious. Treat it that way.

More and more, the spotlight is shining on the issue of security in digital manufacturing processes. As critical-use parts are made, validation is a very serious part of the process – and so is keeping those parts close to the vest. Going back to point one on research, do your research here. New security solutions are arising all the time. Sometimes these are as simple as internal networking or more offline work. Often, encryption and security protocols can be baked into the design process, end to end. Find the best level of security for your specific needs, checking with trusted and validated providers. This is what will actually make your legal team (and your customers’) happy.

Actual approaches

Specialized equipment, as a rule, requires a specialized operating environment. There’s a perhaps surprisingly high risk of explosion or fire from improper material handling in a perhaps surprisingly high number of different AM processes. Ensuring that all due diligence has been performed before an installation is even begun isn’t a short process – but it’s a pretty vital one to have all the building blocks in place for safe operations from day one.

More standards, including safety standards, are evolving constantly in AM. One would be wise to adhere to them.