BASF 3D-printed more than 100 interior and exterior components for the HYMER VisionVenture concept camper .
A design-driven process
Additive manufacturing and / or laser sintering or laser melting can be used to manufacture , coat or repair components with extremely high material requirements . Compared to traditional , ablative manufacturing methods , such as turning or milling , in additive manufacturing the design determines manufacturing . This is why it is referred to as " design for additive manufacturing " ( DfAM ).
“ AM marks an inflection point in manufacturing that allows previously impossible structures to be produced . If you can design it , you can print it . What was once a physical inventory can now become a digital library , bringing a radically more efficient logic to logistics and eliminating multiple links in the supply chain such as packaging , warehousing and transport . Moreover , as an additive process , where only the exact amount of required raw materials are used , AM makes waste a thing of the past . Just imagine what this can do for performance throughout all industries as well as what it means for our planet in the long run ,” commented additive specialist , Sandvik .
“ In additive manufacturing , a complex design is often as easy to produce as a simple one . This means designers can use geometry , rather than bulk , to achieve structural strength with less weight . It ’ s also ideal for components where complex inner shapes – curved channels , for instance – can provide new functionalities and efficiencies ,” it added .
AM changes the relationship of scale to production cost . With AM , components can be produced with individual customisations
A 3D-printed part from Protolabs .
Designers can use geometry , rather than bulk , to achieve structural strength with less weight
3D printing from metal powder .
FOCUS ON ADDITIVE MANUFACTURING
that would be unrealistic with traditional techniques . Prototyping and rapid iteration is now possible without retooling or making new dies .
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 .
“ 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 .
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 . n
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