3D printing for mass manufacturing

Large Scale 3D Printing For Mass Production

There are several ways 3D printing can speed up the process of getting products to market. Whether it be with the seamless creation of prototypes, or the full-scale manufacturing of end-user products, 3D printing alleviates key pain points in the supply chain.

Contact a Carbon Expert

3D Printing In Mass Production Explained

Different Types of Additive Manufacturing

With so many types of additive manufacturing, a.k.a. 3D printing, on the market today, businesses have a plethora of options for streamlining mass production.

More often than not, the type of component you need to make will dictate your choice of 3D printing technology. For example, Fused Filament Fabrication (FFF) is a great choice for low-volume prototypes, while Stereolithography (SLA) is a better option for end-use parts.

Rapid Prototyping to Accelerate Production Processes

Rapid prototyping greatly accelerates mass manufacturing, making it an extremely popular use for 3D printers.

While functional prototypes are critical during the early design phases of new parts, it can take a very long time to outsource prototype manufacturing. With in-house rapid prototyping, engineers can quickly produce physical models to inspect for functionality and design flaws.

Allows for High Volume of Products

Because additive manufacturing technologies like Digital Light Synthesis (DLS) have progressed so much in the last few years, they can now be used to mass-produce high-quality, end-user products. In fact, the Carbon Digital Light Synthesis process was used to print soles for over 100,000 pairs of Adidas shoes in a single year.

Where 3D Printing is Winning in High-Volume Production

Faster Production Processes

Once you have established a working prototype, there are several ways that additive manufacturing can increase your manufacturing volume:

Flexibility in production
High customization
Increased affordability
Rapid tooling

Whether it be printing forms to be used for injection molding or printing custom soles for sneakers, additive manufacturing gets your products to market quicker.

Adaptive to New Technologies

Because 3D printing is extremely customizable, it is also extremely adaptive to new technologies. From manufacturing novel components to integrating software with artificial intelligence (AI), the sky is the limit for 3D printing processes.

High Volume with High Quality

Until recently, 3D printing hasn’t been applicable for mass production.

Traditionally, additive manufacturing processes like FFF printing haven’t been able to produce parts of high enough quality for end-user products. This is where more sophisticated processes, like DLS, come in to reshape mass production as a whole.

As the 3D printing landscape continues to evolve, novel technologies create new opportunities for high-volume production.

The Benefits of 3D Printing For Mass Production with Carbon

From first-rate manufacturing techniques to top-quality composites, Carbon is the top 3D printing company in the industry.

High-speed Manufacturing Process

Carbon has developed a full suite of technologies, materials, and processes to streamline the manufacturing process:

Carbon Digital Light Synthesis 3D printers
Carbon Engine Design software
Carbon Production Network
Carbon 3D printing materials

By working within the carbon network, you have all the tools needed to incorporate additive manufacturing into your business model.

Superior 3D Printing Technology

Carbon DLS technology utilizes photopolymer resins and UV light to print extremely complex geometries and shapes. With Carbon DLS, UV images are cast into a photopolymer, where they then harden into printed parts.

Carbon has a variety of DLS 3D printers available that produce components with unmatched performance, high resolution, and exceptional surface quality.

High-Quality End Products on Any Budget

Because Carbon hardware, software, and services are built with scalability in mind, we are able to offer cutting-edge 3D printing at affordable prices.

Carbon has developed different product offerings to ensure that no matter what your budget, you have access to the world’s top 3D printing technology:

Carbon 3D printer leasing program
Carbon Production Network

If you aren’t exactly sure about your 3D printing needs, start by outsourcing parts from a Carbon Production Partner.

Rapid Prototype Functional Parts

Carbon 3D printers are capable of producing both rapid prototypes and functional parts. No matter what your additive manufacturing needs, Carbon will ensure you produce a greater number of parts in a shorter time.

On-demand Support Whenever You Need It

As part of the Carbon subscription model, we take care of routine maintenance, software upgrades, and system troubleshooting. Even better, if you have questions about operating a Carbon 3D printer, we provide real-time customer support.

Industry Leaders Trust Carbon With Their Mass Production

Whether it be rapid prototyping or mass production, 3D printing reduces the time it takes to get products to market. With the Carbon platform, we’ve taken the best elements of additive manufacturing and built them into an ecosystem that simplifies the production line.

With cutting-edge hardware, software, processes, and composites, industry leaders from across the globe trust Carbon with their 3D printing needs.

Handle Your 3D Printing For Mass Production With Carbon

With Carbon, you can rapidly design, develop, and scale production for better products in less time. Contact Us to discuss streamlining your business with 3D printing for mass production.

3D as It’s Meant to Be

Interested in utilizing Carbon to accelerate product development? Reach out to us at [email protected] to learn more!

When to use 3D printing for mass production

Additive manufacturing has come a long way since the 1980s. Though many believe the value of 3D printing lies in its prototyping capabilities, designers and engineers know that it can be helpful in other situations, notably mass production. 3D printing for mass manufacturing can unlock new products, cut costs, and accelerate production, but you must make sure it’s the best choice for your project.

When is 3D printing good for mass production?

You should consider using 3D printing for mass production if:

1. You need to produce customised goods

Recent studies show that 50 percent of consumers are interested in buying customised products, and many companies are scrambling to adopt a customisation business model to meet demand. Unfortunately, mass customisation isn’t easy with a manufacturing method like injection moulding, which requires expensive tooling and a new mould for each product design.

With 3D printing, creating a personalised part is simply a matter of transferring the design data to the printer and printing it — no extra steps or new tooling required. As a result, mass-producing a customised product won’t necessarily take more time, energy, material, or money than printing a standard, non-custom product.

2.You need to start or shift production quickly

Traditional injection moulding tooling makes starting and shifting production slow and expensive. Tooling time increases lead times, whereas 3D printers can start production immediately. Plus, when shifting production, not only will your manufacturing partner need to invest more money towards creating new tooling, but you'll also have to wait for the new tooling before they can start production.

If you use 3D printing for your mass production needs, your partner can simply stop current prints, upload a different digital file, and continue production quickly instead of waiting several weeks for a new mould. Either way, you’ll be able to stay on top of changes in consumer demand and quickly rectify any design or manufacturing errors.

Expand

Fast Radius

3. You need to meet variable demand

When faced with surges in demand, your 3D printing partner can use more printers to mass produce your parts and seamlessly accommodate higher-volume needs. Similarly, it’s easy to reduce production as demand falls or a product reaches its end of life by using fewer printers.

This also means you won’t be left with a stash of unused products whenever demand dies down, eliminating the fuel, costs, energy, and labor associated with transporting and storing products in warehouses. You can even continue to provide consumers with spare parts after a product has reached the end of its life, which wouldn’t be cost-effective with a manufacturing method like injection moulding.

4. You’re planning a low-volume production run

Executing low-volume production runs with a manufacturing method like injection moulding results in a high cost-per-part, a lower profit margin, and long lead times. 3D printing can help you bring a product to market faster, and you can produce parts cost-effectively no matter the size of your production run. When 3D printing, you won’t need to create hundreds or thousands of parts to achieve a reasonable cost-per-part, so you can start turning a profit with fewer parts.

5. You have a complex part that would be otherwise unmakeable

Since 3D printing technology isn’t restricted by tool access, undercuts, or draft angle, additive allows you to mass-produce parts that would otherwise be impossible to make due to their geometry. For example, you can 3D print complex lattice structures to create parts with high strength-to-weight ratios, excellent shock absorption, high impact resistance, and vibration dampening. You can even create moving assemblies; hollow, walled objects; and fractals.

Plus, you can consolidate complex parts into a single design with 3D printing and eliminate the need for assembly later on. Part consolidation is less expensive, uses less material, and lowers your risk of project or supply chain delays.

Expand

Fast Radius

Obstacles to 3D printing for mass production

3D printing has the potential to revolutionise mass production, but there are still some challenges to overcome. Mass-producing products using 3D printing can be difficult for some parts because the tolerances are not as tight as can be achieved with traditional methods like CNC machining and injection moulding. 3D printing also offers more limited material options compared to traditional manufacturing processes, though many 3D printing companies have expanded their selections of cost-competitive and high-performing engineering materials over the past decade to better fit industry applications.

While many engineers know design for manufacturing (DFM) best practices for older technologies like injection moulding and CNC machining, they may not be as familiar with DFM for specific 3D printing technologies. Taking the time to develop optimised designs and manufacturing processes can improve part consistency and accuracy, as you’ll be able to reduce defects and standardise print conditions as much as possible. You’ll also want to have monitoring capabilities to identify precision problems and better control product quality.

Luckily, you don’t have to go it alone. An experienced additive manufacturing partner will have all of these tools at their disposal to ensure you get the best possible part each and every time.

Starting high-volume production with 3D printing

Although 3D printing has become more mainstream in recent years, many product teams lack the expertise required to get the most out of these technologies. After all, the idea of using 3D printing for mass production is relatively new, so many companies hit a few roadblocks when navigating high-volume 3D printing for the first time.

A knowledgeable 3D printing partner can help you get started on the right foot. Not only will they be able to answer any questions you have, but they can help minimise errors, increase part consistency, accelerate production, and design your parts for additive. As you evaluate production partners, look for a manufacturer with a wide range of 3D printing capabilities and deep expertise in order to ensure you’re selecting the right technology for your project and fully harnessing the benefits 3D printing has to offer.

Want to discuss? Join the conversation on the Additive Manufacturing Global Community Discord.

Get your FREE print subscription to TCT Magazine.

See the latest additive manufacturing and 3D printing developments in person by joining us at RAPID + TCT in Detroit on 17-19th May and at TCT 3Sixty in Birmingham, UK on 8-9th June.

Why mass 3D printing is still not a trend

Photo: asharkyu / Shutterstock, Chris McGrath / Getty Images

The production of goods with individual characteristics is one of the trends in the consumer market. However, personification has not yet become a popular phenomenon. Is this idea promising for business development?

When the problem of shortage of personal protective equipment (PPE) for doctors became acute, the owners of 3D printers united in the volunteer movement #3Dfor doctors. They began to print adapters, which made it possible to connect diving masks with virus-bacterial filters. Manufacturers were able to quickly develop and release adapters in various configurations for popular types of masks found in stores, quickly covered burning needs and saved many lives - and then began to make full-fledged protective masks and shields.

Adapters for masks - example of a customized product (made to order. - RBC Trends ), that is, adapted to different types of masks. How quickly manufacturers were able to design and release a new product with unique characteristics demonstrates the main advantages of 3D printing.

3D printing allows you to create products based on the preferences or personal characteristics of the buyer - personalized goods. This idea arose in the early 2000s, but so far, contrary to forecasts and the rapid development of additive technologies, has not become a mass phenomenon.

Personalization Challenges

Nike and Adidas have been experimenting with 3D printing for sneakers since 2012. The goal is to create sports shoes in the presence of the buyer according to the individual characteristics of his foot. For example, Adidas announced in 2015 that a consumer could walk into a store, spend a couple of minutes on the treadmill, and immediately receive a printed pair of running shoes that take into account the contours of the foot and pressure points while running. At the same time, Nike announced the possibility of printing shoes directly at the customer's home. To do this, you just need to download the file with the parameters of the sneakers and the characteristics of the foot from the corporation's website to your home 3D printer.

However, by 2020 these opportunities remained unrealized. In practice, everything turned out to be more difficult.

The point is the high cost of such products: the consumer is not ready to pay for customized sneakers many times more expensive when you can choose the right model from thousands of more affordable options.

Customization does not take root among automakers either. For example, in 2017, BMW launched the MINI Yours Customized service, which allows you to customize a new or previously purchased MINI car using decorative elements printed on a 3D printer. For example, it was possible to order individual side body inserts, trim parts, LED door sills and LED door projectors. However, the service is currently unavailable.

Where personification has taken root

So far, 3D printing is most actively used in medicine, where it is vital to take into account the individual characteristics of a person. First of all, the technology is useful in orthopedics and dentistry for the manufacture of prostheses and implants. Customization is especially in demand in the production of prosthetic limbs. With the help of 3D scanning, the parameters of the patient are determined, a digital model of the prosthesis is created, which is printed on a 3D printer. In this case, you can create a unique design of the artificial limb. For example, they produce children's prostheses stylized as favorite movie characters.

Another area where 3D printing is being used to customize products is in the jewelry and fashion jewelry industry. There are enterprises that produce mass products using 3D printing, for example, the American brands LACE, Nervous System and others. Customization is carried out, first of all, by small studios and workshops offering exclusive jewelry. They print digital models created according to customer sketches or cast them from precious materials using 3D printed molds.

Economics of innovation Living hand: who creates bionic prostheses in Russia

As for the majority of goods, the price works here in 99% of cases. Especially when the share of online sales is growing. You type in Google "buy a fountain pen is the cheapest" - and no matter where you are, you buy this fountain pen cheaper. This is where mass production wins.

You can think of many products that could be customized. But you need to be clear about who you will sell them to. Are there enough people willing to overpay for customization to keep your business alive? “In your calculations, you need to take into account real consumer demand, and not the desire to make money on hype,” says Vlasov. “The conclusion is simple: personalized production is possible when it will give approximately the same price as mass production.”

Denis Alekseev, Head of R&D and Production at JSC ROBBO (educational robotics, Skolkovo resident), is confident that personalized production will become a popular trend of the future. But in order to attract the mass consumer to this segment, it is necessary to overcome a number of technical and organizational issues. For the end user, the process of ordering a customized product should be as simple as possible: with a few steps, order what he wants, while receiving the finished product quickly and conveniently. The cost of individual products may be higher, but this increase must be of value to the customer.

Main disadvantages of 3D printing:

low production speed;
often low quality products;
high cost of the product when trying to mass production.

How to reduce the cost of a customized product?

The cost of the finished product primarily depends on the materials for 3D printing. One way to cut costs is to produce consumables yourself.

Another option to reduce the cost of consumables is possible with the development of additive technologies and the development of new printing materials.

The main question is: who will buy it?

Entrepreneurs will be able to develop the production of personalized goods if they find the answer to the question: who will buy them? Businesses that already operate in a particular market and feel the needs of their audience can feel the demand. It is almost impossible to guess - you need to be sure of the demand.

Artur Gerasimov notes that small-scale production is promising for business development using additive technologies. One of the areas of work of his company Innovax is the production of parts and mechanisms by order of industrial enterprises from the automotive industry, instrument making, and the aerospace industry.

A customization boom will occur when a customer can get a personalized product at the same price and as quickly as a mass product. Therefore, it is up to the development of technologies and services.

Subscribe to the RBC Trends Telegram channel and stay up to date with current trends and forecasts about the future of technology, economics, education and innovation.

3D Printing Small Batch, Print Batch 3D Printing Small Batch, Print Batch

It goes without saying that 3D printing is a very efficient and precise way of making objects. Even an entry-level 3D printer (Fusion Deposition Printer) is a great and affordable design and prototyping tool that you can easily use in the privacy of your own home, so it's no surprise that these printers are growing in popularity every year.

However, 3D printing technology is still hardly used for the production of hot goods. Of course, some organizations are already showing a small production initiative (check out Shapeways, for example), and several large companies have moved to operate Stratasys industrial-grade 3D printers. However, the vast majority of plastic products are still made using the (age-old) injection molding methods that have become the gold standard for mass-produced plastic parts almost from the beginning of their introduction (since 1872).

Why? Most experts will answer that 3D printing technology is too expensive to compete properly with more established production methods. But is it really so? Recently, an official report was published claiming that 3D printers are theoretically capable of outperforming injection molding methods by a small margin.

Of course, this does not mean at all that your own desktop 3D printer is capable of competing with the mainstream industrial companies, as these promising results are only achieved under very specific conditions.

Volume is the key factor. To achieve the desired results, 3D printing farms are used: “production sites” consisting of numerous affordable and inexpensive 3D printers working in synchronous mode to produce plastic products in large volumes (up to 10,000 objects). Through efficient setup, smooth operation, and other specific conditions, these printers have proven to be able to outperform injection molding methods in terms of complexity, speed, and cost.

Thus, it is not without excitement to assume that this approach can lead to a new era in the production of plastic products. Just don't misunderstand this saying: there are still a lot of rough spots in 3D printing that need to be ironed out, but it can be noted that a new era of volumetric manufacturing is dawning, when products are customized to the desire of the user and customer.

This 3D printing truss has proven to be suitable for optimizing production performance for batch sizes up to 1000 units, a range traditionally considered problematic for industrial production. One of the basic laws in manufacturing is that the larger the batch, the lower the cost per unit, and this is especially true for plastic objects. Injection molding techniques require expensive investments, and iteration and innovation costs can become unacceptably high for small batches.

This is where the new 3D printing trusses come in handy. Not only are they able to produce objects at a fairly high speed (10-20 times faster), the investment in production is also significantly lower: you can buy about twenty 3D printers for the price of one injection molding system. This allows manufacturers not only to achieve higher rates of production growth and more efficient use of labor resources, but also provides more opportunities for innovation and improves resistance to bankruptcy.

The test was carried out on desktop 3D printers, which were theoretically originally developed for small production runs. The promise of 3D printing farms is based on the use of networking and wi-fi capabilities, high production volume and cost-effective modular design: when these aspects are combined together, they are a powerful combination.

All this is very interesting and promising, but, as the survey data show, at present the differences are minimal. The graphs below represent data that comes from a study of three different types of 3D printers, one external 3D printing service, and one type of injection molding production system. It is assumed that the machines have already been purchased (which is reflected in the price of each lot). The calculations are based on a sample of three different batches.

As shown in the graphs, the desktop printer (blue) can, under special conditions, outperform the injection molding system in all respects. Although the advantage is noticeable only in the lower range of production volumes, but, as expected, the differences, unfortunately, become minimal as batch sizes approach the 10,000th mark.

It's no surprise that 3D printing outperforms injection molding at volumes below 100 pieces. All classes of layering production are significantly more profitable in this range (when calculating the cost of one product) than injection molding methods. However, the much higher capital costs of such industrial-grade systems mean that they are no longer competitive (price) at 100 to 200 unit batches.

However, it is worth paying attention to the differences between the trends: blue - desktop 3D printer in special conditions and red - in normal conditions. After increasing production to 800 units, 3D printing is no longer able to compete under normal conditions. Only when twenty printers are running under the supervision of a single operator, during "unmanned" operation, can 3D printing theoretically continue to compete with traditional manufacturing methods. However, when the volume of production exceeds 10,000 units, even this advantage disappears (at the same time, it can be rightly expected that the largest industrial companies overcome this number with ease).

Even when operating under optimal conditions, 3D printing on a large production scale is clearly not able to unseat injection molding methods. But, nevertheless, the results are very impressive: they are much better than what was predicted by the majority.

And they become even more impressive when you take into account other advantages of 3D printing technology. Not only is it faster manufacturing speed, 3D printing with multiple printers increases customization and modification options.