Raising the Bar for Additive Manufacturing with Expert Service & Delivery — Beyond the Status Quo

The business of manufacturing continues as it always has, and typically brings successes and challenges across the workflow. The evolution of how manufacturers produce and deliver their applications is a particularly interesting factor to consider as the number of manufacturing processes available and their capabilities increase and improve. One of the more disruptive technologies to emerge in recent decades is that of additive manufacturing (AM) or industrial 3D printing. This technology set itself incorporates a range of processes, a continually growing palette of materials, and software that enables the technology and improves efficiencies. Utilising industrial 3D printing for any manufacturing discipline, whether for rapid prototyping, tooling, or, increasingly, production on demand, does not come without its own set of challenges, but deploying AM can also bring great advantages.

The benefits of AM are well documented, in essence allowing manufacturers to exploit the ability to build complex parts, in one piece, which were previously impossible. This in turn enables the consolidation of existing parts, reducing assembly requirements and reducing overall costs. In addition, with explicit design for process knowledge, AM parts can also be made stronger and lighter making them more efficient across their life cycle while also reducing material consumption. For low and medium production runs, AM can eliminate the need for tooling, making it a faster and more cost-effective manufacturing option. These advantages mean that AM has become a viable option for many manufacturers.

However, while all of these advantages are enabled by the additive systems that build the parts, in reality, the AM hardware is actually just one piece — albeit a vital piece — of an ecosystem of technologies that enable success with AM.

The building of the parts utilising AM is the essential core of the manufacturing workflow, however what happens before and after the build are also vital to delivering high quality parts in the most efficient and cost-effective way.

Here, we are exploring how a specialised bureau can raise the bar for AM with quality services that extend beyond just the 3D printed parts themselves.

A Holistic Approach to Delivering Quality

Experience and expertise go a long way to alleviating the challenges manufacturers face when using AM. Working with a specialist AM bureau ensures that both come as part of the service from beginning to end. Look for an innovative business model that delivers high quality end-to-end processes including fast, automated ordering and tracking at the beginning and dedicated post-processing and finishing capabilities at the end.

Automated Ordering at the Front End

Automation is a technology area that has also progressed significantly in the last decade. A forward-looking AM service bureau will have grasped this opportunity to develop and embed enhanced efficiencies into its ordering system to improve user experience. A dedicated automated ordering system will greatly streamline the ordering process, allowing clients to place their orders quickly and intuitively, while also providing full tracking capabilities.

An intuitive automated ordering platform should enable customers to upload their files, select material/s, and specify finishes with ease. It should then be able to provide immediate pricing feedback based on material cost, print time, and complexity. Once the order is confirmed, the system can then provide status updates of all orders in real-time, greatly improving transparency and communication.

By leveraging technology to automate ordering, AM service providers enhance customer satisfaction and operational efficiency, making AM more accessible and speeding up the front end of the workflow significantly.

Dedicated Post-Processing Services at the Back End

While we’ve established that the printing process is pivotal, the finish of the parts that come off the AM system often determines its quality and, importantly, its usability. Dedicated post-processing services are also essential for ensuring that 3D printed parts meet client expectations.

It’s probably important to note here, that post-processing is actually an umbrella term for a number of stages that AM parts may need to go through after they come out of the AM system and before they are fit for purpose. This is especially true for powder bed fusion (PBF) AM processes. The term “post-processing” is often used interchangeably with “finishing”, which is somewhat of a misnomer. With any PBF process there are a series of essential post-processing steps that are non-negotiable and must be undertaken prior to the AM-produced part finishing stages, which are optional. Thus “finishing” is actually an important subset of post-processing, not a term that should be used interchangeably with it.

Post-processing for PBF parts typically involves:

• Depowdering / excess material removal

• Cleaning

Of note for polymer PBF processes, support removal is typically not required as the powder bed acts as the support system. Neither are heat treatments to cure the materials.

Finishing of parts can include any or all of the following to improve the aesthetics of the surface finish and, for some applications, the mechanical properties of the part:

• Surface finishing

-       Vibro polishing

-       Vapour Smoothing

-       Bead blasting

-       Sand blasting / Sanding

• Machining

• Colouring (Dyeing / Painting)

• Plating

• Inspection.

For AM production applications, finishing of parts is often a considerable, but overlooked, section of the workflow that can significantly impact the overall cost-per-part and project timelines. This is especially true if the final part characteristics need to be enhanced in terms of functionality and/or aesthetics.

Investing in dedicated finishing capabilities allows an AM service provider to offer a superior product quality, which is vital for industries where precision and aesthetics matter significantly.

Quality finishing, quite simply, differentiates an exceptional part from an average one. Any AM bureau that prioritises high-quality finishing can cater to specific client requirements, under one roof, to raise the bar for AM parts.

To Sum Up

Any business looking to utilise the services of an AM bureau should identify one that is committed to the highest quality 3D printed parts but that also understands how to add value before, during, and after the build. The team at 3D People continues to deliver parts in this way to a growing constituency of clients that recognise their expertise in these areas. We welcome any questions — or, indeed, any challenging applications — from anyone that wants to know more.