{"id":4221,"date":"2022-10-26T19:38:00","date_gmt":"2022-10-27T00:38:00","guid":{"rendered":"https:\/\/sybridge.com\/?p=4221"},"modified":"2024-01-18T17:16:47","modified_gmt":"2024-01-18T23:16:47","slug":"top-challenges-additive-manufacturing-how-to-overcome-them","status":"publish","type":"post","link":"https:\/\/sybridge.com\/top-challenges-additive-manufacturing-how-to-overcome-them\/","title":{"rendered":"The Top Challenges in Additive Manufacturing and How to Overcome Them"},"content":{"rendered":"\n

Originally published on fastradius.com on<\/em> October 26, 2022<\/em><\/p>\n\n\n\n

3D printing<\/a>, also known as additive manufacturing, is a relatively new technology, but it has already come a long way. Since its invention in the 1980s, 3D printing has become increasingly prevalent in the manufacturing industry, so much so that, in 2021, the global 3D printing market was valued at\u00a0$12.6 billion<\/a>, and expected to grow to\u00a0$34.8 billion<\/a>\u00a0by 2026.<\/p>\n\n\n\n

Although companies like\u00a0Adidas<\/a>\u00a0and\u00a0Rawlings\u00a0have used 3D printing technology to create innovative new products, additive manufacturing continues to face adoption challenges at the industrial scale. Research suggests that\u00a063% of enterprises that use additive manufacturing<\/a>\u00a0only use the technology for\u00a0prototyping purposes<\/a>, and just 21% use it to produce items that can\u2019t be manufactured via other methods.<\/p>\n\n\n\n

Common challenges in additive manufacturing<\/h2>\n\n\n\n

Production-grade 3D printers are much cheaper than industrial CNC machines or injection molding machines, but additive manufacturing equipment can still be costly. In fact, in a survey by Stratasys, 25% of respondents<\/a> identified equipment costs as the top challenge when using additive manufacturing. That response is hardly surprising: saving up for the upfront cost of a 3D printer can take time, and most businesses need more than one to handle the volume of orders they receive, which means investing even more money. Some companies simply cannot justify the capital expenditure. <\/p>\n\n\n\n

Then, there are the manufacturing and processing costs themselves. In the same Stratasys survey,\u00a016% of respondents<\/a>\u00a0said the manufacturing costs associated with additive manufacturing were a top concern. While 3D printers are very autonomous, they still need someone to send the digital file to the printer, ensure the printer is configured correctly, and start the printing process. With multi-material\u00a0fused deposition modeling (FDM)<\/a>\u00a0prints, someone may need to be on hand to swap filaments mid-print and, depending on the materials and printer being used, adjust the nozzle, print speed, retraction settings, and bed temperature. Finally, once a print is done, someone will need to remove any\u00a0support structures<\/a>\u00a0and\u00a0process the part to achieve a quality surface finish<\/a>.<\/p>\n\n\n\n

Beyond manufacturing and processing costs are additive equipment maintenance costs. 3D printers can break down without proper maintenance, leaving companies without new parts for days (or even weeks) as they wait for replacement parts to arrive. For FDM printers, maintenance can take the form of routinely adjusting belt tension and removing any accumulated plastic from the nozzle.\u00a0Multi Jet Fusion (MJF)<\/a>\u00a0printers require regular printhead and heating lamp maintenance, which can cost thousands of dollars per year, and\u00a0stereolithography (SLA)<\/a>\u00a0printers require regular resin tank maintenance or even replacement. Over time, these maintenance costs can certainly add up.<\/p>\n\n\n\n

Additive manufacturing also presents challenges when prints are complete. Most 3D printed parts require some form of\u00a0post-processing<\/a>, which takes time and increases the overall labor and overhead costs per unit. For example, SLA parts are covered with viscous excess resin straight out of the printer, and need to be washed in a solvent. FDM parts often require sanding or\u00a0vapor smoothing<\/a>\u00a0due to prominent layer lines or surface blemishes left behind by support structures. With those issues in mind, it\u2019s hardly surprising that\u00a09% of survey respondents<\/a>\u00a0named post-processing requirements as a top challenge to additive manufacturing.<\/p>\n\n\n\n

It\u2019s also worth noting that additive manufacturing is a much younger technology than traditional manufacturing methods. While injection molding and CNC machining have been used for decades, and already have a large database of compatible materials as well as globally-accepted material standards, additive manufacturing has a more limited selection of materials and fewer established material standards.<\/p>\n\n\n\n

Fortunately, additive manufacturing is becoming more popular, and more businesses are investing in developing, standardizing, and qualifying additive materials. In fact, one of the major trends in additive manufacturing in 2021 was the introduction of novel additive materials<\/a>. Eventually, this research will enable manufacturers to close the gap between additive manufacturing and other technologies. The establishment of globally accepted standards in various industries will also help additive manufacturing gain a stronger foothold in the manufacturing landscape.<\/p>\n\n\n\n

Technical challenges to additive manufacturing<\/h2>\n\n\n\n

Compared to injection molding and CNC machining, additive manufacturing may have lower process predictability and repeatability. For example, additively manufactured parts often go through post-processing to improve their surface finish which, when not controlled properly, is prone to human error and can result in components that can\u2019t meet tight tolerance requirements. This issue represents a challenge when it comes to using additive manufacturing within industries that require extremely high levels of accuracy, such as the aerospace or automotive sectors.<\/p>\n\n\n\n

Even though additive manufacturing enables companies to print complex objects without additional assembly, post-processing techniques can lengthen turnaround times and stretch budgets. Furthermore, companies would likely need to invest in inspection and quality control resources to ensure that 3D printed parts comply with any required specifications.<\/p>\n\n\n\n

Operational and organizational challenges with additive manufacturing<\/h2>\n\n\n\n

As a relatively new technology, additive manufacturing also faces operational and organizational challenges. Not only is there no precedent for adopting additive manufacturing at the operational level, but there are a lack of business- and cost-calculation models based on the technology. Many businesses are also wary of using 3D printing because they are uncertain about the ownership of digital designs.<\/p>\n\n\n\n

Adding to those challenges, there are few dedicated educational tracks specifically for careers in additive manufacturing, which has resulted in a shortage of skilled personnel with deep knowledge of the technologies and processes. Those factors, combined with the typically limited knowledge of additive technologies in companies that do not specialize specifically in additive manufacturing, mean that many customers aren\u2019t sure where it can add value to their business, so \u2014 often to their own detriment \u2014 they avoid it altogether.<\/p>\n\n\n\n

Solving challenges by working with an experienced additive manufacturing partner<\/h2>\n\n\n\n

If you aren\u2019t quite sure how to incorporate additive manufacturing into your business, can\u2019t figure out how to design for 3D printing, or aren\u2019t ready for the investments and technical challenges that come with having 3D printers of your own, it\u2019s best to work with a manufacturing partner. An\u00a0experienced 3D printing partner<\/a>\u00a0can help you overcome many of the top challenges associated with additive manufacturing, including upfront equipment costs, inconsistent results, and a lack of 3D printing knowledge. Working with a partner can also give you access to more additive materials and a more comprehensive range of post-processing options.<\/p>\n\n\n\n

When you work with SyBridge, we can provide insight into the design and material selection processes for additive manufacturing technologies, and even identify cost-saving opportunities to help you maximize your savings and profits. Contact us<\/a>\u00a0to speak with an additive manufacturing expert today.<\/p>\n","protected":false},"excerpt":{"rendered":"

Originally published on fastradius.com on October 26, 2022 3D printing, also known as additive manufacturing, is a relatively new technology, but it has already come a long way. Since its invention in the 1980s, 3D printing has become increasingly prevalent in the manufacturing industry, so much so that, in 2021, the global 3D printing market […]<\/p>\n","protected":false},"author":20,"featured_media":4778,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[38],"tags":[54],"class_list":["post-4221","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-articles","tag-3d-printing"],"acf":[],"yoast_head":"\nThe Top Challenges in Additive Manufacturing and How to Overcome Them - SyBridge Technologies<\/title>\n<meta name=\"description\" content=\"Since its invention in the 1980s, 3D printing has become increasingly prevalent in the manufacturing industry.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/sybridge.com\/top-challenges-additive-manufacturing-how-to-overcome-them\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"The Top Challenges in Additive Manufacturing and How to Overcome Them - 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