Designing medical parts? Just as there are countless types of medical procedures, there are also countless types of polymers on the market today. Which ones are best for your medical application? Great question. We’ll attempt to provide some guidance in this design tip, but it’s important to start with the following caveat: The term “medical grade” is ambiguous at best. &nbsp;<a href="https://www.protolabs.com/en-gb/industries/medical/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Medical" target="_blank" rel="noopener noreferrer">Medical device</a> manufacturers must understand and comply with a slew of standards, but for the purposes of this discussion, ISO 10993 takes the lead role. It has nearly two dozen parts, of which four pertain specifically to material selection; of these, ISO 10993-13 is probably the most relevant to polymers.&nbsp;Unfortunately, there’s no catalogue or book that lists which polymers meet which standards, or even which polymers are biocompatible. Compounding matters is the sheer number of resins, pellets, powders, and bulk forms like rod and sheet from which to choose, each with multiple manufacturers that may or may not meet the necessary&nbsp;<a href="https://www.protolabs.com/en-gb/resources/design-tips/manufacturing-tool-kit-for-the-medical-industry/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Manufacturing Tool Kit for the Medical Industry" target="_blank" rel="noopener noreferrer">medical device requirements</a>. Where one might provide medical-grade ABS, the other produces ABS suitable for LEGOs and power tool housings. &nbsp;Of course, one blog post can’t cover all you need to know about medical grade plastics, so don’t forget you can look at the stats on our <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/?category=plastic&utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Comparison Guide" data-anchor="?category=plastic" target="_blank" rel="noopener noreferrer">materials comparison page</a>. All that said, here are six essential polymers to keep in mind for your next medical parts project.&nbsp;<h3 id="isPasted">Comparing Plastics for Medical Parts&nbsp;</h3>Generally, medical device designers and manufacturers should look for polymers that are resistant to corrosion, chemical attack, and high temperatures. These should be non-absorbent and inert, and able to withstand repeated sterilisation cycles in an autoclave. Of course, they shouldn’t react with bodily fluids and human tissue, cause irritation, or create skin sensitivities. Did we mention strength and durability? All of this might seem like a very tall order, but the good news is that a healthy handful of polymers check at least most of these boxes. &nbsp;<h5 id="isPasted">PC&nbsp;</h5>Oftentimes, an optically transparent polymer is needed for medical procedures, and polycarbonate is the material of choice. It checks all the usual boxes in terms of toughness, dimensional stability, heat and chemical resistance, and sterilizability. You won't find it inside the human body, but PC is typically used when it's necessary to see blood, drugs, and other fluids flowing through a device. Many of Protolabs' medical customers will 3D-print their designs from PC-like materials such as Acura 5530 or PerFORM, then go on to machined or injection-moulded polycarbonate as production needs increase. &nbsp;<h5 id="isPasted">UHMW-PE&nbsp;</h5>Since we’re discussing orthopedic implants, here’s another important polymer to keep in mind: ultra-high molecular weight polyethylene. If you’ve had a knee or hip replacement, chances are good that you have some of this stuff inside you. UHMW-PE is an extremely dense, low-friction member of the polyethylene family. If you’re looking for some machined medical components (or wear-resistant machinery parts), UHMW-PE has excellent impact strength and abrasion resistance, and here again, is eminently biocompatible. And for slightly less demanding applications, “regular” polyethylene (PE) and high-density polyethylene (HDPE) are good, all-around polymers for a wide range of medical applications, especially for single-use products and the PPE gear that’s become so prevalent over the past few years. &nbsp;<h5 id="isPasted">PEI&nbsp;</h5>Like PEEK, polyetherimide borders on super-polymer territory. Better known by its trade name Ultem, PEI is a rigid, semitransparent, and heat-resistant 180°C polymer that is amber in colour and boasts great tensile strength. Because it also has high dielectric characteristics and resistance to flame, it is widely used in electronic components, medical or otherwise. We machine and injection mould PEI into various shapes, with potential uses including handles for surgical instruments, medical device enclosures, insulators, electrical connectors, and more. Lastly, PEI is readily sterilised via autoclaving and gamma radiation. &nbsp;<h5 id="isPasted">PSU&nbsp;</h5>Another amber-coloured polymer is PSU, short for polysulfone. Recognised for its toughness and rigidity at elevated temperatures, PSU is less strong than PEI but more impact resistant. It might be machined or moulded into filter housings, catheter ports, surgical instrument trays, and sizing devices for use during heart valve replacements. Polysulfone is said to be one of the few polymers able to withstand more than 1,000 cycles of steam sterilisation (as can PEEK and PSU’s even more impact- and heat-resistant cousin, polyphenylsulfone, or PPSU).&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519080624-1734519080624.png" class="fr-fic fr-dib" style="width: 806px;">This medical component from IDEXX Laboratories, Inc. is part of an instrument that veterinarians use to test blood and urine.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519116565-1734519116565.png" style="width: 808px;" class="fr-fic fr-dib">Moluded part manufactured with medical-grade liquid silicone rubber.<h5 id="isPasted">PEEK&nbsp;</h5>Polyetheretherketone is a great place to start. Long considered an “engineering-grade” thermoplastic, PEEK enjoys broad use in the medical industry. Orthopedic surgeons use it for trauma fixation, spinal implants, and replacement joints, while dentists use it in crowns and bridges. PEEK is both lightweight and strong, is radiopaque (meaning it appears on x-rays), and maintains its strength and dimensional stability at high temperatures. And seeing that PEEK is often inserted into the human body for extended periods of time, it goes without saying that it’s biocompatible and sterilisable. Protolabs routinely CNC machines and plastic injection moulds PEEK into mechanical components such as gears, bearing surfaces, and manifolds, as well as a host of medical parts. &nbsp;&nbsp;<h5 id="isPasted">Silicone&nbsp;</h5>The stuff of weatherproofing adhesive and cooking utensils, silicone is also an excellent choice for many medical components. Silicone is available in various hardness levels, from soft and stretchy like a rubber band or rigid like a tire tread. It withstands temperatures from sub-zero to oven hot 55°C to 210°C, is hydrophobic (repels water), resistant to solvents and acids, and has good vapour permeability, making it a favourite for prosthetic devices. Protolabs 3D-prints a variety of medical components, including seals, gaskets, and surgical models, and injection moulds all manner of prototypes and end-use production parts using liquid silicone rubber (LSR). You can even 3D print in silicone, a great option for prototyping parts using this material for complex parts or prior to moving to injection moulding for production quantities. In addition, there’s also an optical grade of liquid silicone rubber, OSLR, which enjoys superior refractive and light transmission properties compared to its PC or PMMA (acrylic) alternatives. It is therefore popular for use in lenses and lighting applications, or anywhere that a clear, non-yellowing, heat- and chemical-resistant biocompatible polymer is needed. &nbsp;&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519177098-1734519177098.png" class="fr-fic fr-dib">An operator removes a silicone part from the LSR press. Due to the elasticity of silicone parts, manual removal is necessary.<h3 id="isPasted">More Options to Consider&nbsp;</h3>Those six medical-grade polymers are just the starting point. We’d be remiss if we didn’t mention PTFE, better known as Teflon, a super-lubricious polymer used in everything from catheters and stents to heart-lung machines. Impact and chemical-resistant acrylonitrile butadiene styrene (ABS) is sometimes used to replace metal structural components in medical equipment, as is acetal (you might know it as Delrin), while polyvinyl chloride (PVC) might be considered a flexible version of polycarbonate in certain applications. Polyethylene terephthalate (PET) resists attacks by microorganisms, making it just as suitable for soft drink containers as it is for wearable sensors. Polypropylene (PP)—although considered a commodity plastic—finds widespread use in specimen bottles, prescription containers, and disposable hypodermic syringes (it’s also a great option for parts that would benefit from a living hinge). &nbsp;As with any manufacturing application, choosing the best material for a medical device comes down to its physical, chemical, and electrical requirements, not to mention its operating environment. There’s also manufacturability to consider and all the design rules that go along with that. And at the end of the design and prototyping process waits the FDA approval ordeal. It can be a confusing landscape to navigate, which is why we encourage you to upload a file, get a quote, and give us a call to discuss your options. We've helped countless others who were once in your shoes. &nbsp;

Safety and longevity are key to this list of medical-grade plastics.

Plastics for Medical Devices and Applications

We’ve recently covered the&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-manufacturing/">benefits of 3D printing in manufacturing</a> where we outlined how in today’s fast-paced manufacturing environment, operational efficiency and adaptability are more critical than ever.Whether you're an operations manager looking to streamline production workflows or an engineer tasked with solving complex design challenges, 3D printing has become a transformative tool in modern manufacturing.This article will explore&nbsp;how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507534509-0H6A3681-2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2>Custom Jigs, Fixtures, and Tooling</h2>Across the entire manufacturing landscape, jigs, fixtures, and tooling play a pivotal role in ensuring product quality, assembly accuracy, and production speed. Traditionally, creating these components required time-intensive machining and significant costs, especially for customized solutions. 3D printing allows for a vastly more rapid, efficient, and cost-effective way of producing these parts.Several of our clients such as ERIKS, Volkswagen Autoeuropa, Zeiss, and IME Automation have already implemented 3D printing technology to create various jigs and fixtures to streamline and improve their manufacturing capabilities.Here’s a few examples:<h3>ERIKS - Motor and drill alignment jigs</h3>The implementation of the motor jig, for example, allowed for an easier assembly of the components minimizing the chance of assembly errors while also making the process 3 times faster (assembly time previously took around 3 minutes which was cut down to one).According to ERIKS:<blockquote>For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.</blockquote><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507587853-1734507587853.png" class="fr-fic fr-dib"><h3 id="isPasted">Volkswagen Autoeuropa - Manufacturing tools</h3><a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa</a> has switched to 3D printing in order to produce the vast majority of tools used in their manufacturing line and has seen tool development time reduced by up to 95% and costs by 91% (saving an estimated $375.000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507613298-1734507613298.png" class="fr-fic fr-dib"><h3 id="isPasted">Zeiss - Adapter plate and label placement gauge</h3>For&nbsp;<a href="https://ultimaker.com/learn/zeiss-precision-parts-for-serial-production/">Carl Zeiss Optical Components</a>, precision is paramount when manufacturing microscopes, multi-sensoric machines and optical sensors for industrial measurement and quality assurance purposes.Their implementation of <a href="https://ultimaker.com/">UltiMaker’s 3D printing</a> technology not only enabled them to create bespoke adapter plates for each of their microscopes in serial production streamlining the process but also made supporting those parts for their clients a lot easier, as spares could be printed on demand and sent to a client’s location. Previously they had to produce several parts, mount them together, and adjust them which was a more costly and time-consuming process.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507633041-zeiss-adapter-plate-ultimaker-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Taking label placement gauges as another example, previously made out of POM (polyoxymethylene), the sharp corners would lead to breakage if dropped. Adding in the fact that POM is traditionally made by injection molding or extrusion, itself a costly process, would often require CNC machining to create the desired part.In contrast, the new 3D printed gauges allowed products to slide in and out of the tool effortlessly while also being less fragile, more wear-resistant and could be printed to achieve tight tolerances, all while having a print time of just 3 hours at €2.20 per part.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507646971-Zeiss.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">IME Automation - Box folding jig</h3>With a focus on precision, efficiency, and innovation in the field of building custom automated robotics for manufacturers<a href="https://ultimaker.com/learn/3d-printing-for-flexible-manufacturing-with-ime-automation/">&nbsp;IME Automation turned to 3D printing</a> to test and create a wide range of applications to be more agile and flexible in their manufacturing process.One of the most notable examples is the one that started them on the path of using 3D printing technology, their patented box folding jig.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507662261-Copy-of-IME-Sparky-close-up-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Used to erect or fold cartons their customers previously had to either buy an off-the-shelf carton erector or a full-fledged cartoner which were big, cost prohibitive, and offered no flexibility to changes due to the long times required to adapt them.The 3D printed folding box jig IME Automation developed was a game changer as they could iterate a wide variety of shapes and sizes with less than 2-minute part changeover times.<h2>Rapid Prototyping and End-Use Parts Production</h2>As previously hinted, 3D printing allows for direct fabrication of prototypes from CAD models, bypassing the need for complex tooling or molds. This capability significantly shortens development cycles and enables designers to test, modify, and validate designs with a high degree of speed and flexibility.Unlike traditional subtractive manufacturing processes, additive manufacturing allows for the creation of designs with complex geometry, overhangs, and organic shapes at a reduced cost and complexity. This innate feature allows 3D printing to bridge the gap between prototyping and large-scale production, allowing companies to produce end-use parts without the need for expensive and time-consuming tooling. Our clients Sylatech and Snow Business offer some great examples in this regard:<h3>Sylatech - Yacht propeller prototype</h3>An investment casting firm, Sylatech was previously unable to test design functionality without using tooling investment casting, a time-consuming and costly process, typically taking three to four weeks with customers paying £2,000-4,000 per tool. Add in the fact that approximately 30% of tools require some sort of alteration, which can cost up to £900, it’s easy to see why they needed a solution to reduce lead times and costs.Using UltiMaker’s 3D printing technology they were able to reduce the development time of a yacht propeller from four weeks to just three days and brought down the total cost from £17,100 to £15,660 (including casting tooling costs).Taking into account that with 3D printing only 5% of tools needed alteration, Sylatech’s ROI for an UltiMaker 3D printer was less than 3 months.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507676679-yacht-propeller-and-prototype-image.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Snow Business - Snow machine nozzle</h3>With over 35 years of experience in the artificial snow industry for film and TV effects production, Snow Business has leveraged 3D printing to prototype, functionally test and create final parts for their machines. For example, the nozzles on their snow machines could be 3D printed in-house within seven hours at £2.50 each, negating the need for an SLS service which took up seven days with a minimum £125 per order. They estimate that their UltiMaker printer paid for itself within just two weeks.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507691141-snow-business-ROI-calculator.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">On-Demand Spare Parts and Maintenance</h2>In traditional manufacturing, maintaining a stock of spare parts for machinery or production lines often requires significant investment in inventory and storage space. Long lead times for replacement parts can result in costly production delays.3D printing eliminates these challenges by enabling the on-demand production of spare parts directly on location, aside from the greater flexibility and cost efficiency in maintenance operations, manufacturers can leverage 3D printing to also extend the lifespan of existing machinery far beyond the OEM’s support cycle which is an often underreported benefit that directly translates to lower production costs and higher production uptimes.Some of our clients, such as Trivium and Heineken, have integrated UltiMaker’s ecosystem precisely for this reason:<h3>Trivium - Conveyor infeed worm and silicone seals &amp; gaskets</h3>In Trivium’s case, the original packaging machine had worn out and was no longer available from the supplier and manufacturing it via traditional methods such as CNC milling was cost prohibitive and time consuming. 3D printing the part in a low cost material such as ABS allowed them to validate the design and switching to carbon reinforced nylon netted them a durable replacement part that allowed them to keep their production rolling.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507706706-image.webp" style="width: 100%px;" class="fr-fic fr-dib">Similarly, the molds needed for silicone seals and gaskets needed for different machines were either too expensive or, as was the case for the infeed wheel, no longer available.Using ABS printed with a 60 micron layer height, Trivium was able to cleare smooth and accurate molds for silicone which could be reused and reprinted on demand, saving time and money.<h3>Heineken - Stopper tool</h3>After the implementation of 3D printing technology in their Seville plant, Heineken was able to improve their manufacturing process in terms of output, uptime, and safety. We recommend reading further on&nbsp;<a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">how Heinken ensured production continuity with 3D printing</a> for a more comprehensive list of applications, but for this example, we want to showcase their stopper tool.As a custom tool used to loosen or tighten the columns for the guiding wheels that apply bottle labels, the 3D printed version of the tool was 70% cheaper to produce than the previously CNC machined one and done within a single day instead of three.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507722244-heineken-ultimaker-3d-printed-tools-speed-up-maintenance-.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Materials Enabling Versatility in Manufacturing</h2>UltiMaker’s ecosystem of advanced printing solutions provides manufacturers with the flexibility to choose from a wide range of materials tailored to specific applications. From durable industrial plastics to flexible polymers, these materials enable the production of functional parts that can withstand the rigors of industrial environments even replacing traditional materials such as aluminum or steel in certain applications without compromising on part reliability or function.As a reference starting point here are 3 of the materials used in the above examples:<a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerTPLA">UltiMaker Tough PLA</a>:<ul><li>Applications: Strong and impact-resistant parts such as jigs, fixtures, and prototypes.</li><li>Use case: Heineken uses Tough PLA to print durable production line components, including bottle guides and tool organizers, ensuring longevity while maintaining cost-effectiveness</li></ul><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/ULTIMAKERNYLON12CFMETHOD">UltiMaker Nylon CF</a><ul><li>Applications: High-strength, abrasion-resistant parts like gears, bushings, and conveyor belts.</li><li>Use case: Trivium Packaging leverages carbon reinforced nylon for parts like conveyor infeed worms, which must endure high wear and tear in a manufacturing environment</li></ul><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerABS">UltiMaker ABS</a><ul><li>Applications: Durable parts requiring smooth surface finishes, such as molds and protective covers.</li><li>Use case: Zeiss’s adapter plates and label placement gauges are both made from ABS.</li></ul>We recognize that material selection is one of the cornerstones of successful 3D printing applications in manufacturing and with a selection of over 200+ materials on the Marketplace, we’ve recently expanded the possibilities available on a single print with our dual-extrusion&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/">Factor 4 printer</a>:<ul><li>Support Materials: Soluble supports like PVA allow for complex geometries with overhangs or internal structures that would otherwise be impossible to produce through traditional methods.</li><li>Composite Structures: Pairing flexible materials like TPU with rigid materials like nylon creates parts with hybrid properties, such as flexible joints or shock-absorbing elements.</li></ul><h2>IMES3D - The Power of Partnership</h2>For a holistic view of how UltiMaker’s complete ecosystem can help manufacturers and businesses integrate 3D printing technologies into their workflows effectively, we turn to <a href="https://ultimaker.com/learn/imes3d-expert-support-for-industry-level-3d-printing/">IMES3D</a>, one of our clients and partners, as an example of leading the charge in the transformative nature of 3D printing technology.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507740966-imes3d.webp" style="width: 100%px;" class="fr-fic fr-dib">Offering professional support and a full suite of comprehensive services, IMES3D specializes in designing and implementing 3D printing solutions tailored to their customers specific operational needs. From printing parts and support in selecting the right materials they also offer consulting services for companies looking to adopt additive manufacturing and integrate it into existing workflows.In order to support their clientele spanning a wide range of industries, including automotive, food and beverage, military and medical sectors, they rely on UltiMaker’s unique ecosystem to ensure that their 60+ printer fleet is utilized as efficiently as possible.Elaborating on UltiMaker’s ecosystem this is comprised of 3 main parts:Hardware:<ul><li>S Series</li><li>Method Series</li><li>Factor Series</li></ul>Software:<ul><li>Cura</li><li>Digital Factory</li></ul>Materials &amp; Partners:<ul><li>UltiMaker materials</li><li>3rd party partner materials</li></ul>Along with UltiMaker Cura which is a fast and easy-to-use slicer, Digital Factory is used to easily manage all of the printers in the network, and ensure that projects get sent to the right printer and queues are monitored. Additionally, some customers have also started using Digital Factory which enables IMES3D to leverage the software as a key support tool being able to remotely send and queue prints from their facility.Their expertise spans technology, material science, and production optimization, which is why we highly recommend watching our&nbsp;<a href="https://ultimaker.com/learn/how-imes3d-unlocks-industrial-3d-printing-with-the-ultimaker-ecosystem/">recent webinar with IMES3D</a> to get a full picture of how they are advancing industrial 3D printing together with UltiMaker’s ecosystem.But for those interested in a couple of short granular examples of applications we’d like to showcase two that were made possible with the addition of the new UltiMaker Factor 4 printer:<h3>Flexible bumpers for PDA’s</h3>Considering that most PDA manufacturers do not make any protective covers for their devices, resulting in drastically reduced lifespans due to accidental drops or mishandles, IMES3D designed and printed a wide variety of custom bumpers made out of soft TPU filament.The ability to print in a variety of colors also allowed IMES3D to color code the bumpers according to their customer’s specifications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507763014-1734507763014.png" class="fr-fic fr-dib"><h3 id="isPasted">Mold for part injection</h3>The ability to print in UltiMaker’s new PPS CF carbon reinforced filament, opened up the possibility of replacing metal parts with the new composite material. With extreme durability and high-temperature resistance (HDT B of over 230°C printing), IMES3D was able to create a mold connector used for injecting parts for water and air pipes.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507784011-imes3d-1.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Become an industry leader with UltiMaker</h2>3D printing is not merely a complementary technology, it is reshaping the manufacturing landscape. At the cutting edge, UltiMaker’s Factor 4 empowers companies to innovate rapidly, cut costs, and create complex designs and paves the way for a more agile and efficient future.If you want to know how UltiMaker can help you change the game for your business don’t hesitate to&nbsp;<a href="https://ultimaker.com/quote-request/">contact us</a> and our team of experts would be more than happy to reach out!

This article will explore how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations

Applications of 3D Printing in Manufacturing

<a href="https://xometry.eu/en/injection-moulding/" target="_blank" rel="noreferrer noopener">Injection molding</a> is a very efficient and widely used plastic manufacturing process for producing parts in large quantities. Mold development is a critical aspect of this process, essential for accurately shaping and forming molten plastic with high precision. The creation of molds, as one of the first steps, demands great precision and accuracy to ensure the quality and consistency of the final products.There are various ways to classify molds in injection molding, including by plate type, runner type, cavity design and class. Among these classifications, mold cavity design—single-cavity, multi-cavity, and family molds—plays a pivotal role in determining production efficiency and quality. Single-cavity molds are simpler and offer high-quality parts, ideal for low-volume production and intricate designs. Multi-cavity molds enhance production speed and reduce the cost per part for large volumes, but require precise balancing to avoid defects. Family molds allow for the simultaneous production of different parts, optimizing manufacturing for multi-part products but increasing design complexity and the potential for defects.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989703073-complex-injection-mold-scaled.webp" style="width: 100%px;" class="fr-fic fr-dib"><blockquote><section>When selecting the right mold type, it’s important to consider your immediate production needs but also the long-term performance and durability of the mold. Molds are classified based on how long they’re expected to last. Class 101 molds can handle over a million cycles, so they’re great for really high production levels. On the other hand, Class 105 molds are good for up to 500 cycles, which makes them perfect for prototypes and low-volume production. At Xometry, we typically use molds that last at least 10,000 shots for our injection molding projects.<h4 id="isPasted">Dmitry Romanov, Lead Injection Molding Engineer</h4></section></blockquote><h2 data-counter-attr="value0">What Type of Mold Is Used in Injection Molding?</h2>Injection molds can be categorized in several ways, each affecting various aspects of the production process. Here’s a detailed look at these categories and their significance:<h3 data-counter-attr="value1">Plate Type</h3>The plate type influences the mold’s cost, the finish of the final product, and overall production efficiency.<ul><li>Two-Plate Molds: Consist of two main parts—the cavity and the core. They are simpler and less expensive but may have limitations in complex part designs.</li><li>Three-Plate Molds: Include an additional plate for separating parts from the runners, improving part ejection and quality. They are more versatile but also more costly.</li><li>Stacked Plate Molds: Utilize multiple levels of cavities, doubling the output without increasing the footprint. They are ideal for high-volume production but require precise alignment and complex design.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989693840-two-plate-three-plate-injection-mold.webp" style="width: 100%px;" class="fr-fic fr-dib">Comparison of injection molds: Three plate mold vs two plate mold (Source: plasticmoulds.net/)<h3 data-counter-attr="value2" id="isPasted">Runner Type</h3>The runner type impacts mold design flexibility, material waste, and the amount of post-processing required.<ul><li>Cold-Runner Molds: Use unheated channels to guide the molten plastic into the mold cavities. They are less expensive but require more post-processing to remove the runners from the final product.</li><li>Hot-Runner Molds: Incorporate heated channels, keeping the plastic molten until it reaches the cavities. They reduce waste and post-processing needs but are more complex and expensive.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989725939-cold-hot-runner-injection-mold-1536x961.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value3" id="isPasted">Mold Cavity Design</h3>The mold cavity design plays a crucial role in production efficiency and part quality, directly influencing the speed, cost, and consistency of the manufacturing process.<ul><li>Single-Cavity Molds: Single-cavity molds produce one plastic part per injection cycle. This gives single-cavity models the slowest production times of the three types of molds we are discussing. However, due to their size and relative simplicity, they are quite affordable to produce, making them a good option for small production volumes in which production speed isn’t the biggest factor.</li><li>Multi-Cavity Molds: Multi-cavity molds contain multiple cavities, as the name suggests. These molds produce multiple copies of the same plastic product in each production cycle. They are ideal for mass production purposes, with high production speeds and a low price per part at large production volumes. Multi-cavity molds are complex and expensive to design and produce, however this can be offset when working with large production volumes.</li><li>Family Molds: Family molds are injection molds that produce multiple different parts per production cycle. They are useful for manufacturing multi-part products quickly but are very complex to design and more prone to molding defects.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989750655-injection-molding-mold-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Multi-cavity injection mold designed for high-volume production of identical parts<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989786780-Injection-family-mold-scaled.webp" style="width: 100%px;" class="fr-fic fr-dib">Injection molded parts from a family mold, illustrating the simultaneous production of different componentsAdditionally, the SPI (Society of the Plastics Industry) classifications provide a standardized method (Class 101 to 105) to evaluate mold life expectancy and suitability for different production volumes.<h2 data-counter-attr="value4">Comparing Single-cavity, Multi-cavity and Family Molds</h2>The table below compares the three types of injection molding molds:<table><thead><tr><th>Property</th><th>Single-Cavity Mold</th><th>Multi-Cavity Mold</th><th>Family Mold</th></tr></thead><tbody><tr><td>Applications</td><td>• High-quality plastic products (e.g. containers for which aesthetics matter). • Intricate geometries or designs with precise control over material flow and injection pressure.• Prototypes with design changes and new mold iterations.• Low-volume production in which cost is a more significant factor than production speed.</td><td>• Large production volumes (over 40,000 products per month). • Applications for which price per part is the most important factor.•&nbsp;High-demand products that require short lead times for high volumes (e.g. bottle caps or packaging).</td><td>• Multi-part products, for which all the parts can be manufactured in a single production cycle. • Prototyping with multiple variations of parts being manufactured simultaneously.• Medium to large production volumes with the same part’s material and color.</td></tr><tr><td>Cost</td><td>Low cost, with the simplest design and tooling requirements.</td><td>High, requiring more complex design and tooling.</td><td>Highest, due to being the most complex to design.</td></tr><tr><td>Complexity</td><td>Low, as it doesn’t require balancing of pressures between multiple cavities.</td><td>High, with complex runner, cooling, and gate systems needed.</td><td>Highest, with multiple different cavities requiring careful design to balance injection pressures and uniformity.</td></tr><tr><td>Lead Time</td><td>Lowest, due to the simpler design process.</td><td>High, requiring careful design.</td><td>Highest, with a long design and simulation process.</td></tr><tr><td>Production Speed</td><td>Slowest, limited to one part per injection cycle.</td><td>Fastest, multiple copies of a part can be made simultaneously.</td><td>Fast, multiple different parts can be made in a single injection cycle.</td></tr><tr><td>Surface Quality</td><td>Highest, with minimal post-processing needed.</td><td>High, with some post-processing needed and risk of defects.</td><td>Medium, with the highest risk of unbalanced injection and defects.</td></tr><tr><td>Advantages</td><td>• Lowest risk of molding defects. • The simplest and fastest type of mold to design and manufacture.</td><td>• Fastest production speed of the three mold cavity types.</td><td>• One mold can produce multiple different parts. • Fast production speeds, especially for multi-part products.</td></tr><tr><td>Disadvantages</td><td>• Lowest production efficiency (only one part can be produced at a time). • Highest cost per part at large production volumes.</td><td>• Highly complex to design and manufacture. • Requires higher maintenance than single-cavity molds.• More prone to unbalanced injections and molding defects than single-cavity molds.</td><td>• Very complex to design and manufacture. • Long lead times for new mold designs, due to design complexity.• More post-processing is required than for single- or multi-cavity molds.</td></tr></tbody></table><h2 data-counter-attr="value5">What Are the Components of Injection Molding Molds?</h2>The injection molding mold itself consists of several components, each with its own specific function within the mold.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989825178-two-plate-injection-mold.webp" style="width: 100%px;" class="fr-fic fr-dib">Detailed structure of a two-plate mold with labeled parts (Source: CustomPartNet)The components are:<ul><li>Mold base: The mold base or mold frame is the foundational infrastructure for the mold assembly, providing rigidity and strength against the internal pressure experienced during injection molding.</li><li>Cavity: The cavity, or cavities, shape the external geometry of the part. The cavity and the core form two halves of the final mold cavity in which the molten plastic is injected.</li><li>Core: The core shapes the internal geometry of the part, and mates with the cavity to form the mold cavity. Multi-cavity and family molds will have multiple pairs of cavities and cores for the multiple parts that they produce.</li><li>Inserts:&nbsp;Inserts are separate components that may be inserted into the mold to create specific geometric features. They are separate from the cavity and core but also help form the internal and external geometries.</li><li>Runner system: The runner system distributes molten plastic throughout the mold cavity to ensure an even distribution of material. They are a network of channels that ultimately end in gates, which are the openings into the mold cavities. Good runner system design is vital for ensuring even material distribution and minimizing defects.</li><li>Nozzle &amp; sprue bushing: The nozzle controls how the molten plastic flows into the mold from the feeding system of the injection molding machine. The sprue bushing is a component of the mold that positions the nozzle to ensure it is centered and aligned.</li><li>Ejector pins: They are used to help eject the part from the mold after it has solidified and the mold has been opened. The part can potentially stick to the mold cavity, and ejector pins are used to automatically provide a force that ejects the part from the mold.</li><li>Cooling system: The cooling system helps maintain the temperature of the mold in order to prevent damage and maintain quality of the finished part.&nbsp;</li><li>Venting system:&nbsp;The venting system provides a way for air and gases to escape from the mold during the injection process. This system consists of various channels, pins, and grooves that allow air to escape, but are small enough to keep plastic inside.</li><li>Guides: The guides of the mold are a series of bushings, sleeves, and guiding pins on the two halves of the mold that help with alignment and assembly.</li></ul><h2 data-counter-attr="value6">What is Injection Mold Life Expectancy?</h2>The life expectancy of an injection mold is determined by the number of molding cycles it can perform, with each cycle consisting of the mold opening and closing. Several factors influence this lifespan, including the mold class, operating conditions, environment, maintenance practices, and the materials used.The Society of the Plastics Industry (SPI) categorizes injection molds into five distinct classes, which are independent of the mold cavity classification. Each class is characterized by specific criteria defined by the SPI, ensuring standardized evaluation for mold life expectancy and suitability for various production volumes.The table below compares the 5 injection mold classes:<table><thead><tr><th>Mold Class</th><th>Cycles</th><th>Production Level</th><th>Uses</th><th>Investment</th></tr></thead><tbody><tr><td>Class 101 Mold</td><td>1 million or more</td><td>Extremely high</td><td>Ideal for high-volume production with fast cycles</td><td>Class 101 molds are the most expensive, crafted from top-tier materials</td></tr><tr><td>Class 102 Mold</td><td>Not exceeding 1 million</td><td>Medium to high</td><td>Suitable for parts requiring durable plastic materials and tight tolerances</td><td>Class 102 molds are quite expensive, made with high-quality materials</td></tr><tr><td>Class 103 Mold</td><td>Not exceeding 500,000</td><td>Medium</td><td>Commonly used for low to medium production runs</td><td>Class 103 molds are priced moderately, falling within average price ranges</td></tr><tr><td>Class 104 Mold</td><td>Not exceeding 100,000</td><td>Low</td><td>Best for limited runs with non-abrasive materials</td><td>Class 104 molds are lower in cost, suitable for limited to moderate production runs</td></tr><tr><td>Class 105 Mold</td><td>Not exceeding 500</td><td>Very low</td><td>Used primarily for prototyping</td><td>Class 105 molds are the least expensive, designed for producing a limited number of prototype parts</td></tr></tbody></table><h2 data-counter-attr="value7">Get Injection Molding Services for Your Next Project</h2>Choosing the right mold is just the beginning of the plastic manufacturing process. Once the mold type is selected based on your production needs and SPI classification, the next steps involve finalizing and validating your design. This includes reviewing the CAD file for any necessary adjustments, producing the T1 sample to test and verify the mold’s performance, and making any required modifications to ensure optimal part quality.After validating the mold, you can proceed with full-scale production, ensuring that all parameters are set correctly for consistent, high-quality output. Partnering with experienced manufacturers, like Xometry Europe, provides the <a href="https://xometry.eu/en/injection-moulding/">injection molding expertise</a> and <a href="https://xometry.pro/en-eu/articles/injection-moulding-eu/" target="_blank" rel="noreferrer noopener">resources</a> needed for successful and efficient production. Begin your injection molding project confidently by using our <a href="https://get.xometry.eu/?locale=en"></a><a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noreferrer noopener">Instant Quoting Engine</a> to get a free quote for your next project.

CNC machining can be used to manufacture metal injection molds

This article explores the different types of molds (design cavity, class) used in plastic injection molding, discussing their ideal applications, strengths, weaknesses and lifespan, and design tips for creating effective molds based on one's manufacturing needs.

Injection Molding Molds: Types, Lifespan and Design Tips

Even the smallest design flaw or mold imperfection can lead to big quality issues in injection molding—warping, sink marks, or weak structural integrity. High-quality parts require more than just a well-thought-out design; they demand a proactive approach to ensure manufacturability. This is where Mold Flow Analysis (MFA) steps in, providing critical insights to refine designs, reduce defects, and pave the way for efficient production.<h2 dir="ltr">What Is Mold Flow Analysis?</h2>Mold Flow Analysis is a simulation technique that predicts the flow of molten material within a mold cavity during injection molding. Using advanced software tools, it evaluates critical parameters such as flow patterns, cooling efficiency, pressure distribution, and potential defects like warping or sink marks. This process helps engineers optimize designs and material selection, significantly reducing the need for physical prototypes and minimizing risks during production.<h2 dir="ltr">When Should Mold Flow Analysis Be Used?</h2>For projects requiring precision or complex geometries, Mold Flow Analysis is highly recommended. It provides crucial insights to ensure the design is manufacturable, minimizes defects, and helps save time and costs in the long run. By identifying potential issues early, it reduces trial-and-error cycles, ensuring smoother production and better-quality parts.<h2 dir="ltr">How Mold Flow Analysis Supports Design for Manufacturability (DFM)</h2>Mold Flow Analysis plays a pivotal role in optimizing the design and manufacturing process by addressing potential challenges early. Here are keyways MFA contributes to&nbsp;Design for Manufacturability (DFM):<ul><li dir="ltr"><h3>Refining Gate Placement</h3></li></ul>Proper gate placement is critical for ensuring a smooth and consistent material flow within the mold. By simulating different gate positions, MFA identifies the optimal placement to minimize weld lines, air traps, and other flow-related defects. This not only improves part quality but also enhances the structural integrity and appearance of the final product. For example, poor gate placement can lead to uneven filling, which may weaken specific areas of the part or result in visible imperfections.<ul><li dir="ltr" style="font-weight: bold;">Balancing Material Distribution</li></ul>Mold Flow Analysis evaluates how material fills the mold cavity, identifying regions where uneven distribution might occur. If one section fills faster than another, it can lead to defects like overpacking or underfilling. MFA allows engineers to adjust runner and gate designs to balance the flow, ensuring the material is distributed evenly throughout the cavity. This step is essential for achieving consistent wall thickness, preventing sink marks, and reducing the risk of part failure under stress.<ul><li dir="ltr" style="font-weight: bold;">Improving Cooling Strategies</li></ul>The cooling phase is one of the most critical stages in injection molding, as uneven cooling can lead to warping or dimensional inaccuracies. MFA simulates cooling patterns, helping engineers design efficient cooling channels that ensure uniform temperature distribution. By reducing cooling-related defects, MFA not only enhances part quality but also shortens the overall cycle time, improving production efficiency and lowering costs.<ul><li dir="ltr" style="font-weight: bold;">Predicting Shrinkage and Warpage</li></ul>Different materials shrink at different rates during cooling, which can distort the final part dimensions. Mold Flow Analysis predicts these shrinkage patterns and highlights areas where warpage might occur. By accounting for these factors in the design phase, engineers can make necessary adjustments, such as altering the mold dimensions or modifying material choices, to ensure parts meet exact specifications.<ul><li dir="ltr" style="font-weight: bold;">Reducing Cycle Times</li></ul>By analyzing filling, packing, and cooling phases, MFA provides insights into optimizing the entire molding process. For instance, it can identify opportunities to speed up material flow without causing defects or to streamline cooling times by improving channel designs. These optimizations not only increase production speed but also lower manufacturing costs, making the process more efficient.By incorporating Mold Flow Analysis early in the design process, manufacturers can significantly enhance the manufacturability of their parts, ensuring smoother production, higher quality, and fewer delays caused by defects or design inefficiencies. This proactive approach is a key driver of successful injection molding projects.<h2 dir="ltr">RPWORLD: Comprehensive Injection Molding Solutions</h2>At RPWORLD, we go beyond Mold Flow Analysis to offer a full range of injection molding services tailored to your needs:<ul><li dir="ltr">Lead Times as Fast as 7 Days:&nbsp;Delivering production-ready parts quickly to accelerate your product to market.</li><li dir="ltr">100+ Material Options:&nbsp;From engineering-grade plastics to specialized materials such as medical-grade materials, food-grade materials and more, we provide flexibility to meet diverse application requirements.</li><li dir="ltr">In-House Mold Design &amp; Fabrication:&nbsp;Expertly designed molds to match your project specifications, reducing lead times and improving precision.</li><li dir="ltr">Rigorous Quality Assurance:&nbsp;Advanced inspection tools combining with stringent quality controls ensure every part meets exact specifications, from first article inspection to final quality checks.</li><li dir="ltr">Extensive Finishing Options:&nbsp;Choose from surface finishing, painting, texturing, and more to achieve the perfect part appearance and functionality.</li></ul><hr><h3 dir="ltr">Ready to Optimize Your Injection Molding Project?</h3>With over 20 years of experience, RPWORLD delivers customized manufacturing solutions from prototyping and production, helping you achieve consistent high-quality parts within fastest time, launching products to markets soon.<a href="https://www.rpworld.com/en/get-a-quote/">&nbsp;Contact Us</a> for a free consultation and discover how our advanced injection molding services, including Mold Flow Analysis, can bring your designs to life!

Mold Flow Analysis is a simulation technique that predicts the flow of molten material within a mold cavity during injection molding.

Unlocking Quality in Injection Molding: The Role of Mold Flow Analysis

<h3 id="isPasted">Why Choose Metal 3D Printing for Fixture Construction?</h3>Metal 3D printing transforms fixture construction by enabling customized, efficient, and precise solutions tailored to specific applications. Its ability to directly produce components from CAD designs overcomes the limitations of traditional manufacturing methods.Key Benefits Include:<ul><li>Design Flexibility: Additive manufacturing allows for the creation of intricate geometries and application-specific features that traditional methods often cannot achieve. Fixtures can be optimized for exact functionality, enhancing performance and reliability.</li><li>Time Efficiency: The streamlined process of designing and producing fixtures with 3D printing significantly reduces lead times. From concept to production, projects can be completed in days rather than weeks, allowing manufacturers to respond quickly to changing needs.</li><li>Material Savings: Unlike traditional subtractive manufacturing, 3D printing uses only the material required for the design, reducing waste and lowering material costs. This makes it a more sustainable and economical choice.</li><li>Cost-Effectiveness for Customization: 3D printing eliminates the need for tooling, making it ideal for low-volume or highly customized fixtures. Manufacturers can produce tailored solutions without incurring additional setup costs.</li><li>Improved Workflow: The ability to go directly from CAD data to production simplifies the manufacturing process, eliminating the need for extensive preparation or machining. This leads to faster execution and greater adaptability.</li><li>Durability and Strength: Metal 3D printing materials like stainless steel provide the robustness needed for demanding industrial environments, ensuring that fixtures can withstand rigorous use.</li></ul>

Metal 3D printing at Hoedtke metal solutions

Hoedtke metal solutions is using metal 3D printing to print fixture constructions. The video demonstrates how the use of additive manufacturing helps them to improve their processes and capacities. 

Fixture Construction

As the world struggles to reduce greenhouse gas emissions, researchers are seeking practical, economical ways to capture carbon dioxide and convert it into useful products, such as transportation fuels, chemical feedstocks, or even building materials. But so far, such attempts have struggled to reach economic viability.New research by engineers at MIT could lead to rapid improvements in a variety of electrochemical systems that are under development to convert carbon dioxide into a valuable commodity. The team developed a new design for the electrodes used in these systems, which increases the efficiency of the conversion process.The findings are reported today in the journal&nbsp;Nature Communications, in a paper by MIT doctoral student Simon Rufer, professor of mechanical engineering Kripa Varanasi, and three others.“The CO2 problem is a big challenge for our times, and we are using all kinds of levers to solve and address this problem,” Varanasi says. It will be essential to find practical ways of removing the gas, he says, either from sources such as power plant emissions, or straight out of the air or the oceans. But then, once the CO2 has been removed, it has to go somewhere.A wide variety of systems have been developed for converting that captured gas into a useful chemical product, Varanasi says. “It’s not that we can’t do it — we can do it. But the question is how can we make this efficient? How can we make this cost-effective?”In the new study, the team focused on the electrochemical conversion of CO2 to ethylene, a widely used chemical that can be made into a variety of plastics as well as fuels, and which today is made from petroleum. But the approach they developed could also be applied to producing other high-value chemical products as well, including methane, methanol, carbon monoxide, and others, the researchers say.Currently, ethylene sells for about $1,000 per ton, so the goal is to be able to meet or beat that price. The electrochemical process that converts CO2 into ethylene involves a water-based solution and a catalyst material, which come into contact along with an electric current in a device called a gas diffusion electrode.There are two competing characteristics of the gas diffusion electrode materials that affect their performance: They must be good electrical conductors so that the current that drives the process doesn’t get wasted through resistance heating, but they must also be “hydrophobic,” or water repelling, so the water-based electrolyte solution doesn’t leak through and interfere with the reactions taking place at the electrode surface.Unfortunately, it’s a tradeoff. Improving the conductivity reduces the hydrophobicity, and vice versa. Varanasi and his team set out to see if they could find a way around that conflict, and after many months of work, they did just that.The solution, devised by Rufer and Varanasi, is elegant in its simplicity. They used a plastic material, PTFE (essentially Teflon), that has been known to have good hydrophobic properties. However, PTFE’s lack of conductivity means that electrons must travel through a very thin catalyst layer, leading to significant voltage drop with distance. To overcome this limitation, the researchers wove a series of conductive copper wires through the very thin sheet of the PTFE.“This work really addressed this challenge, as we can now get both conductivity and hydrophobicity,” Varanasi says.Research on potential carbon conversion systems tends to be done on very small, lab-scale samples, typically less than 1-inch (2.5-centimeter) squares. To demonstrate the potential for scaling up, Varanasi’s team produced a sheet 10 times larger in area and demonstrated its effective performance.To get to that point, they had to do some basic tests that had apparently never been done before, running tests under identical conditions but using electrodes of different sizes to analyze the relationship between conductivity and electrode size. They found that conductivity dropped off dramatically with size, which would mean much more energy, and thus cost, would be needed to drive the reaction.“That’s exactly what we would expect, but it was something that nobody had really dedicatedly investigated before,” Rufer says. In addition, the larger sizes produced more unwanted chemical byproducts besides the intended ethylene.Real-world industrial applications would require electrodes that are perhaps 100 times larger than the lab versions, so adding the conductive wires will be necessary for making such systems practical, the researchers say. They also developed a model which captures the spatial variability in voltage and product distribution on electrodes due to ohmic losses. The model along with the experimental data they collected enabled them to calculate the optimal spacing for conductive wires to counteract the drop off in conductivity.In effect, by weaving the wire through the material, the material is divided into smaller subsections determined by the spacing of the wires. “We split it into a bunch of little subsegments, each of which is effectively a smaller electrode,” Rufer says. “And as we’ve seen, small electrodes can work really well.”Because the copper wire is so much more conductive than the PTFE material, it acts as a kind of superhighway for electrons passing through, bridging the areas where they are confined to the substrate and face greater resistance.To demonstrate that their system is robust, the researchers ran a test electrode for 75 hours continuously, with little change in performance. Overall, Rufer says, their system “is the first PTFE-based electrode which has gone beyond the lab scale on the order of 5 centimeters or smaller. It’s the first work that has progressed into a much larger scale and has done so without sacrificing efficiency.”The weaving process for incorporating the wire can be easily integrated into existing manufacturing processes, even in a large-scale roll-to-roll process, he adds.“Our approach is very powerful because it doesn’t have anything to do with the actual catalyst being used,” Rufer says. “You can sew this micrometric copper wire into any gas diffusion electrode you want, independent of catalyst morphology or chemistry. So, this approach can be used to scale anybody’s electrode.”“Given that we will need to process gigatons of CO2 annually to combat the CO2 challenge, we really need to think about solutions that can scale,” Varanasi says. “Starting with this mindset enables us to identify critical bottlenecks and develop innovative approaches that can make a meaningful impact in solving the problem. Our hierarchically conductive electrode is a result of such thinking.”The research team included MIT graduate students Michael Nitzsche and Sanjay Garimella, &nbsp;as well as Jack Lake PhD ’23. The work was supported by Shell, through the MIT Energy Initiative.This work was carried out, in part, through the use of MIT.nano facilities.

A conceptual schematic of the new woven electrode design. Researchers wove a series of conductive copper wires (the brown-orange pipe) through a very thin membrane to reach the catalyst. Image: Courtesy of the researchers, edited by MIT News

A new electrode design boosts the efficiency of electrochemical reactions that turn carbon dioxide into ethylene and other products.

Engineers make converting CO2 into useful products more practical

The Challenge: Simplifying Data Integration in Complex Manufacturing Environments<a href="https://www.techgest.it/?origin=arduino" target="_blank">Techgest</a> is a leader in ERP integration and software development, delivering custom solutions to a wide range of clients – from mechanical manufacturing to fashion. One consistent challenge they noticed across all industries is managing the massive volumes of data generated by industrial operations. Therefore, the company set out to develop an affordable, highly adaptable IO device that could facilitate seamless data integration with their <a href="https://www.techtree.it/?origin=arduino" target="_blank">TechTree MES platform</a>, while also enabling real-time monitoring and efficiency improvements.&nbsp;The result is TechIO, a device that can be implemented quickly and works across a range of equipment, independent of third-party platforms, to enable seamless integration of production data with their proprietary MES and WMS platform.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731940123834-tecnico-quadro.jpg" style="width: 100%px;" class="fr-fic fr-dib">&nbsp;A Flexible, Open-Source Solution for Data AcquisitionTo meet these goals, Techgest turned to the <a href="https://www.arduino.cc/pro/portenta-machine-control" target="_blank">Arduino Portenta Machine Control</a>. This powerful, open-source control unit provided the flexibility needed to develop a custom IO device with full API support, allowing clients to integrate even legacy production machines into TechTree. Its customizability and cost-effectiveness enabled Techgest to implement TechIO swiftly, keeping costs under control while avoiding the limitations of vendor-specific solutions.According to Stefano Girardi, CEO of Techgest, “We evaluated various standard IO interfaces but found them lacking in terms of power and customization. We needed a solution that would allow us to build our own system exactly as imagined, without vendor lock-in.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731940167352-PMC.jpg" style="width: 100%px;" class="fr-fic fr-dib">Benefits of TechIO for ManufacturersTechIO enables manufacturers to leverage the real-time capabilities of the TechTree platform. Clients can now monitor production processes in real time, improve energy management, and enhance quality control KPIs, all without expensive retrofitting. One customer shared that the cost savings from energy efficiency alone helped them justify an investment of approximately €1 million in just 18 months, making TechIO a smart solution for boosting both operational and financial efficiency.&nbsp;Curious to find out more?&nbsp;Read the&nbsp;<a href="https://www.arduino.cc/pro/case-studies-techgest" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta Machine Control brings Industry 4.0 within reach for any manufacturer.

By utilizing the Arduino Portenta Machine Control, Techgest helped manufacturing clients improve real-time monitoring, energy efficiency, and production optimization – all without vendor lock-in or costly retrofits. 

Techgest Unlocks Industry 4.0 for Manufacturers with Smart ERP Integration

The Challenge: Optimizing Real-Time Quality Testing<a href="https://www.snaptron.com/" target="_blank">Snaptron</a>, a leading manufacturer of tactile dome switches used across industries from aerospace to medical, originally developed the Sapphire Force Testing Machine to ensure rigorous quality control. However, as technology advanced, their Director of Engineering, Kevin Albertsen, recognized the need for an upgrade. Their existing setup, which used stacked PC/104 cards on a single-board computer, was complex and costly, lacking the efficiency needed for real-time data analysis.Snaptron’s goal was clear: streamline the system to reduce expenses and increase processing speed, providing a high-quality solution without a hefty price tag.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731939443698-Sapphire_lo.jpg" style="width: 100%px;" class="fr-fic fr-dib">A Simple, Cost-Effective Solution: The Portenta H7 Lite&nbsp;Snaptron chose the <a href="https://www.arduino.cc/pro/hardware-product-portenta-h7/" target="_blank">Portenta H7 Lite</a> to upgrade the Sapphire machine. The board’s versatility allowed for rapid prototyping and iteration, reducing development time significantly. With seamless data transfer via USB and straightforward integration of digital and analog connections, Snaptron could simplify in-house PCB assembly and low-volume production.Albertsen noted the benefit of Arduino’s extensive library support and open-source resources, which accelerated the prototyping phase, freeing up resources for other projects. The Portenta H7 Lite’s cost-effectiveness also helped Snaptron manage their budget, allowing for further improvements to their system.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731939463624-ABX00045_05.unbox.jpg" style="width: 100%px;" class="fr-fic fr-dib">Expanding Market Opportunities with a New Product LineWhat began as an internal solution for quality control quickly revealed market potential. Snaptron discovered that customers also needed a similar force-displacement switch tester, prompting them to develop a commercial product based on the upgraded Sapphire. This new offering has since opened up a fresh revenue stream, showcasing how rapid prototyping can lead to unexpected opportunities.&nbsp;Curious to find out more?&nbsp;Read the&nbsp;<a href="https://www.arduino.cc/pro/case-studies-snaptron" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta H7 Lite provides an efficient and cost-effective solution for quality testing.

Snaptron optimized their quality testing machine, Sapphire, to enable faster data processing and lower costs. Leveraging Arduino’s Portenta H7 Lite, they not only improved in-house quality control but also opened up a new market segment for force-displacement testing solutions. 

Snaptron Streamlines Quality Testing with Efficient Prototyping

The 23rd edition of the Precision Fair, held at Brabanthallen in 's-Hertogenbosch, has once again positioned itself as the pinnacle event for the high and ultra-precision technology sectors. This year,&nbsp;375 exhibitors&nbsp;and experts from international companies, research institutions, and academia gathered to push the boundaries of precision engineering. The event was enriched with 50 inspirational sessions delivered by industry leaders and innovators, encompassing a diverse range of topics from mechatronic systems to micro processing and motion.The fair not only facilitated a networking arena for professionals but also hosted the prestigious DSPE awards, celebrating significant achievements in the field. Additionally, this year marked the introduction of the International Precision Conference, further highlighting the event’s dedication to fostering global collaboration in pursuing technological advancements.By bringing together the best of industry and academia, the Precision Fair continues to be a critical hub for sharing knowledge and shaping the future of precision technology.Wevolver attended the fair and spoke with a few of the innovative exhibitors.&nbsp;<h2 dir="ltr">Hexagon: Enhancing Engineering Processes&nbsp;</h2>At the Precision Fair, Hexagon showcased its comprehensive approach to streamlining product development and manufacturing processes with advanced hardware and software solutions. Faruk Pehlivan, representing Hexagon, extended an invitation to their upcoming event,<a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven">&nbsp;Hexagon LIVE Eindhoven</a>, highlighting their commitment to technological innovation.Hexagon's solutions facilitate various stages of product development, from CFD analysis to optimise design functionality to G-code preparation for precise manufacturing execution. The standout at the event was their new MarvellScan, an optical scanning device designed for detailed quality checks and reverse engineering. This scanner is distinguished by its autonomous control, flexible movement capabilities, and wireless functionality, making it ideal for ensuring product quality directly against CAD models and enhancing legacy parts through reverse engineering.These innovations underscore Hexagon's leadership in integrating technology that enhances production efficiency and product reliability, setting a high standard for quality assurance in manufacturing.<a href="https://www.wevolver.com/article/harnessing-manufacturing-intelligence-to-enhance-operational-excellence-in-aerospace">Read more about Hexagon here.&nbsp;</a><h2 dir="ltr">Muon Group: Creating microstructures in glass</h2>Muon Group, through its member LouwersHanique, showcased its cutting-edge technology for creating microstructures in glass at the Precision Fair. Their process involves a two-step method using femtosecond laser technology. Initially, the glass is precisely modified by the laser, which changes its internal structure. This modification is followed by wet chemical etching, selectively removing the altered glass to create intricate 3D microstructures.This technique achieves remarkable precision, allowing for features as small as 1 µm, with tolerances and surface smoothness ideal for specialised industrial applications. Muon Group’s process supports various glass materials like fused silica, sapphire, and borosilicate, catering to a wide range of industries requiring high-precision glass components. Their full suite of capabilities includes not only microfabrication but also complementary services such as optical assembly, CNC milling, and cleanroom packaging, underscoring their comprehensive approach to high-tech glass manufacturing.<h2 dir="ltr">Versatile, agile and efficient: Maxon's SCARA Robotics Innovations at the Precision Fair</h2>Maxon showcased its innovative solutions for SCARA robots at the Precision Fair, featuring a holistic approach that optimises robotic motion and design for enhanced efficiency. Representatives Francis De Wilde and Mark van Zutphen introduced a full setup including a driver and a hollow-axis motor which allows for efficient cable management and increased space-saving on production lines. Their specialised programming facilitates dynamic flipping motions between work areas, improving pick-and-place operations. Maxon's focus on compact design and powerful performance optimises the use of space and resources in industrial settings, with future goals aimed at increasing the versatility and speed of robotic arms.&nbsp;<h2 dir="ltr">New era in precise inspection launched by ZEISS</h2>ZEISS launched the O-INSPECT Duo at the Precision Fair, introducing a large-scale measuring machine capable of inspecting items like circuit boards and batteries with optical, tactile, and microscopic methods. This innovation addresses the challenges of measuring large objects without cutting them, offering rapid and precise analysis. The system utilises ZEISS's established metrology and analysis software, and was showcased with demonstrations at the event, underscoring its potential to streamline quality control processes in manufacturing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731678709332-ZEISS-lanceert-nieuwe-O-INSPECT.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr">Innovative Duo Wins Prestigious Wim van der Hoek Award at Precision Fair</h2>The Wim van der Hoek Award, also known as the Constructors Award, was presented during the 22nd Precision Fair. For the first time, the award was given to a duo, Marc Slob and Youp Verbakel, for their innovative design of a machine for automatic assembly of shovels and spades. Their project, which originated from Avans University of Applied Sciences, excelled in terms of design freedom, cost considerations, and production reliability, earning them this prestigious accolade in mechanical engineering design.For more details, you can visit the<a href="https://www.dspe.nl/awards/wim-van-der-hoek-award/">&nbsp;DSPE website</a>.<h2 dir="ltr" id="isPasted">Liquid hydrogen-powered retrofit aircraft wins Young Talent Award</h2>On the inaugural day of the fair, student teams from the nation's top three technical universities competed in the Young Talent Pitch Award, presenting their innovative projects to a panel. The entries included diverse technologies ranging from autonomous racing cars and electric motors to hydrogen-fueled aircraft, a rover designed for the South Pole, and an actual rocket. The competition, which judged entries based on their technical feasibility, social impact, and creativity, concluded with Team Aero Delft claiming the top spot, followed by DARE - Stratos V from Delft in second place.Aero Delft is pioneering a transformative approach in aviation with its development of a liquid hydrogen-powered retrofit aircraft. The team is committed to advancing hydrogen propulsion technologies, planning a shift from gaseous to liquid hydrogen to drastically reduce aviation emissions. The jury lauded Aero Delft for their project's technical feasibility and innovative approach, highlighting it as a significant stride towards sustainable aviation. Koen Pijnacker's compelling pitch further solidified their standout status in the competition.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731678583425-54141210051_2ddebb5594_c.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">Looking Ahead to 2025 and beyond</h2>The fair not only provided a platform for these technological showcases but also set the stage for future collaborations and innovations. Each presentation underscored the industry's focus on enhancing precision and efficiency, driving the boundaries of what's possible in technology and manufacturing.The next edition will take place on 12th&nbsp;and 13th&nbsp;November 2025.&nbsp;For more details on the event and future plans, visit<a href="https://mikrocentrum.nl/en/precision-technology/overview-precision-fair/">&nbsp;Mikrocentrum's Precision Fair</a>.

The 23rd Precision Fair showcased innovations like Hexagon's MarvellScan and Maxon's SCARA robots, with Aero Delft winning the Young Talent Pitch for their hydrogen aircraft.


Precision in Practice: Highlights from the 23rd Precision Fair

<h2 id="isPasted">Understand the Future of Metal 3D Printing</h2>The Metal 3D Printing Technology Report is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMzODI4MzY0NTM2LTUgUmlzaW5nIFRyZW5kcyBmb3IgQUkgQWRvcHRpb24gaW4gTWFudWZhY3R1cmluZyAoMTkyMCB4IDUwMCBweCkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"> <iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp; </iframe>Read an excerpt from <a href="https://www.wevolver.com/draft/article/chapter-1-core-metal-3d-printing-technologies" id="isPasted">chapter 1</a> here or download the full report.&nbsp;<h2 dir="ltr" id="isPasted">Metal 3D Printing Materials&nbsp;</h2>The metal additive manufacturing materials market spans several metal grades and a handful of material feedstock types, accommodating the different printing technologies outlined in the previous chapter. The main metal feedstock type by some distance is powder, which is used in key technologies such as LPBF, some forms of DED, and binder jetting. Other feedstock types include metal wire, which is used in some forms of DED, and bound metal filament, which is used in metal extrusion technologies. Around 600 tons of additive manufacturing feedstock are consumed annually in powder, rod, or other forms.<h3 dir="ltr">Powders</h3>Metal powders make up the majority of metal 3D printing materials. They are used in key processes—like LPBF, electron beam melting, DED, and binder jetting— and span many metals, grades, and alloys.&nbsp;Common metal powders include:<ul><li dir="ltr">Aluminum alloys&nbsp;</li><li dir="ltr">Cobalt chromium alloys</li><li dir="ltr">Copper alloys</li><li dir="ltr">Nickel alloys&nbsp;</li><li dir="ltr">Steels<ul><li dir="ltr">Stainless steels&nbsp;</li><li dir="ltr">Tool steels&nbsp;</li><li dir="ltr">Case hardening steels</li></ul></li><li dir="ltr">Titanium alloys</li></ul>To ensure successful printing, metal powders must have good flow properties, a small range of particle sizes, and reasonably consistent particle shape, with spherical powders capable of the highest performance. Powders are usually developed for a specific printing process. Particle sizes for LPBF powders measure around 10–60 microns, while those for electron beam melting measure 60–105 microns. Binder jetting can benefit from finer particles.Powders for metal additive manufacturing are most often produced via gas atomization. In this process, molten metal is forced through a nozzle before a stream of inert gas breaks it up into small, solid, spherical particles. An alternative production process is plasma atomization. In this process, wire feedstock is melted with a plasma torch, creating spherical particles. Plasma atomization is the superior process for producing highly spherical particles but is more expensive than gas atomization. It is typically used for high-value metals and applications.Many companies manufacture metal powders for 3D printing. The largest of these have previously been active in powder metallurgy prior to the rise in metal 3D printing seen in the last two decades.&nbsp;Leading powder producers include:<ul><li dir="ltr">GKN Powder Metallurgy:&nbsp;Part of the UK’s Dowlais Group plc. Produces most types of metal powder, for LPBF, DED, and binder jetting. Also makes dual-phase and custom alloys for additive manufacturing.</li><li dir="ltr">Höganäs AB: The world’s largest producer of metal powders, based in Sweden. Uses gas atomization to produce a large portfolio of powders for LPBF, EBM, DED, binder jetting, and cold spray. Also develops custom powders.</li><li dir="ltr">Sandvik AB: A multinational engineering company and major powder producer based in Sweden. Has been producing gas-atomized powders for 45 years in a range of particle sizes to suit different technologies.</li></ul>Metal powders for additive manufacturing require strict safety considerations. Fine particle sizes pose a risk as they can be easily inhaled. PPE is required during powder handling and machine operation, and care should be taken to prevent the spread of powder outside of dedicated operating space. Some powders (aluminum, titanium) pose a fire risk so prevention of electrostatic buildup should be established. Industrial additive manufacturing users may install an automated powder handling solution to prevent risk and maximize efficiency.<h3 dir="ltr" id="isPasted">Wire Feedstock</h3>Metal wire feedstock is less widely used than metal powders, as it is compatible with fewer processes. However, it is used with certain DED technologies, including Wire Arc Additive Manufacturing (WAAM) and Electron Beam Additive Manufacturing (EBAM) from Sciaky. Advantages of wire feedstock include simpler and safer material handling, lower cost, and reduced material waste, though resolution is limited. Wire may be produced using the wire rod reduction or metal strip forming processes.Common metal wire types include:<ul><li dir="ltr">Aluminum alloys&nbsp;</li><li dir="ltr">Cobalt chromium alloys</li><li dir="ltr">Copper alloys</li><li dir="ltr">Nickel alloys&nbsp;</li><li dir="ltr">Refractory metals<ul><li dir="ltr">Niobium</li><li dir="ltr">Tantalum</li><li dir="ltr">Tungsten</li></ul></li><li dir="ltr">Steels<ul><li dir="ltr">Stainless steels&nbsp;</li><li dir="ltr">Tool steels&nbsp;</li><li dir="ltr">Case hardening steels</li></ul></li><li dir="ltr">Titanium alloys</li></ul>In general, wire printing technologies can process ordinary welding wire feedstock. This means the material range for such technologies is slightly wider than powder processes. At present, refractory metals like tungsten are more readily available in wire feedstock than powder. However, although many machines support the processing of standard welding wire, several companies manufacture wire feedstock specially formulated for additive manufacturing.3D printing wire producers include:<ul><li dir="ltr">Alloy Wire International (AWI): British manufacturer of high-performance exotic alloys established in 1946.</li><li dir="ltr">Fortius Metals: Colorado-based specialist in welding wire for large-format 3D printing. Offers custom material development service.</li><li dir="ltr">WAAM3D Ltd.: A leader in WAAM hardware and materials based in the UK. Its wire feedstock includes five aluminum alloys in 1.2 mm diameter.</li></ul>Wire requires fewer safety considerations than metal powder, greatly reducing facility and labor costs, as there is no air particulate risk. In general, PPE is not required for wire material handling and vacuum cleanup after use is not necessary. Wire also poses minimal storage risks and has a long shelf life if kept in a relatively dry environment.<h3 dir="ltr">Bound Metal Feedstock</h3>Extrusion-style metal 3D printing systems can process bound metal materials, typically as filament or rod feedstock. These materials consist of metal powders encased within a wax and polymer matrix (binder) material that must be removed via thermal or chemical processing after printing. One of the most popular materials in this category, BASF Ultrafuse 316L, uses a 4:1 ratio of metal powder to binder. Such materials may be printed on specialist metal 3D printing hardware such as the Desktop Metal Studio System or on adapted FFF machinery normally used for printing thermoplastics, such as the UltiMaker Metal Expansion Kit, which makes it possible to process metal filaments on the UltiMaker S5 and S7 3D printers.Common bound metal materials include:<ul><li dir="ltr">Copper</li><li dir="ltr">Nickel alloy Inconel 625</li><li dir="ltr">17-4PH Stainless Steel</li><li dir="ltr">316L Stainless Steel</li><li dir="ltr">H13 Tool Steel</li><li dir="ltr">A2 Tool Steel</li><li dir="ltr">D2 Tool Steel</li><li dir="ltr">4140 Low-Alloy Steel</li><li dir="ltr">Ti64 Titanium</li></ul>Advantages of bound metal feedstock include simpler material handling, safety advantages, and compatibility with low-cost machinery. Disadvantages include a limited material selection and slower overall production times due to the speed of the extrusion process and the extensive post-processing required.&nbsp;<blockquote>“There is a need for more materials,” says Andre Gasperini, Product Manager at UltiMaker. “Limited material availability is one of the key challenges to enriching the range of applications for metal FFF and going to new markets.”</blockquote>Several companies make bound metal materials for 3D printing. These include manufacturers of extrusion 3D printing hardware such as Desktop Metal and Markforged, as well as larger material companies like BASF, whose Ultrafuse composite filaments have become an industry standard.Bound metal material producers include:<ul><li dir="ltr">BASF: The world’s leading chemical company, headquartered in Germany. Makes Ultrafuse 316L and Ultrafuse 17-4 PH stainless steel filaments for FFF printers.</li><li dir="ltr">Desktop Metal: Disruptive metal additive manufacturing company, recently acquired by Nano Dimension. Makes copper, nickel, low-alloy steel, stainless steel, tool steel, and titanium rods for extrusion.</li><li dir="ltr">Markforged: Close competitor of Desktop Metal in low-cost metal 3D printing. Makes copper, Inconel 625, stainless steel, and tool steel bound filaments for extrusion.</li></ul>In terms of safety and handling, bound metal feedstock has more in common with ordinary thermoplastic filament than fine particle metal powders. Most bound metal materials and their suitable systems can be used in non-laboratory environments with fewer PPE and storage requirements than powders.Read more excerpts of the report here:<a href="https://www.wevolver.com/article/metal-3d-printing-technology-report"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839532576-1733839532576.png" class="fr-fic fr-dii"></a> <a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839532604-1733839532604.png" class="fr-fic fr-dii"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839532588-1733839532588.png" class="fr-fic fr-dii"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839532596-1733839532596.png" class="fr-fic fr-dii"></a> Or download the full report below.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMzODI4MzgzMzI5LURPV05MT0FEIEJFTE9XLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> <iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp; </iframe>

The metal additive manufacturing market features various feedstock types, with powder being the dominant choice for LPBF, some DED methods, and binder jetting. Metal wire and bound metal filament are also used in specific technologies.

The Metal 3D Printing Technology Report: Chapter 2: Metal 3D Printing Materials

In manufacturing, the ability to quickly produce high-quality components on demand is critical. While metal 3D printing is often associated with producing unique, complex parts, its potential for serial production is frequently overlooked. This case study of the driver component for the <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">BOLDseries</a> by <a href="https://oneclickmetal.com" target="_blank" rel="noopener noreferrer">One Click Metal</a> demonstrates how metal additive manufacturing can effectively meet the challenge of producing components quickly and repeatedly, offering a viable alternative to traditional manufacturing methods that rely heavily on external suppliers.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731664133191-3.png" style="width: 508px;" class="fr-fic fr-dib">The Challenge: Quick and Frequent Production with Limited Supplier RelianceOne Click Metal faced a pressing need to produce a large quantity of driver components for their BOLDseries metal 3D printer. The driver is a key part responsible for opening and closing the powder-filled cartridges, and it needed to be produced with precision and durability. Traditionally, these parts would be manufactured through CNC machining, which, while reliable, comes with significant drawbacks—especially when rapid production is required. Outsourcing to suppliers often leads to long lead times, high costs, and the need to order in large quantities to make production cost-effective. This dependency on external suppliers can cause delays and hinder a company’s ability to respond quickly to demand. The Solution: Metal 3D Printing for Fast and Flexible ProductionTo address these challenges, One Click Metal turned to their in-house Laser Powder Bed Fusion technology. By utilizing metal 3D printing, they were able to produce the driver components much faster and with greater flexibility than traditional methods would allow. This approach eliminated the long lead times typically associated with external suppliers, allowing the company to quickly produce the parts they needed, when they needed them.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731664085880-2.png" style="width: 524px;" class="fr-fic fr-dib">A significant advantage of using metal 3D printing in this scenario was the ability to maximize production efficiency. By stacking 144 drivers on a single build plate, One Click Metal could produce a large batch of components in just over 60 hours. This capability not only met the immediate production needs but also reduced the cost per part to €11.05—a significant savings compared to traditional manufacturing costs. Benefits of Metal 3D Printing in Meeting Production Demands <ol><li data-list-indent="1" data-list-type="numbered">Rapid Production: Metal 3D printing enabled One Click Metal to produce a large number of components quickly, without the delays associated with traditional supply chains. This allowed the company to respond swiftly to production needs.</li><li data-list-indent="1" data-list-type="numbered">Cost Efficiency: By producing the parts in-house and utilizing the full build volume of the printer, the cost per driver was significantly reduced, making metal 3D printing a cost-effective option even for serial production.</li><li data-list-indent="1" data-list-type="numbered">Supply Chain Independence: With the ability to produce components on-demand, One Click Metal reduced its reliance on external suppliers, which is particularly beneficial when quick turnarounds are required.</li><li data-list-indent="1" data-list-type="numbered">Material and Design Efficiency: The LPBF process allowed for precise control over material usage, reducing waste and enabling the production of lightweight, optimized designs that still met all functional requirements.</li></ol> Conclusion: Metal 3D Printing as a Versatile Manufacturing ToolThe production of the driver component for the BOLDseries is a clear example of how metal 3D printing can be effectively used not only for unique, complex parts but also for the quick, repeated production of essential components. By leveraging this technology, manufacturers can gain greater control over their production processes, reduce dependency on suppliers, and achieve cost and time savings. Metal 3D printing proves to be a versatile tool that can meet a wide range of manufacturing needs, including those that require speed and flexibility.

In manufacturing, the ability to quickly produce high-quality components on demand is critical. While metal 3D printing is often associated with producing unique, complex parts, its potential for serial production is frequently overlooked.

Fast and Repeated Production with Metal 3D Printing

In <a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">traditional manufacturing</a> and <a href="https://xometry.eu/en/3d-printing/" target="_blank" rel="noreferrer noopener">additive manufacturing</a>, the design and production phases are often the main focus. However, end products, whether they are industrial machines or electronic devices, often require post-processing to enhance their appearance or durability characteristics.<a href="https://xometry.pro/en-eu/articles/post-processing-eu/">Post-processing</a> in traditional manufacturing includes machining, polishing, and coating to smooth surfaces, remove excess material, or apply protective finishes. Additive manufacturing employs specific methods like support removal, surface smoothing, spray painting, and curing. For instance, resin 3D prints require UV light or heat post-curing to solidify and enhance their mechanical properties.But what impact does post-processing have on the dimensional accuracy of parts? Will the part expand or contract? These are critical questions to consider when creating a 3D model to ensure that the part meets design specifications, functions correctly, and fits together seamlessly.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731520083327-vapor-smoothed-part-accuracy-1536x1152.webp" style="width: 100%px;" class="fr-fic fr-dib">Measuring the accuracy of a vapor-smoothed 3D-printed part using a digital caliper.<h2 data-counter-attr="value0" id="isPasted">Common Post-Processing Techniques in Manufacturing</h2>In designing, post-processing is important since it enhances part aesthetics as well as functionality. This also implies that it affects dimensional accuracy. There are several typical post-processing methods which are employed in CNC machining, sheet metal fabrication, and 3D printing:<ul><li>Bead blasting: This technique uses a high-pressure stream of small beads, often made from glass or plastic, directed at the surface of the part, removing any faults it has and making it even all over. The process can smooth sharp edges slightly, thereby possibly changing key dimensions, particularly where intricate detail abounds.</li><li>Electropolishing: This is an electrochemical method that removes very thin layers from steel, ensuring shiny surfaces after cleaning. However, the removal process produces bluntness, and results in minimal adjustments to fit precision requirements due to dimension changes.</li><li>Vapor smoothing: Vapor smoothing involves bringing objects created from 3D printing in contact with chemical vapors, resulting in melting and regulating the outer surfaces. This process may alter small features and round off sharp edges, particularly for finely detailed parts.</li><li>Media tumbling:&nbsp;In addition to burr removal, media tumbling also polishes surfaces through placing them into vibratory containers fitted with abrasive media. This process is not suitable for fragile part features like sharp edges.</li><li>Sandblasting: Sandblasting uses high-speed particles for cleaning surfaces as well as texturing prior to painting or other treatments.</li><li>Powder coating: Here, dry powders are applied electrostatically onto an object that will then be heated to cure the coat into a long-lasting one. However, the process increases dimensions slightly and may cause trouble in fitting tight components together.</li><li>Plating: Plating involves depositing a metallic coating onto a surface to enhance electrical conductivity, wear resistance, and corrosion protection.</li><li>Anodizing: Anodizing, which comes in different types (Type II and Type III being the most commonly used), is an electrochemical process used for increasing the oxide layer on metal surfaces.</li><li>Passivation: This is the process by which stainless steel parts are treated to remove free iron and obtain better resistance to corrosion through the formation of a protective oxide layer.</li><li>Spray painting: This process is used to apply paint to parts for aesthetics and protection, potentially altering dimensions slightly.</li></ul><section>Some post-processing methods can be combined for enhanced results, such as vapor smoothing followed by spray painting to achieve a smooth, colored surface, or sandblasting followed by anodizing for a matte, corrosion-resistant finish.<h2 data-counter-attr="value1" id="isPasted">How Different Post-processing Techniques Impact Dimensional Accuracy</h2>When considering post-processing for parts, it is important to understand how each technique impacts both dimensional accuracy and surface finish. The table below compares different post-processing methods (all available on <a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noreferrer noopener">Xometry’s Instant Quoting Engine®</a>), including their effects on the material’s dimensional accuracy and the typical surface finish you can expect.<table><thead><tr><th>Technique</th><th>Dimensional Change</th><th>Surface Finish</th><th>Typical Applications</th><th>Materials They Work With</th></tr></thead><tbody><tr><td>Bead Blasting</td><td>Negligible&nbsp;</td><td>Matte/satin, grainy</td><td>Aesthetic finishing, surface preparation for coatings</td><td>Metals, plastics, composites</td></tr><tr><td>Electropolishing</td><td>Slight reduction (0.00635 mm)</td><td>Bright, smooth</td><td>Improving corrosion resistance and smoothing out micro-peaks and valleys</td><td>Stainless steel, aluminium, copper</td></tr><tr><td>Vapor Smoothing</td><td>Minor reduction (~0.023 mm)</td><td>Glossy, smooth</td><td>Enhancing surface quality of 3D printed parts</td><td>Thermoplastics</td></tr><tr><td>Media Tumbling</td><td>Negligible</td><td>Satin-like finish</td><td>Parts with smoothed surface</td><td>Metals, plastics</td></tr><tr><td>Sand Blasting</td><td>Slight reduction (~0.005–0.025 mm)</td><td>Dull finish</td><td>Surface preparation for paint</td><td>Metals, plastics</td></tr><tr><td>Powder Coating</td><td>Addition (~0.02–0.05 mm)</td><td>Matte or glossy, colored</td><td>Wear-resistant parts, aesthetics</td><td>Metals, plastics</td></tr><tr><td>Plating</td><td>Addition (~0.005–0.025 mm)</td><td>Metallic finish</td><td>Electrical components, wear-resistant parts</td><td>Metals (e.g., copper, nickel)</td></tr><tr><td>Passivation</td><td>Negligible</td><td>Matte, enhanced resistance</td><td>Aesthetic enhancements, surface protection</td><td>Stainless steel</td></tr><tr><td>Spray Painting</td><td>Addition (~0.02–0.1 mm)</td><td>Smooth, colored</td><td>Surface enhancement and protection&nbsp;</td><td>Metals, plastics</td></tr><tr><td>Anodizing (Type II)</td><td>Addition (~0.0025 mm)</td><td>Matte or glossy, colored</td><td>Corrosion resistance, durable parts</td><td>Aluminium</td></tr><tr><td>Anodizing (Type III)</td><td>Addition (~0.025 mm)</td><td>Matte or slightly rough, colored</td><td>High-wear applications, mechanical components, corrosion resistance, &nbsp;durable parts</td><td>Aluminium</td></tr><tr><td>Spray painting and vapor polishing</td><td>Addition (~0.012–0.25 mm); slight reduction (negligible)</td><td>Smooth, colored; Glossy, smooth</td><td>Combining surface enhancement/protection and quality improvement for 3D printed parts</td><td>Thermoplastic</td></tr><tr><td>Sand blasting and anodizing</td><td>Negligible reduction (~0.0025–0.025 mm)</td><td>Matte or satin, grainy; Matte or glossy, colored</td><td>Surface preparation and protection for aluminium parts</td><td>Aluminum</td></tr></tbody></table><h2 data-counter-attr="value2">Regulations and Standards for Maintaining Dimensional Accuracy During Post-processing</h2>Here is a brief overview of standards related to dimensional accuracy maintenance during post-processing commonly used in Europe, the UK and Turkey:<table><thead><tr><th>Standard</th><th>Usage</th><th>Objective</th><th>Example of Application</th></tr></thead><tbody><tr><td><a href="https://www.iso.org/standard/7748.html" target="_blank" rel="noopener">ISO 2768</a></td><td>Establishes general tolerances for linear dimensions, angular dimensions, and geometrical tolerances in unassociated metal parts</td><td>Ensures consistency in size throughout different manufacturing processes and post-production stages</td><td>Indicating medium tolerances for a CNC-machined metal shaft with a 50 mm diameter as “ISO 2768-m” on the drawing</td></tr><tr><td><a href="https://www.iso.org/standard/66777.html" target="_blank" rel="noopener">ISO 1101</a></td><td>Sets permissible limits for variations in part geometry, focusing on form and position tolerances</td><td>Ensures components meet geometric standards despite dimensional changes during finishing operations</td><td>Specifying perpendicularity: ⊥ 0.1 ISO 1101 for a hole to remain within a 0.1 mm tolerance zone relative to a given datum plane</td></tr><tr><td><a href="https://www.gdandtbasics.com/asme-y14-5-gdt-standard/" target="_blank" rel="noopener">ASME Y14.5</a></td><td>Describes how GD&amp;T symbols specify allowable variations in sizes and shapes of parts using controls such as position control</td><td>Ensures uniformity and high accuracy during and after manufacturing</td><td>Using positional tolerance symbol on the drawing:&nbsp;Position: Ⓟ 0.2 | ⌀10 | A B C*</td></tr><tr><td><a href="https://www.astm.org/d0618-21.html" target="_blank" rel="noopener">ASTM D618</a></td><td>Describes the practice for conditioning plastics for testing purposes after molding to test for thermal or chemical smoothing effects</td><td>Ensures dimensional accuracy by conditioning samples for equilibrium before further operations</td><td>Conditioning plastic samples for 48 hours at 50°C, then 96 hours at 23°C with 50% relative humidity before chemical smoothing</td></tr></tbody></table>*The center of the hole must fall within a zone of 0.2mm diameter about datums ‘A,’ ‘B,’ and ‘C’ so that accurate assembly can be achieved during post-processing.<h2 data-counter-attr="value3">Tools and Technology for Monitoring and Controlling Dimensional Changes</h2>Monitoring/controlling dimensional changes during post-processing requires accurate tools/technologies. Some key solutions include:<ul><li>Coordinate Measuring Machines (CMMs): These machines use a probe to accurately measure the physical shapes of an object. They are useful for checking measurements as well as detecting any deviation from design specifications. They excel in precision, often achieving measurements within micrometers (0.001 mm), far surpassing the typical accuracy of digital calipers, which is around 0.01 mm.</li><li>Laser scanners: Laser scanners provide non-contact measurement. They generate high-resolution 3D models of parts that are then compared to CAD designs to ascertain any dimensional change.</li><li>Optical comparators: These devices project the profile of a part onto a screen and allow for visual comparison against pre-set standards. They are most useful in monitoring dimensional changes in small and intricate parts.</li><li>Digital calipers and micrometers: For fast, accurate measurements, digital calipers and micrometers provide excellent accuracy when it comes to measuring lengths or thicknesses, which is imperative for quality control.</li><li>Surface roughness testers: These determine surface finish quality by identifying changes that would affect dimensional accuracy resulting from practices like sanding or polishing through post-processing.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731520160516-engineer-using-cmm-measuring-3d-printed-part-close-up-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Engineer inspecting a part using a coordinate measuring machine (CMM) for dimensional accuracy<h2 data-counter-attr="value4" id="isPasted">How to Reflect Tolerances on Technical Drawings</h2><ul><li>To reflect the finishing processes, such as anodizing, on technical drawings, it is necessary to indicate post-treatment tolerances for any specific customer requirement (e.g. hard anodizing 50µm).&nbsp;</li><li>Clearly specify on the drawing that tolerances on the drawing are&nbsp;post-treatment.</li><li>For thin treatments (&lt;10 µm), final tolerances can often be assured. For any treatments thicker than 10 µm, it is recommended to mask certain surfaces to prevent unpredictable dimensional changes post-treatment (e.g. mask threaded holes to ensure they remain within tolerance and functional after a thick anodizing layer is applied).</li><li>Add any surface finish symbols (roughness) and specific tolerances (linear or geometric) that will ensure the part meets its functional requirements.</li></ul></section>

This article will discuss the different post-processing methods and their impact on dimensional accuracy, helping you navigate potential challenges and ensuring your designs achieve the precision and quality they require.

Impact of Post-Processing on Dimensional Accuracy of Parts

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3>The Metal 3D Printing Technology Report is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730910790125-Mitsubishi+Chemical+Group++Growth+Garage++Open+Innovation+Program+%289%29.png" style="width: 100%px;" class="fr-fic fr-dib"><h4>Why Read This Report?</h4>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:<ul><li>Materials &amp; Post-Processing – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li>Industry Applications – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li>Future Trends – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.<h4>Get Inspired by Real-World Successes</h4>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.<h4>Download Now</h4>

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3>The Metal 3D Printing Technology Report is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733828027720-5+Rising+Trends+for+AI+Adoption+in+Manufacturing+%281920+x+500+px%29.png" style="width: 100%px;" class="fr-fic fr-dib"><h4><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; </iframe></h4><h2>Why Read This Report?</h2>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:<ul><li>Materials &amp; Post-Processing – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li>Industry Applications – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li>Future Trends – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.<h3>Get Inspired by Real-World Successes</h3>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.<hr><h2>Report introduction</h2>Metal 3D printing, also known as metal additive manufacturing (AM), is a production technology whose origins date back just three decades to 1994, when German company EOS GmbH launched a system based on its Direct Metal Laser Sintering (DMLS) technology1. Despite this short history (particularly compared to metal casting, which dates back thousands of years), metal AM has progressed significantly since its earliest iteration, with various new types of processes being developed, new materials and applications being validated, and consistent market growth. This growth—and the continued proliferation of metal AM technologies—is evident by simply looking at the number of metal AM systems sold from year to year. From 2022 to 2023, for instance, the shipment of metal AM systems grew by 24.4% (from 3,049 systems in 2022 to 3,793 systems in 2023). To put it into perspective, just ten years ago, the number of metal AM systems sold was barely over 5002.Amongst 3D printing users more generally, there has also been an increase in metal AM adoption, from 39% in 2019 to over 90% in 20233. This indicates how the technology has matured and offers a viable production method for a growing number of prototyping and production applications that benefit from the technology’s propensity for complex designs and small-volume production. While challenges to the broader adoption and implementation of metal AM still exist, efforts are being made across the industry to address these barriers through hardware, software, and materials advances as well as industry-wide cooperations.&nbsp;This report delves into the metal 3D printing market, whose estimated global value in 2023 was as high as $7.73 billion4, for a full spectrum view of the state of the industry. This report includes insights into the leading metal 3D printing processes available on the market today as well as metal AM materials. The report also highlights other vital steps in the AM process chain, including design and post-processing. The fifth chapter of the report covers metal 3D printing applications, with a focus on the three leading adopter industries: aerospace, medical, and automotive. The next two chapters comprise an analysis of the challenges and limitations facing the metal AM industry as well as the key trends that indicate where the future of the industry is headed. The report’s final chapter presents exclusive insights from three companies active in the metal AM space: manufacturing service Xometry, FFF 3D printing company UltiMaker, and software specialist Aibuild.<h3>Tess Boissonneault</h3>Report Editor-in-Chief<hr>Read an excerpt from the chapters here:<a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839362803-2.png" style="width: 100%px;" class="fr-fic fr-dib"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839370060-3.png" style="width: 100%px;" class="fr-fic fr-dib"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733839376300-4.png" style="width: 100%px;" class="fr-fic fr-dib"></a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733826746296-DOWNLOAD+BELOW.png" style="width: 100%px;" class="fr-fic fr-dib"> <iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 630px; border: none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; </iframe><h2>Acknowledgements:</h2>Thank you to contributing author Benedict O’Neill.&nbsp;Huge gratitude to the experts at UltiMaker, Xometry and AIBuild with who we consulted with on the texts.&nbsp;<h2>References:</h2>1. Singh A, Singh H. Metal additive manufacturing: from history to applications. InInnovations in Additive Manufacturing 2022 Jan 31 (pp. 3-32). Cham: Springer International Publishing.&nbsp;2. Wohlers Report 2024 [Internet]. Wohlers Associates; 2024. Available from: <a href="https://wohlersassociates.com/product/wr2024/">https://wohlersassociates.com/product/wr2024/</a>&nbsp;3. Jabil Unveils Findings of Global Survey on 3D Printing Technology Trends [Internet]. Jabil; July 27, 2023. Available from: <a href="https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx">https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx</a>&nbsp;4. Metal 3D Printing Market Size, Share &amp; Trends Analysis Report By Technology, By Software, By Component (Hardware, Software, and Services), By Application, By Printing Type, By Vertical, By Region, And Segment Forecasts, 2024 - 2030 [Internet]. Grandview Research; 2024. Available from: <a href="https://www.grandviewresearch.com/industry-analysis/metal-3d-printing-market">https://www.grandviewresearch.com/industry-analysis/metal-3d-printing-market</a>

Introduction

An engineer’s guide to understanding the state
of the art in metal 3D Printing

Metal 3D Printing Technology Report

Most large corporations are already heavily invested in automating their operations, but smaller manufacturing businesses usually face greater constraints on their budgets.&nbsp;It’s not beyond the power of SMEs to adopt automation technologies if you leverage cost-effective and intelligent strategies. You can enhance the efficiency and competitiveness of your SME by first identifying what you see as your greatest challenges. You should be clear about your objectives for implementing automation, such as downsizing your workforce, increasing output or just a general long-term reduction of costs.<h2 dir="ltr">How Can SMEs Implement Automation?</h2>Successful implementation of automation for small manufacturers starts with selecting the most appropriate technologies and equipment. You don’t need to be a large corporation to implement automated technology, as you can find equally good and cost-effective choices that will deliver major benefits. Plug-and-play technologies or turnkey options require little in the way of set-up and you don’t need skilled personnel to do it. You should research potential systems carefully, taking into account the vendors’ industry reputation and track record.<h3 dir="ltr">Inexpensive Automation Equipment</h3>Many smaller companies are put off the idea of automation because of the machinery costs, but it’s not always necessary to go for large and expensive items. You can make a significant impact on cost-effectiveness using only low-cost equipment like conveyor belts. These automate the movement of materials and finished products so they don’t need to be hand-carried. You can also integrate them with sensors so that you can sort items automatically, improving accuracy and minimising errors.Other low-cost automation tools worth consideration include automated packaging machines, which increase packaging consistency and reduce the amount of manual labour required. Automated sorting systems can help you achieve faster throughput, further reducing human error. These systems work by setting predefined criteria for sorting and categorising different items, which they do at speed and with great accuracy.Once you start to achieve efficiencies with low-cost automation tools, you can gradually begin to implement more advanced automated systems. These could be more expensive, but you can add components piecemeal as your budget permits. For instance, you don’t always need to replace your existing equipment with costly automated machinery. Instead, you might enhance a machine’s current capabilities with automated components, like robotic arms.You might consider investing in collaborative robots, or&nbsp;<a title="Cobots" href="https://www.rowse.co.uk/blog/post/7-manufacturing-ai-benefits" target="_blank" rel="noopener">cobots</a>, which work alongside your human employees. You can program them to carry out various tasks, with increased safety and efficiency. Cobots are a valuable automation tool that can be operated with minimal technical expertise. Another useful addition to your small manufacturing premises is automated guided vehicles (AGVs). You can program these machines to follow specific routes around the factory floor, where they interact with machinery. Autonomous transportation of materials offers seamless and more efficient material handling.<h3 dir="ltr">Manufacturing Execution Systems</h3>In addition to automation hardware, you can also gain valuable business insights by implementing smart sensors. You can analyse data in such areas as inventory management, process optimisation and predictive maintenance. Businesses of all sizes have adopted the marketing concept of&nbsp;<a title="Key Performance Indicators" href="https://www.rowse.co.uk/blog/post/smart-maintenance-guide" target="_blank" rel="noopener">Key Performance Indicators</a> (KPIs), which provide an excellent way to monitor your performance.&nbsp;Through KPIs, you can establish benchmarks to measure your current performance, which then helps to identify areas where implementing automation would offer improvements. Enterprise resource planning (ERP) systems can help you do this with easily installed and managed software. This can manage practically everything in your business operations.&nbsp;On its own or as part of an ERP software package, a manufacturing execution system (MES) module can help you set up and monitor your KPIs. You can track every product you manufacture and gather information about its performance through every stage of its progress. This means you can automate the monitoring and assessment of your production and identify areas for improvement.<h3 dir="ltr">Cloud-Based MRP Software</h3>ERP systems specifically designed for manufacturing are called manufacturing resource planning systems (MRP). These are useful and cost-effective tools if you’re intending to automate. You can choose a cloud-based system so that you don’t have to invest anything up front, making the first steps of automation an economically viable proposition.&nbsp;MRP software can go a long way towards automating your processes through meticulous production planning. It uses complex algorithms to monitor data such as current orders, available capacity and inventory levels to create a master production schedule. From this, optimised production schedules can be extrapolated, ensuring the most efficient use of resources. They’ll reduce idle time in processes and help eliminate production bottlenecks.&nbsp;With MRP software, you can easily automate processes for inventory and order tracking, as well as forward planning. Stock levels are easily monitored, from which you can forecast future material requirements. You’ll get alerts when stocks are low, so you can raise pre-filled purchase orders on demand, preventing both overstocking and stock-out situations. Your stoppages will be minimised, and you can free up cash that would otherwise be committed to unused inventory.&nbsp;Continuous updates and alerts give you instant visibility into the progress of any order. This improves the effectiveness of order tracking and management, reducing delays and ensuring your customers receive their deliveries with the minimum delay.<h2 dir="ltr">Why Small Manufacturers Should Embrace Automation</h2>Even small manufacturing businesses can benefit from implementing automation. If you’re worried about your budget, you can start small, adding inexpensive tools and gradually building up your capabilities. Automated devices and MRP software will help you reduce operational costs, improve your efficiency and allow you to remain competitive.&nbsp;Automated&nbsp;<a title="Reporting And Analytics" href="https://blog.isa.org/real-time-analytics-achieve-industrial-operational-excellence" target="_blank" rel="nofollow noopener">reporting and analytics</a> help to improve your manufacturing performance with real-time insights into dozens of automated processes. This means you’ll be able to assess things like overall equipment effectiveness (OEE) and be in a better position to make informed decisions. This will help you to achieve overall operational excellence.

Small and medium-sized enterprises (SMEs) hold a greater share of business in the manufacturing industry than most people realise. However, they may find it harder to keep up with the technological developments of Industry 4.0. 

How To Implement Automation For Small Manufacturers

Using technological tools can help you schedule machine maintenance in a predictive manner, which will help to improve the efficiency of your maintenance team.<a title="Preventive" href="https://www.rowse.co.uk/blog/post/what-is-predictive-maintenance" target="_blank" rel="noopener">Preventive, preventative or predictive maintenance</a> is the strategy by which you can reduce the chances of equipment failure and unplanned downtime. You can apply it across the whole facility, including machinery, electronic equipment and vehicles. Planning ahead will help you achieve greater long-term cost and energy efficiencies, so creating a preventive maintenance schedule to benefit your entire business strategy.<h2 dir="ltr">How To Create A Preventive Maintenance Schedule</h2>A preventive maintenance schedule is a detailed list of your equipment and repairable assets. It should set out the frequency of inspections and regular maintenance tasks you need to carry out to keep these items always in the best possible working order. Repair crews and technicians should be equipped with precise instructions to guide them through this process, with clear deadlines for its completion.You’ll need a maintenance manager or supervisor to monitor the schedule and keep an adequate stock of spare parts to cover possible repairs. They’ll also have to match up the maintenance requirements to the available resources at your facility. This includes matching the availability and skills of your team as closely as possible to each maintenance task.<h2 dir="ltr">Plan Or Schedule?</h2>You or your director of operations will usually be responsible for coordinating an overall preventive maintenance plan. This ensures that the goals of your maintenance team are aligned with your business goals, focusing on the bigger picture of what needs to be done.Your maintenance manager or supervisor will be in charge of the preventive maintenance schedule. This ensures the plan is successfully executed. The schedule concerns what work needs to be done, when, how often and by whom.To create a preventive maintenance schedule, follow these five main steps:<h3 dir="ltr">1. Inventory</h3>First, determine which of your assets need routine maintenance:<ul><li dir="ltr">Is an asset more prone to failure with age?</li><li dir="ltr">Could you prevent failures by regular inspection and maintenance?</li><li dir="ltr">Is this asset a critical factor in your business operation?</li></ul>Any asset answering yes to these points should be included on your inventory list, which can form an electronic catalogue or spreadsheet. Include full information on each item of inventory, such as the make, model and serial number, plus the asset’s location, maintenance history and necessary spare parts.&nbsp;<h3 dir="ltr">2. Prioritise</h3>If you have a substantial operation, it will take time to create preventive maintenance schedules for all your assets. This means strict prioritising so that you deal first with your most essential assets. You can do it systematically by calculating the levels of each asset’s risk, taking into account factors such as the likelihood of the risk being detected, the probable frequency of failures occurring and the potential severity of a failure. You can assign a numerical ‘weight’ to each factor by calculating its&nbsp;<a title="Risk Priority Number" href="https://www.6sigma.us/six-sigma-articles/risk-priority-number-rpn/" target="_blank" rel="nofollow noopener">Risk Priority Number</a>.<h3 dir="ltr">3. Establish Intervals</h3>Most of your assets are likely to require different intervals between scheduled maintenance – and there are different ways to deal with this. For some items, a floating time-based schedule will work best, but for others, a meter-based schedule is preferable. You should always refer to the manufacturing manual and previous maintenance data to determine what maintenance interval is appropriate for all items of equipment.<h4 dir="ltr">Time-Based Schedules</h4>Time-based schedules are calendar-based so that maintenance is performed according to set periods – e.g. every week, every month, etc. These can be further divided into fixed or floating time scheduling. Fixed is when you schedule maintenance after a set and unchanging period, ignoring variables such as whether the last maintenance was completed on time. Floating means that you schedule maintenance in direct relation to the last time it was performed.<h4 dir="ltr">Meter-Based Schedules</h4>Meter- or usage-based scheduling can be simpler, especially if your equipment is controlled by a PLC or other device. In this case, maintenance is triggered when the asset reaches a certain preset threshold, such as the number of production cycles performed or hours operated. It incorporates a certain amount of flexibility, to allow cycles to complete before undertaking maintenance.<h3 dir="ltr">4. Schedule Recurring Tasks</h3>Recurring tasks and inspections are important when establishing a preventive maintenance schedule, so plan carefully. You can do this on paper, on a computer spreadsheet or by using proprietary software, depending on the size of your operation and its maintenance requirements. Preventive maintenance software is the easiest because it allows you to set up the tasks, intervals and instructions for every item and then relax until you get an alert on your calendar.<h3 dir="ltr">5. Monitoring</h3>It’s essential to monitor your maintenance schedules regularly to ensure that each piece of equipment is properly maintained. You can assess the failure frequency to see if it’s dropping since you implemented the schedule. If you’re still experiencing frequent failures, the maintenance frequency may need adjusting. Alternatively, you may find that you need to scale back if routine maintenance is being performed too often.<a title="Metrics" href="https://servicechannel.com/blog/essential-maintenance-metrics/" target="_blank" rel="nofollow noopener">Some metrics</a> you can use to monitor your schedule include the Mean Time Between Failures, which should increase if your schedule is working effectively. Overall Equipment Effectiveness tracks the equipment’s availability, performance, and quality, while Planned Maintenance Percentage is a measure of lateness if a preventive maintenance task is overdue. This may indicate that you have insufficient maintenance staff or identify other deficiencies.&nbsp;<h2 dir="ltr">Why Creating A Preventive Maintenance Schedule Is Important</h2>A preventive maintenance schedule is vitally important in keeping your operations running smoothly and successfully. It will make your maintenance operations more systematic, providing your maintenance crews with guidance and structure, thus increasing overall team efficiency. You’ll reduce&nbsp;<a title="Downtime" href="https://www.rowse-automation.co.uk/blog/post/how-to-reduce-equipment-downtime" target="_blank" rel="noopener">unscheduled equipment downtime</a>, so preventive maintenance will extend your equipment’s lifespan. Creating an effective preventive maintenance schedule on any scale can deliver great benefits to your organisation.

Preventive maintenance is a key factor in the running of industrial facilities. While it’s always been sensible to inspect and check your equipment for faults and repairs, the advent of Industry 4.0 has made it a far more effective business practice

manufacturing systems

Profiles