As a person working for a 3D printing service provider, I know that in the end 3D printed parts often require a lot of trial and error. Perfecting this process is crucial, especially when it comes to mainstream manufacturing, because there is little time for piloting and limited error space.
3D printing has become an important tool to shorten the new product introduction (NPI) cycle and shorten the time to market. The dental and medical markets have already benefited from early adoption, and most other departments are just beginning to consider using 3D printing to make small batches of products. In order to take full advantage of 3D printing as a viable production solution, companies must adopt best practices to reduce risk and apply rigorous manufacturing from design to delivery.
There are five steps:
Step 1: Identify the correct items and avoid "Paperweights" or "RabbitHole";
The first step requires the executive, engineering, operations and supply chain teams to coordinate around the business problem you are trying to solve, because their collective investment will determine the success or failure of any 3D printing project. If no consensus is reached, you will eventually pay a price for this.
It is also important to avoid the "complexity is free" trap. Although 3D printing facilitates design freedom, it is not always the best solution for producing complex product designs. Start by identifying the correct project and introduce the ideal part of 3D printing and the best business case.
Jabil recently helped industrial customers use advanced 3D printing technology to produce "under hood" air ducts for trucks. The component requires only a small amount, the materials and aesthetics can be easily supported, and it is also economically meaningful. In the end, the success of this project was a good entry point for 3D printing, and created interest and analysis of follow-up opportunities.
Step 2: Build a business case to understand the impact of "real costs";
Establishing a business case requires an analysis of economics, not just the price of each product, but the overall cost of integrating 3D printing into the manufacturing process. Actual costs include construction area, utilities, depreciation, maintenance, inspection, packaging, transportation, etc. This list is constantly being ignored by team members outside the manufacturing field.
The cost comparison between 3D printing and traditional manufacturing methods requires careful analysis to determine all variables, such as shortened delivery time or reduced inventory. Some variables will resonate in R & D, while others will resonate in the supply chain. Therefore, all aspects that take quality, cost and risk as the main determinants are very important.
Step 3: Lead the business and supply chain team on the 3DP journey
Most global manufacturing solution providers have business operations teams and supply chain experts who are willing to reduce risk at every stage of the production and manufacturing life cycle. Supply chain risk is usually related to quality and cost, but it goes deeper. A bolt that costs a penny can still pose a risk of tens of thousands of dollars for the company ’s products if it is a single source and is not easily available.
Since procurement poses significant risks, it is worth considering using multiple 3D printing technologies or solutions to reduce risks. Another way to reduce risk is to work with reliable manufacturing partners who have accumulated early experience in 3D printing success.
However, business and supply teams must find opportunities to reduce their investment risks and create conditions for demand. Positioning these key elements to win more business will make them 3D printing champions, which will eventually pave the way for more adoption of 3D printing technology.
The fourth step: apply for manufacturing, every day, every stage of application;
World-class brands expect manufacturing partners to provide the best products. Whether you are using traditional manufacturing methods or additive manufacturing, quality is critical. Extensive certification and verification of materials, processes and machines (MPM) and complete supply chain integration are the entry cost for any manufacturer to add 3D printing technology to its solution portfolio.
Manufacturers are required to pay attention to and apply strict manufacturing standards to ensure long-term consistent part quality and mechanical integrity, making them the same as traditional manufacturing. It is worth noting that supplier qualifications can be extensive and include strict standards and audit requirements. For example, Jabil recently partnered with a large manufacturer of medical implants with strict requirements, including for packaging inspection, quality assurance / quality control, MPM qualification, closed clean room, complete audit trail, post-processing, packaging Sterilization and recycling.
Advanced process engineering ensures process repeatability and overall machine utilization, which is crucial in providing additive manufacturing design (DfAM), whether it is about specific processes or design highlights / costs. Initially, companies should be cautious when implementing DfAM, because designing added value will not make the design too complicated and affect the economic model.
Step 5: Education, communication and attraction components;
In order to drive the momentum of 3D printing, it is important to showcase milestones and share early success stories so that customers can start to imagine their possibilities. In addition, open communication with key members of the 3D printing ecosystem is crucial to the development of the entire 3D printing industry.
Remember, your overall goal should be to communicate progress. Reaching the right audience at the right time is crucial, which is why design engineers are hired early in the product development process. To this end, the company must ensure that design engineers understand its value and determine all methods of introducing 3D printing.
Here are a few:
Product enhancement-better performance, such as high engine heat transfer;
By combining multiple parts into one part to achieve part consolidation, cost savings, such as General Electric ’s 3D printed fuel nozzle, combine about 20 parts into one;
Reduce the weight of components by applying additive design methods, lightweight-topology optimization to reduce the weight of satellites into space;
Reduce costs, such as materials and eliminate mold costs-use the same manufacturing method for structural design and prototyping;
Speed ​​up the schedule and shorten the time to market-classic prototype design, while accelerating the development of automated processes and providing traditional mass production devices and materials;
New business models include personalization / customization, low quantity / high mix, unit cost, distributed manufacturing / local to local;
For most companies, the 3D printing journey has just begun. Following practical methods and best practices will help early adopters close the gap in bringing 3D printing to mainstream manufacturing. Borrowing some of BillGates' wisdom, we may overestimate what we can do in one year and underestimate what we can do in ten years. Although the pace of adoption is still unclear, 3D printing will definitely have an indelible impact on the future of manufacturing. 
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