How additive leaders plan to tackle scale, automation and complexity in 2022.
Siemens Digital Industries Software has submitted this post.
Written by: Aaron Frankel, VP of Additive Manufacturing Software Program, Siemens Digital Industries Software
As we move into 2022, the 3D printing and additive manufacturing industry is going to continue to evolve from improvements to existing, well-established technologies along with the introduction of breakthrough processes, workflows and capabilities. The key to success is determining how to better leverage the technologies and build processes that are available, focusing in on three fundamental themes: Scale, Automation and Complexity.
Scaling for Production
As it has been for some time now, a key driving factor for additive is going to be the continuing scaling for industrial applications. Just as the machine vendors continue to scale up production rates and improve reliability, repeatability and consistency across the entire additive spectrum, the digital toolset used to define the part geometry, build parameters and preprocessing is becoming ever more attuned to maximize efficiency and productivity. Design for Additive Manufacturing is one thing—but perhaps more accurately, it should be called Optimization for Additive.
Whether it’s optimizing for additive build during design, optimizing the build process itself or in the post processing/post machining of components to remove supports and unsolidified resin or powder, scaling production will require a more holistic approach than ever before. The earlier that best practice is baked into parts during design, the better the end results will be. Software tools that work to ensure that scalability and efficiency are baked into parts from the earliest of stages of design will help develop efficient workflows from the very outset and ultimately lead to better, more consistent parts.
The concept of the digital twin is well established, but within the additive realm, this could really start to bear fruit. The concept of a system whereby the design of a part is not only based on performance data, but also on data captured during previous physical builds, is incredibly intriguing to many.
Automation
Automation is going to play a huge role in fostering greater innovation in additive processes and will touch every point, from the concept design phase through the printing of parts and even extending into the post process, supply chain management and beyond.
In the product development world, automation is something that I’ve seen huge interest in as organizations explore the benefits of additive and start to focus on its use in current projects. The ability for tools within software to capture geometry, link it to design and manufacturing knowledge, rules and best practices in the form of rapidly configurable templates can make the long-discussed concept of mass customization a reality.
That rapid iteration could be used for manufacturing aids on a production line with some clever thinking and a desktop printer, or for building smart bionic prosthetics like our friends at Unlimited Tomorrow. They are changing how prostheses are not only manufactured (using polymer-based powder bed fusion), but also how their form can be quickly and cost effectively adapted to the needs of each user through the use of knowledge capture templates.
The Complexity Conundrum
The additive manufacturing industry is one that both looks to solve the problems of complexity, but also thrives on it. Simulation technologies continue to demystify how the mix of lasers and inert gases will bring powdered exotic alloy metals together to form parts that simply could not be manufactured any other way. At the same time, interest in multi-axis, multi-material production of parts is growing, and I expect it to continue to do so in the coming year.
There are even companies like Ingersoll Machine Tools, who are taking advantage of our broad solution expertise to deliver hybrid manufacturing machines that combine complex CNC machining, robot programming and additive to manufacture innovative parts with unprecedented ease and scale.
An Encouraging Outlook
The outlook for the world of additive industry is one that needs to “square the circle” of an amazing technology that can achieve the previously impossible with the need to ensure that its benefits are understood and taken advantage of purposefully by a much wider audience outside of the subject matter experts.
The team at Schaeffler AG has been doing some fascinating work to take its in-house additive expertise and find new innovative ways to make this knowledge available to a wider audience in its distributed design team. It’s using a web-based platform to guide its global team of designers and engineers through the additive part qualification process, as defined by its experts, while shop floor operations and machine utilization are streamlined.
While the benefits of automation as a means of gaining control over complex processes and workflows has been discussed, the reality is that the most benefits from automation in the world of design and engineering form creation can be derived from tackling the seemingly mundane and monotonous, which frees up key resources to take on the real challenges.
Imagine placing an electric drive unit in a new vehicle. At some point, someone will need to design the mounting brackets for it. Rather than repeating the same process multiple times, instead take a rich digital twin model, define the connection points between the drive unit and the body and have the system design the optimal forms, ready for manufacture—opening up resources for more challenging tasks and finding room for innovation.
Additive holds many benefits, but the key for 2022 is going to be increasing understanding of how it can be applied to truly reap the advantages that it brings.
About the Author:
Aaron Frankel is vice president of Siemens additive manufacturing software program. He has over 20 years of experience in the PLM software industry and has held various positions in engineering services, product management, and marketing – all focused on helping manufacturers take advantage of the latest digital design and manufacturing technology.