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When you’re considering entering the world of 3D printing, it’s valuable to understand the context in which the industry developed to the point where it is now helping to reshape the present and reimagine the future.
In the beginning, 3D printing was largely a basic prototyping tool. But, even then, 3D printing for manufacturing was developing at a remarkable pace.
Today, it has evolved into an essential, sophisticated, simulation, production, and supply chain component. This rapid progress has been driven by advancements in additive manufacturing technology combined with the imagination of engineers, applications that incorporate complex geometries, and different, exciting materials.
The advantages of 3D printing for machine components
Depending on production volumes, 3D printing can be less costly overall for certain product categories. It offers you the ability to make lighter machine or equipment parts that are easier to customize, enabling, for example, equipment efficiency and reduced energy consumption. You can also produce complex parts that literally can’t be made with conventional Computer Numerical Control (CNC) machining.
Beyond this, 3D printing technologies like HP Multi Jet Fusion, can build parts without the need for the support structures that other 3D printing technologies such as FDM, SLA, or Material Jetting require – which offers even more design freedom and cost-efficiency.
Case studies: benefits of 3D printing
The Biesse Group: comparing HP Multi Jet Fusion with other 3D printing technologies
Machines made by the Biesse Group support a diverse set of assembly needs in the woodworking industry. The company creates a wide range of highly customized parts and tools as well as machines ranging from small, semi-automatic devices to large, automated, and customized production machines.
Asked to produce a gearbox (see Figure 1) that originally required multiple manufacturing technologies, including injection molding and CNC machining, Biesse turned to 3D printing for woodworking.
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Figure 1
The company’s engineers compared the production time and cost enabled by HP Multi Jet Fusion technology with that of other 3D printing technologies as well as with traditional manufacturing methods and found they could create the part with more efficiency and at a lower cost than previously.
By optimizing the part’s geometry in ways that couldn’t be accomplished with subtractive technologies, they redesigned the gearbox for 3D printing - demonstrating one of the key advantages of 3D printing over traditional manufacturing.
Additive manufacturing advantages and production flexibility for L’Oréal
The benefits of additive manufacturing include shorter lead times and the design freedom to create complex geometries impossible to produce using subtractive or formative manufacturing methods. You also have the flexibility to quickly and easily alter parts to adapt to the semi-custom needs of an application.
This power to move quickly and offer flexible design and production capabilities allows you to easily modify parts to suit your particular application needs.
Cosmetics giant L'Oréal worked with HP to design and produce large volumes of modifiable “pucks” to move, fill and label products. The 3D printing process allowed L’Oréal to develop customized pucks and quickly respond to changes in consumer behavior driven by the impact of the COVID-19 pandemic on its global supply chains (see Figure 2).
Not only did this solve a problem on the packaging lines, but L'Oréal also gained the ability to customize products more rapidly. Overall, L’Oréal concluded that the change reduced costs by 33% and increased time saved by 66%.
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Figure 2: L’Oréal, the cosmetics giant, worked with HP to design and produce large volumes of modifiable “pucks” to move, fill and label products on its assembly line.
Producing customized labels: Campetella Robotic Centre
Label and packaging providers face an increasing demand to produce customized labels in a variety of substrates. To meet this, Campetella Robotic Centre, an Italian robotics company that designs and manufactures industrial automation solutions, invested in HP Multi Jet Fusion technology for its in-house 3D printing capabilities.
This allowed Campetella to produce robotic machines with custom end effectors that can handle labels of all shapes and sizes based on the label provider’s specifications (see Figure 3). Most of the components that Campetella produces using HP’s 3D printing technology add a final, personalized touch to the end-product.
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Figure 3: Campetella produces robotic machines with custom gripping hands that can handle products such as labels of all shapes and sizes based on the label provider’s specifications.
HP’s Multi Jet Fusion technology allows the company to manufacture mechanical parts and components in-house quickly and cost-effectively without compromising on quality, precision, or material strength. On-board sensors monitor the printing process, while HP’s support services help to schedule maintenance and minimize downtime.
By integrating additive manufacturing solutions, Campetella has been able to achieve previously unattainable goals. They have reduced the weight of spindles for dairy and yogurt manufacturing machines by 50% and slashed the time to market from eight to four weeks.
HP’s Multi Jet Fusion technology: optimizing part design for improved performance
Beyond reduced lead times, lower costs, and greater design freedom and customization, choosing the right additive manufacturing solution can improve durability, performance, and sustainability.
HP’s Multi Jet Fusion technology offers the improved durability essential in tough production environments due to isotropic part strength. The technology’s fusing method results in higher cross-layer fusion compared with other printers that offer only limited z-axis strength or flexibility. This enables you to optimize part design for improved performance even more.
Case study: benefits of 3D printing
Bowman: optimizing part design using 3D printing
Bowman produces industrial split roller bearing cage assemblies which play a significant role in bearing performance. Because of their extremely complex geometries, they also can be difficult to manufacture with traditional techniques such as injection molding.
The company explored HP Multi Jet Fusion technology to optimize the design of its industrial split roller bearing cage assemblies to make it easier for manufacturers to assemble, maintain and repair their equipment (see Figure 4).
HP Multi Jet Fusion allowed Bowman to take prototyped parts into production and volume production easily and efficiently.
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Figure 4: Bowman was able to optimize the design of its industrial split roller bearing cage assemblies to make it easier for manufacturers to assemble, maintain, and repair their equipment.
Designing parts with non-conventional geometries
Eliminating design restrictions found in traditional manufacturing technologies allows you to design parts with non-conventional geometries, which can guarantee better product performance. It also becomes easier and faster for you to customize without increased manufacturing costs, as would be the case with molding or machining operations.
Reimagining your production process
Additive manufacturing capabilities enable you to reimagine your production process to meet customer requirements and make it easier for spare parts orders. 3D printing also allows you to create non-standard parts of all types and provide serial numbers, QR codes, engravings and textures in the same printing process.
Reducing inventory and logistics costs
With in-house additive manufacturing machines, you can reduce inventory costs and logistics costs from design through production.
You can also enjoy cost savings thanks to sustainability features such as less or almost no material waste compared to machining parts, no material waste because support structures are eliminated, using reusable and plant-based materials such as PA11 and material recyclability of 70-90%.
Working with new, lighter-weight alloys
Because of advancements in material properties, design engineers can look beyond aluminum or stainless steel to new, lighter-weight alloys. This enables higher performance parts, reduces the capital investment required and lowers energy consumption for applications such as robot end effectors and other automation applications.
Case study: benefits of 3D printing
Havatec and HP Multi Jet Fusion technology
Havatec evaluated using 3D printed parts in its advanced grading, bunching, and handling machines for the flower-cutting industry (see Figure 5). When designing its new “Wave” machine, which mechanically bunches flowers, Havatec selected HP Multi Jet Fusion technology to meet its complex manufacturing needs.
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Figure 5: HP Multi Jet Fusion technology allowed Havatec to design and produce stronger and more durable parts for its flower-bunching machine.
The Wave machine uses more than 200 different part SKUs which are 3D printed using HP 3D High Reusability PA6 116 material, with several copies of each SKU integrated into one machine unit. Havatec engineers selected this material because of its enhanced elongation at break and impact resistance, properties that contribute to better machine performance.
Havatec’s tests validated that parts made with HP 3D High Reusability PA6 116 lasted for approximately five million cycles because of its strength and durability. Havatec manufactures five to 10 Wave machines per year and expects to increase production annually, resulting in two to three HP MJF-produced buckets per week, including prototypes and final parts.
Reducing the design-to-manufacture process
Reducing the design-to-manufacture process by shortening the time from design iteration to prototyping to finished product is among the many advantages of 3D printing.
When functional prototyping and final parts production operate on the same system, it not only reduces time to production but also eliminates process delays. Design and production teams are working from the same functional model—and as changes are made to the design, they are replicated in production.
You also benefit by eliminating the additional operator time needed for a second setup, as well as the time and cost that goes into additional testing and validation for materials.
3D printing case study:
Langhorne Carpet Company, ProtoCAM and HP Multi Jet Fusion technology
Textile machinery manufacturer Langhorne Carpet Company used ProtoCAM, a 3D parts provider, to produce spare parts for its looms (see Figure 6) with 3D printing.
Working with HP Multi Jet Fusion 3D printing and using HP 3D High Reusability PA 127 material, the company saved on the cost of producing the specialized wooden components and decreased delivery time. In addition, HP MJF 3D printing allowed the company to improve the design of its parts, substituting vents for drilled holes to enhance the weaving process.
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Figure 6: Using 3D printed parts, Langhorne Carpet Company was able to improve the design of components and enhance the weaving process.
Researching before you invest in 3D printing
If you’re just getting into the 3D printing world, there are many ways to gain information.
Most 3D printing equipment manufacturers and service bureaus offer educational sessions and virtual demos online. Engineers can also interact online or in person at trade shows to discuss specific applications, check out parts physically, and evaluate one technology against another.
3D printing service bureaus are often willing to assist with converting conventional part designs using DfAM techniques. This can include a comprehensive evaluation of production strategies and cost reduction opportunities. These suggestions are particularly valuable to companies not ready to purchase an industrial 3D printer.
If you’re not yet committed to directly implementing additive manufacturing solutions in-house, you can benefit from outsourcing opportunities for 3D printed parts. Although outsourcing can increase part costs, it also allows your in-house engineers to explore multiple 3D printing technologies and materials while eliminating the upfront costs of capital equipment.
You may want to take a look at the HP Digital Manufacturing Network—a global network and directory of 3D parts suppliers that can help accelerate your business’ digital transformation with 3D printed parts - enabling rapid innovation, fast time-to-market, distributed manufacturing, and a lean supply chain.
HP Digital Manufacturing Network partners have been evaluated and qualified based on their end-to-end 3D printing service capabilities for production at scale, as well as their manufacturing and quality processes. HP Digital Manufacturing partners offer:
- Advanced Additive Manufacturing processes
- Industry standard certifications
- Robust quality management
- Volume job production
Search the HP Digital Manufacturing Network directory to connect with a wide network of HP certified 3D parts suppliers around the world.
3D printing: more than just customized products
The new dimension that 3D printing offers allow not just customized products, but a more customized manufacturing strategy. As technology and the benefits of 3D printing continue to expand, you can respond to market changes more quickly and meet industry demand for flexibility and faster turnarounds through the integration of additive manufacturing solutions.
Inevitably, you’ll need to evaluate 3D printing pros and cons for your own unique circumstances. But this article should make it abundantly clear that 3D printer benefits are many, depending on your business and industry.
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Footnotes and disclaimers
- Data courtesy of Biesse Group
- Data courtesy of L'Oreal
- Data courtesy of Campetella Robotic Centre
- Data courtesy of Bowman
- Data courtesy of Havatec
- HP Jet Fusion 3D Printing Solutions using HP 3D High Reusability PA 11 provide up to 70% powder reusability ratio, producing functional parts batch after batch. For testing, material is aged in real printing conditions and powder is tracked by generations (worst case for reusability). Parts are then made from each generation and tested for mechanical properties and accuracy.
- HP Jet Fusion 3D Printing Solutions using HP 3D High Reusability PA 12 provide up to 80% powder reusability ratio, producing functional parts batch after batch. For testing, material is aged in real printing conditions and powder is tracked by generations (worst case for reusability). Parts are then made from each generation and tested for mechanical properties and accuracy.
- Data courtesy of Langhorne Carpet Company