ADDITIVE MANUFACTURING is the magazine devoted to industrial applications of 3D printing and digital layering technology. We cover the promise and the challenges of this technology for making functional tooling and end-use production parts.
Issue link: https://am.epubxp.com/i/667993
MAY 2016 Additive Manufacturing FEATURE / Technology 36 By Stephanie Hendrixson Three Things to Watch in AM Additive manufacturing is diverse, encompassing processes ranging from polymer-based flament deposition to laser- powered melting of metal powders. Yet, AM users and OEMs alike are facing many questions in common. An event hosted earlier this year by the Dayton Region Manufacters Association made this clear to me, from the questions posed by OEMs, local AM users and curious observers in attendence. Based on that discussion, here are three AM issues worth watching: 1. Software limitations. Specifcally, limitations in design and simulation software. To make the best use of AM technology, the industry needs better tools for designing and manufacturing parts that are optimized to additive processes. Software that can simulate additive processes accurately will be especially signifcant in improving part design. 2. Design and manufacturing optimization. A related challenge is how to optimize part designs for AM, and match them with the best process and machine. "We have to design for the process," said Adam Clark, chief strategy ofcer of Tangible Solutions, a service bureau that provides AM parts for aerospace, medical and other industries. But optimization challenges extend beyond initial design. "We need to tweak the process— rapidly," added John Maguire of software company Scientifc Simulation Systems. Simulation software such as what Ma- guire's company is developing will help in making process adjustments prior to an AM build, while technologies such as meltpool monitoring will help with opti- mization during manufacturing. Here are three challenges of additive manufacturing that OEMs, users and others are watching with interest. Improved software and knowledge sharing will help advance AM product design. En- gineers at Renishaw's Solutions Centers work with customers to optimize AM parts. Read more at gbm.media/solutions2. As AM machines become faster and build plates grow, it becomes more economical to produce larger volumes. Read how this batch of through-coolant drills was made with DMLS at gbm.media/mapal. 3. Equipment speeds. For proto- types and small batches, 3D printing can be faster than traditional methods like injection molding, but when it comes to larger volumes AM often can't compete. At what point does it stop making sense to use AM for production? According to Rick Nef, sales manager for Cincinnati Inc.'s Big-Area Additive Manufacturing (BAAM) system, the answer is based on volume, but is changing. As AM machines get faster, the batch sizes that are economical for production will likely increase.