Additives’s Impact on Manufacturing Pt. 1: How 3D Printing Is Changing Manufacturing Today

Over the last decade, 3D Printing has garnered many headlines. Whether it's the hype around consumer 3D Printing or the massive impact on the industrial community, a substantial amount of ink has been dedicated to the technology. 3D Printing changes manufacturing through the way we design, make production parts, and support products in the aftermarket. In this blog post, in conjunction with CMTC and the NIST MEP Network, we will spell out a variety of ways that additive is changing manufacturing today. Also, keep an eye out for an upcoming post where we will discuss how additive stands to further change manufacturing in the future.

3D Printing Changes How Fast Products Get to Market

A direct result of 3D Printing's impact on design processes is the rate at which new products can be developed. Instead of having to wait for tooling for a given design, designers can simply print onsite or send a CAD file to a service bureau and get parts in hours or days. Previously, waiting for weeks, months, or even years was the norm. This has a comprehensive effect on the overall product development life cycle. Decisions on final part designs can be reached much faster because the amount of time required for effective design is compressed.

3D Printing Changes How Effectively We Design

3D Printing grew up as a prototyping technology. It offered a faster way to go from an idea to a tangible model than previously imaginable.  By allowing for designs to be drafted in a computer program and then printed once a viable design is reached, the time to market for new designs was condensed massively - sometimes by an order of magnitude.  In conjunction with this speed, 3D printing has also helped better products come to market.  By allowing for fast iteration on tangible designs, design flaws and bad ergonomics that might have taken months (and a lot of additional investment in tooling) to identify can be spotted sooner, and fixes incorporated into the design.  As a result, the general quality of parts is improved by designers’ ability to explore more designs in a shorter period of time, arriving at a better final design.

3D Printing Changes the Way We Make Tools

A lot of attention has been focused on how 3D Printing helps us create end-use parts through prototyping. Now, increased attention has been paid to how 3D printers are fabricating actual end-use parts for select applications. However, one of the first uses outside of prototyping was tool creation. Around a decade ago, the range of polymers available for 3D Printing expanded significantly. This happened in conjunction with the emergence of extrusion and powder bed 3D Printing systems, which processed true thermoplastics rather than thermoset resins like vat photopolymerization (a.k.a. SLA) machines.

Once engineering thermoplastics like ABS, polycarbonate, and polyetherimide became available, managers and engineers began considering if 3D Printing could solve unique practical challenges that they encountered on a daily basis. These shop floor applications extended well beyond fit or form models, such as creating custom jigs, fixtures, or end arm effectors to allow for better handling of items. 3D printers are capable of economically fabricating these often unique geometries that would never be suitable for mass production. In this way, 3D Printing changed how manufacturing supports people on the shop floor as well as the ones designing and fabricating end use parts.

3D Printing Changes the Way We Fix Things

Another way that 3D Printing changes manufacturing today is in how we fix things. 3D Printing allows for on-demand fabrication of replacement parts. Naturally, this is not always necessary. Sometimes a replacement part is readily available at Lowe's, Home Depot, Grainger or McMaster-Carr, to name a few. But sometimes those parts are difficult to come by, especially for products out of production. If your collector car from the 1950s breaks down, it can sometimes make sense to print replacement parts rather than attempt to hunt them down in the global marketplace.

This is even more pronounced if a 50-year-old part breaks down on your assembly line and the holdup is costing revenue every minute. Or perhaps you are in a forward-deployed location and your aircraft cannot fly without printing a replacement part straight away. In any of these circumstances, the ability to 3D print stopgap solutions is significant, and with the rapid advancement we have experienced in printing quality, these “short-term solutions” may soon become “long-term” ones.

Summary: Additive is Changing Manufacturing in Many Ways and More is to Come

As we explained in this post, additive manufacturing has fundamentally changed the way we manufacture things. From design to tooling to replacement parts, additive manufacturing is a game changer. And its impact is just beginning to be felt, as the speed and capability of machines has just passed a tipping point.  You may note that we hardly touched the topic of actual production parts, which we view as still just breaching the tip of the iceberg at the moment, but that’s soon to change. Read our next blog post when we talk about how additive manufacturing will come to further impact manufacturing in the years to come.

Walters & Wolf Engages 3Diligent to Manufacture Exterior Wall Components That Contribute to Unique Look of Seattle’s Upcoming Rainier Square Tower

3Diligent Worked with Walters & Wolf from Prototype Through Production; Provided 3D Printing of 140 Unique Aluminum Nodes in Varying Dimensions

El Segundo, Calif. – March 6, 20193Diligent announced today that Walters & Wolf, a commercial cladding company, engaged 3Diligent to manufacture 140 unique exterior curtain wall nodes that Walters & Wolf designed to deliver the iconic exterior look and feel of the upcoming Rainier Square Tower in Seattle.

Expected to be finished in 2020, the new Rainier Square Tower will become Seattle’s second-tallest building. The structure will be a 58-story tower with a unique sloping appearance. With a step back on each building floor, the cladding system for each floor will have a different angle and require complex geometries to fit together perfectly.

Walters & Wolf worked with 3Diligent from prototype through production to produce 140 unique nodes with varying dimensions up to nearly a cubic foot in size. As geometries changed throughout the building’s design, 3Diligent leveraged its deep metal 3D Printing expertise to ensure each unique geometry met Walters & Wolf’s exacting specifications.

“From an operations standpoint, we were impressed with 3Diligent’s consistency in delivery of highly accurate and complex parts in a timely fashion that was in sync with the production schedule we established early on,” said Tony Parker, Project Executive at Walters & Wolf.  “At the end of the day, 3Diligent upheld their end of the bargain – they simply did what they said they would do.”

3D Printing of Challenging Geometries

NBBJ rendering by Atchain

Each piece of the curtain wall needed to be custom fabricated to meet the unique geometry of that section of the building. Walters & Wolf determined the best approach would be to create v-shaped nodes that ranged in size that would bring together square cut parts of the curtain wall. After experimenting with a variety of manufacturing processes and having some vendors say they couldn’t complete the work, Walters & Wolf turned to 3Diligent.

3Diligent presented two manufacturing processes – investment casting and 3D Printing - and delivered first articles from the different processes. These were assembled into curtain wall units and sent for performance mock-up testing. After testing, Walters & Wolf selected 3D Printing as their preferred path forward.

“We were honored when Walters & Wolf engaged 3Diligent as its manufacturing partner for this project,” said Cullen Hilkene, CEO of 3Diligent. “Both the tower and these specific parts represent the sort of innovation that 3Diligent strives to enable every day.  It was great collaborating with Walters & Wolf on such a compelling project and look forward to seeing the completed tower in 2020!”

To download the full case study highlighting Walters & Wolf’s work with 3Diligent, visit this case study's page.

About 3Diligent

3Diligent is an innovative digital manufacturing services provider offering CAD/CAM-based fabrication services such as 3D Printing, CNC machining, casting, and injection molding.  3Diligent launched in 2014 to provide businesses seeking a more convenient and efficient way to utilize cutting edge digital manufacturing technologies such as additive manufacturing.  3Diligent uses the right combination of in-house engineering expertise and data science-driven algorithms to assess, price, and fulfill customer requests with its global manufacturing network.  3Diligent counts companies from Fortune 500 enterprises to startups among its customers.

For more information on 3Diligent and its capabilities, visit https://www.3diligent.com.