ADDITIVE MANUFACTURING
Sandvik 3D created the world ’ s first 3D printed , all-metal , smash-proof guitar and challenged guitar virtuoso , Yngwie Malmsteen , to break it .
The strengths of additive manufacturing lie in those areas where conventional manufacturing reaches its limitations . The technology is of interest where a new approach to design and manufacturing is required to come up with solutions . It enables a design-driven manufacturing process - where design determines production and not the other way around .
Additive manufacturing allows for highly complex structures which can still be extremely light and stable . It provides a high degree of design freedom , the optimisation and integration of functional features , the manufacture of small batch sizes at reasonable unit costs and a high degree of product customisation , even in serial production .
But not all components are suitable for metal additive manufacturing . Additive manufacturing remains relatively costly , and many types of components are still produced more cost-effectively at scale with traditional , subtractive methods . Sandvik has produced a checklist for additive manufacturing ; if a component meets any of the criteria below , it told ISMR , it is likely to be a good candidate for printing .
■ Complex shape .
■ Expensive material .
■ Low weight is essential .
■ Revolutionary design .
■ Individual variations ( tailored ).
■ Spare-part ( to reduce lead-times , inventories and Net Working Capital ).
■ Potential to merge sub-parts into one component .
■ A need to reduce assembly time / increase productivity .
■ Smaller series .
Global AM market value
According to analyst , Persistence Market Research , the global additive manufacturing is expected to be worth US $ 25.9 billion in the year 2022 and will witness a catalytic CAGR of 21.6 % between 2022 and 2028 . It will reach US $ 83.5 billion by the year 2028 , said the analyst .
“ North America and Europe respectively hold more than 30 % of the market share . However , the developing economies are the ones worth watching in the upcoming period . Countries like India , Turkey and Brazil are
A 3D metal printer produces a steel part ; revolutionary additive technology for sintering metal parts .
being driven by customisation and on-demand production . Adopting additive manufacturing could result in reduction of time-to-market . The other countries helping in the rapid expansion of additive manufacturing market include Malaysia , Indonesia , South Africa and China ,” it said .
The increase in demand for additive manufacturing is attracting global players to include additive manufacturing in their product offerings . According to analyst Grand View Research , the global 3D printing market size was valued at US $ 13.78 billion in 2020 and is expected to expand at a compound annual growth rate ( CAGR ) of 21 % from 2021 to 2028 . Globally , 2.1 million units of 3D printers were shipped in 2020 and the shipments are expected to reach 15.3 million units by 2028 .
“ The aggressive R & D in three-dimensional printing ( 3DP ) and the growing demand for prototyping applications from various industry verticals ( particularly healthcare , automotive , aerospace and defence ) are expected to drive market growth ,” said the analyst .
Additive Manufacturing ( AM ) is defined as the process of joining materials to make objects from 3D model data , usually layer upon layer , as opposed to subtractive manufacturing methodologies . It offers design flexibility , mass customisation , process sustainability and rapid product development .
The term AM encompasses many technologies including subsets such as 3D Printing ; Rapid Prototyping ( RP ); Direct Digital Manufacturing ( DDM ); layered manufacturing and additive fabrication .
According to analyst SmarTech , the market for DED and large-format Additive Manufacturing machines and materials will reach US $ 739 million by 2026 . It identifies and quantifies
the opportunities presented by Directed Energy Deposition ( DED ), Wire Arc Additive Manufacturing ( WAAM ) and other large-format metal additive technologies . In addition to the fabrication of large parts , large-format printing is used for the repair of worn or deteriorated parts ; adding new features to an existing part ; metal coating and the creation of new materials from multiple metals .
Major metals used in the global additive manufacturing market are stainless steel , aluminium and titanium . The rise in demand for lightweight materials is expected to positively impact the global market .
Why choose AM ?
Additive manufacturing has many advantages such as flexible design , a faster production cycle , a slower resource requirement and substantial savings on tooling over manufacturing technologies such as vacuum casting ,
CNC machining and injection moulding .
AM hardware and materials are advancing rapidly , and cost per part is continuing to fall , opening a more comprehensive range of low- to mid-volume applications . Leading manufacturers are leveraging additive manufacturing to save money , shorten lead times , solve complex problems and improve processes from prototyping to production .
“ One of the greatest benefits of this more modern technology is the greater range of shapes which can be produced ,” explained SmarTech Analysis . Designs that cannot be manufactured in one entire piece using traditional means can easily be achieved . For example , shapes with a scooped-out or hollow centre can be produced as a single piece , without the need to weld or attach individual components together . This has the advantage of being stronger with no weak spots which can be compromised or stressed .
“ 3D printing is benefiting manufacturers in terms of prototyping ; designs of structures and end products ; modelling and time to market . As a result , production expenses have reduced considerably and manufacturers are in a position to offer better products at reasonable prices . As a result of these benefits , the demand for 3D printers is expected to increase
3D-printed parts for the WASP motorcycle .
ISMR April 2022 | sheetmetalplus . com | 19