Not only were incredible new products being made in a layer-by-layer fashion, but soon an entire billion-dollar economy sprang up with 3D printers capable of making industrial, high-performing parts for the most critical of applications like aerospace and medicine. Materials science abruptly became even more vast, and increasingly more interesting as interested parties began to take the deep dive into a novel world of resources that is still continually expanding, from versatile thermoplastics to the strongest metal.

Mainstream 3D Printing Soon Turned to End-Use Parts

Prior to all the hoopla surrounding the world of additive manufacturing as licenses expired, the technology was being used quietly behind the scenes by a select number of big names with big resources—and no eagerness to share their secrets while engaged in research and development. NASA comes to mind instantly, as a major aerospace organization and space leader that began using 3D printers in the 90s for rapid prototyping.

While 3D printing may have at first only been considered a sophisticated iteration tool, the technology quickly evolved into a production method for making complex geometries never before possible with traditional manufacturing like CNC machining or injection molding. Industrial users quickly discovered its potential upon testing the limits of 3D design and all that came afterward. With such overwhelming curiosity and the constant push to create new objects, came the ultimate discovery of a tool that allows for infinite innovation.

Reaping the Rewards is Possible Without Huge Investments

While rapid prototyping may still be part of the process, today it has been superseded by the knowledge that 3D printing has the capacity to make strong, highly customized parts on demand and in high volumes. In working with Shapeways, this also means that businesses of all sizes may realize an entirely new future and trajectory in terms of production of quality parts and products in bulk printing—without having to train staff or invest hundreds of thousands of dollars in industrial equipment.

That FDM 3D printer for the desktop at home or the office may allow for a good start in terms of product development—or even, yes, the replication of a necessary household utensil as foretold, that is not the scenario for rapid production in mass volumes; however, Shapeways bulk 3D printing solutions give customers access to high-volume 3D printing using at the most advanced manufacturing technology and materials like Selective Laser Sintering (SLS) using popular materials like Nylon 12 [Versatile Plastic] or PA11.  

Mass Customization and Production Too

For Shapeways customers like 67 Designs, the appeal of 3D printing materials, and a dedication to the technology overall outweighs the benefits of traditional manufacturing. For CEO Paul Stener, there has always been a strong adherence to both quality in design and conformation, which he considers to be the main requirements for creating quality products.

“Sometimes you can look at a product and it seems really cool, but during the manufacturing process or due to the materials that have been used, it doesn’t last very long,” said Stener. “That perhaps is a sign that there wasn’t good conformance to the design.”

Stener could have chosen to move on to mass production with injection molding but was sold on 3D printing due to their customized rugged design for an iPad mount, a luxury vehicle accessory mainly used in off-roading vehicles with a tendency to traverse remote and incredibly beautiful areas. Stener also wanted to continue using Nylon 12 [Versatile Plastic] due to the quality surface finish available.

While highly customized products may be offered in small volumes on demand, once they are highly desired by a customer base, Shapeways can mass produce those same parts too. Powder-based technologies like SLS are conducive to mass production because:

1. There is no need for supports. 

Due to unsintered powder bolstering up and naturally supporting parts during production, dealing with the headaches of planning for support mechanisms are eliminated from the design process—offering much greater freedom regarding design and innovation. 

2. Nested bulk builds are now possible.

Shapeways engineers do not have to plan for supports while packing parts in each build. This makes the process of nesting much more streamlined, and allows for hundreds and even thousands of parts to be 3D printed in one build.

No Tooling Saves Time and Expense

The process of manufacturing expensive tooling is eliminated during 3D printing, along with jigs and fixtures. This also reduces additional setup and costs, streamlining the process further—even for massive production jobs. In other cases, faster, more affordable tooling may also be created for traditional manufacturing, like creating economical, customized 3D printed molds.

Shapeways customers like Voytek Medical weighed out their options carefully when comparing their prospects between 3D printing and injection molding, as an example. Because they did not want to spend thousands of dollars of precious capital, Voytek chose to move from desktop 3D printing and the idea of injection molding to work with Shapeways instead for additive manufacturing of specialized devices to organize medical cords. The decision ultimately brought them great success as they were able to get large batch orders quickly—and with true accuracy and repeatability, parts were received each time without cosmetic or build quality flaws.

Greater Latitude in Making Design Changes to Complex Parts at Any Time

Customers like Tilt Hydrometer took full advantage of the ability to 3D print over a hundred iterations of their hydrometer used to measure the fermentation process while home brewing craft beer. During manufacturing of the end-use parts, they also enjoyed the full range of colors available with Nylon 12 [Versatile Plastic], 3D printing through SLS technology.

“I ended up learning a lot about technology,” said CEO Noah Neibaron. “I was passionate about brewing, and I really wanted the business to take off.”

“Shapeways was a large part of that. They were really great with fast service, quality, and the range of colors which actually ended up affecting our whole product line because we now make eight different colored 3D printed tilts—and those are the colors Shapeways sells.”

Expanded freedom in design is one of the greatest advantages in additive manufacturing, and that is equally true for both prototyping and production. In traditional manufacturing if a part was made with a defect or needed a slight change, that could mean long periods of time in between the re-design process and waiting on third parties to fix errors or sudden decisions to make changes. With 3D printing if there is a problem or if the manufacturer suddenly takes a different turn, the 3D model can be swiftly changed without waiting on anyone—and production can resume quickly.

Get Products to Market Faster

Adhering to the old adage that time is money, 3D printing becomes the best option for businesses of all sizes and types—especially when they may be in the process of creating an innovative product and need to get to market as soon as possible in hopes of watching their new brand take off as planned. From the concept and design phase to prototyping and then manufacturing, 3D printing offers new opportunities for businesses interested in creating and customizing new parts with considerably less constraints, and less waiting on third parties in the initial stages. Changes can be made as quickly as a few clicks at the desktop rather than waiting for weeks or even months. In many cases, prototypes and parts can be manufactured exponentially faster, and with less waste of materials and resources.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post The Benefits of Additive Manufacturing for Mass Production appeared first on Shapeways Blog.

With the trend for devices like tablets and iPads continuing to tick upward, Stener noticed an obvious need for high-quality mounting systems for tech-savvy users and their accompanying devices. Rather than shooting for a consumer-driven pricepoint, however, the team at 67 designs was more concerned with making an excellent and much needed design for drivers to stow their tablets while driving (or even working at their desks).

“There’s only two types of quality,” explains Stener. “There’s the quality of design, and then there’s the quality of conformance to design—and you must have both of those.”

“Sometimes you can look at a product and it seems really cool, but during the manufacturing process or due to the materials that have been used, it doesn’t last very long. That perhaps is a sign that there wasn’t good conformance to the design.”

Shapeways and 67 Designs were able to manufacture a third-generation product with the MagMount, and especially as the Shapeways team was able to clearly view the project as one driven by industrial business needs rather than that of an individual consumer. For Stener, an ongoing dedication to 3D printing meant sticking with use of the technology due to the intrinsic benefits available—despite more conventional ideology which might have pointed toward a return to traditional manufacturing in the face of success, and subsequent larger volumes.

Selective laser sintering (SLS) offers tempting benefits for designers and especially with a material like Nylon 12. Used in a variety of applications—to include architecture, mechanical processes, prosthetics, environmental applications, and even luxury jewelry design, Stener settled on Nylon 12 for the MagMount due to the quality finish. 67 Designs devices are expected to be extremely rugged, so choice in materials is critical (especially considering the reputation the company has to uphold with so many rental vehicles using their products, and not one problem in five years).

Stener’s commitment to 67 Designs revolved around getting back into industrial engineering, as well as a strong desire to be an active member of his community:

“I made the decision to jump back to the industrial engineering side, and a division of the company was originally meant to give back and contribute to the community in which I live. Part of that was to have fifty percent of the workforce made up of people with learning differences, and the balance to be made up of experienced people in manufacturing.”

“It really started as a social mission.”

Stener is clearly fulfilling numerous, positive goals with 67 Designs as a vehicle. Enjoying a commitment to the promise of additive manufacturing, his company is producing quality products for adventurers around the world, living to the fullest (without leaving their technology behind). Workers are being hired and learning new skills, and Stener also allots time to focus on younger generations that may have little exposure to learning how to actually make things. The hope is that 3D printing will fill in some of those gaps, as well as teach students to take necessary risks in design and production.

For Stener, now responsible for a variety of successful high-quality offroading accessories, the rewards have obviously outweighed the risks.

Enjoy the benefits of our advanced technology and wide range of materials for printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Read about case studies, find out more about our solutions, and get instant quotes here.

The post 67 Designs: A Vision for the Future & Commitment to Additive Manufacturing appeared first on Shapeways Blog.

Shapeways’ bulk 3D printing solution gives you access to high-volume 3D printing using the most advanced manufacturing technology and materials at affordable prices.

Advantages of using additive manufacturing vs traditional manufacturing for bulk orders

While additive manufacturing is on the rise as an end-use production process, often the first thought is that it is a low-volume endeavor. Bringing 3D printing into industrial production, though, can actually offer significant advantages over traditional manufacturing workflows, like on-demand production, fewer kinks in the supply chain, reductions in storage and inventory costs, and reduced waste.

Advanced planning vs printing on-demand

One of the biggest advantages of additive manufacturing is that 3D printing does not require tooling or molding to be made. This can lead to a much faster turnaround time, as well as lower material and labor costs, as a major step of traditional manufacturing workflows — think injection molding — is bypassed completely.

This can lead to relatively immediate on-demand production; all that’s needed is a digital file to be 3D printed. Shortening lead times between design and production means less upfront work for you — so if you don’t have the time for a hefty chunk of time to plan in advance, moving to 3D printing on-demand can kickstart the process.

Supply chain kinks

Traditional bulk production often includes calculated supply chains built on the premise of low-cost supplies, which in many cases means reliance on overseas suppliers. When those supply chains are confronted with unforeseen kinks — perhaps international borders closing due to a global health crisis, for example — operations can completely shut down.

On-demand production with additive manufacturing goes hand-in-hand with decentralized production. 3D printing has been on the rise due to recent global events that have overturned traditional supply chains, as international logistics are unnecessary. Shapeways is headquartered in New York City, with manufacturing facilities in Long Island City and the Netherlands, maintaining a prominent global presence around the world.

Storage and inventory costs

A major need for bulk parts comes from the ongoing need for spare or replacement parts. In many cases, these parts are made at the same time as original parts and physically stored in massive warehouses, ready to be pulled from the shelf and shipped out as needed. That can be convenient — but can also lead to tricky situations when those physical parts take up physical space that needs to be paid for, and when they run out after a design becomes obsolete without regular inventories being made anymore.

3D printing spare and replacement parts on demand removes the need for physical storage. When spare parts are stored as digital files, no shelf space need be taken up, freeing up warehouse floor space and the costs needed for physical storage. Only as many parts as are required at a given time need be made, and so long as that design is available they can be made at any point, even if the original supplier is unavailable, obsolete, or out of business.

Reduced waste

Milling, casting, molding, and other traditional forms of manufacturing broadly require significantly more material than just what goes into a final part. Subtractive processes like cutting and milling carve out parts from larger blocks of material, inherently creating waste in the production stage. That waste ultimately adds up in terms of both cost and lack of sustainability. For molding and casting, additional tools like molds are needed as well.

Additive manufacturing is, well, additive. Many 3D printing processes build up a part layer by layer, using only the material necessary. Even when support structures are required during the build, these are often lattice-like structures that use much less material than would otherwise be cut away on a CNC machine. Using only the material required is a major cost- and waste-saving measure that is unique to additive manufacturing when it comes to production — and especially so when it comes to bulk orders.

Factors to consider when choosing a manufacturing service

Working with a manufacturing service for your bulk production needs can create a smoother workflow. When you work with Shapeways bulk 3D printing, you immediately gain access to expert-driven design, customer service, and production quality. A manufacturing service like Shapeways also comes fully equipped with a broad variety of hardware, software, materials, and — perhaps most importantly — the expert know-how about when and why to choose the best-fit option for each. Making the choice to work with a manufacturing service, though, is still a multi-faceted decision-making process that includes factors like upfront costs, volume, model complexity, material, time-to-market, and future iterations.

Upfront costs

In-house production can often make a lot of sense. Using your own equipment and personnel shortens supply chains, tightens turnaround, and ensures you always know what’s happening. It does, though, limit production efforts to what you have already invested in. New industrial manufacturing equipment requires substantial upfront investment and training, and while that equipment will presumably be targeted toward the process(es) you use most, it may not always be the best choice for a new application.

When you need a run of parts for a bulk order, but that isn’t a standing need that would offer a logical return on investment that would merit buying in to new industrial equipment, turning to a manufacturing service offers immediate access to the appropriate manufacturing capabilities. Costs are limited to the order you place without additional capital investment.

Volume

Outsourcing bulk production frees up your time and team to focus on your own operations. When having parts manufactured at volume, there will inherently be a good amount of time dedicated to that manufacturing. A manufacturing service offers access to an industrial facility designed for volume production.

This includes access to industrial 3D printing equipment. An industrial SLS machine, for example, can produce magnitudes more individual prints than could a desktop 3D printer. Final quality of those parts would also be superior due to post-processing capabilities geared toward handling large quantities of parts at a time. End-to-end fulfillment can be greatly enhanced in a full-scale production facility.

Model complexity

Design for additive manufacturing (DfAM) is a dedicated discipline that requires attention to a new set of design parameters for this new form of manufacturing. While designing a relatively simple geometry for your part may be in your wheelhouse, a more complex 3D design that leverages some of the biggest advantages possible with additive manufacturing — think lattice structures that offer strength but with less material and lighter weight, or reducing part counts — requires thorough DfAM knowledge.

Working with experts in DfAM who work day-in-day-out with these technologies can help you generate the perfect design for your model, as well as gain access to the technology and materials to make it come to life. When you’re in the market for bulk manufacturing, ensuring the perfect design is a critical step before producing that design en masse.

Material

With more than 10 3D printing technologies and more than 75 different choices of material to suit, Shapeways has you covered for plastic, metal, sandstone, and casting needs. Each of these processes and materials can be suited for bulk orders of any size. Our automatic bulk pricing for Nylon 12 makes bulk 3D printing seamlessly easy, for example.

Time to market

If you have a design file ready to go for bulk 3D printing, great! It’s off to the 3D printers and shortly to you. If, though, you need some work in designing, rapid prototyping, and getting market-ready first, we have full workflows in place to ensure that your time-to-market can be fully optimized. Working with 3D printing — and DfAM experts — at every step can streamline your go-to-market process.

What would traditionally take months or even years to be market-ready can be cut down to days or weeks with on-demand 3D printing including for bulk orders.

Future iterations

Many products on the market today can be updated to keep up with new capabilities or new user needs. Think about smartphones and other regularly-updated products — these take the best of an established design and continue to build it into something better, often in response to user demand. This process is made all the easier with digital designs.

Rapid prototyping isn’t just for the prototyping stage; iterating to update for future designs can be done at any time. This is one of the key benefits to working with a digital manufacturing technology like 3D printing. Your next-generation update — complete with access to bulk production — is just an updated design file away!

Customer example

As popular wisdom holds that “show, don’t tell” is the best way to prove a point, we’d like to share an example of customer work achieved through the Shapeways platform.

Voytek Medical

Voytek Medical offers a service often sought-after in the medical field, though perhaps not discussed very often. The company develops products that lock patient cables to appropriate bedside or roll stand monitors, ensuring the safe performance of untangled cables — without potentially voiding warranties or needing to modify the equipment itself. These carefully designed products benefit from being 3D printed as they can be designed to keep up with market feedback and needs, all without the increased overhead costs inherent in injection molding.

“Voytek has always been a big proponent of desktop 3D printing, it has its benefits and limitations. Desktop 3D printing is great for prototyping and making changes on the fly and testing different designs. What the technology begins to fall short is in the build quality of the materials, and production times. I would not be able to fulfill orders on a desktop printer, the labor of which would sink the turnaround time. Shapeways allows me to get large batch orders quickly and without cosmetic or build quality flaws,” Voytek explains.

Working with Shapeways’ bulk 3D printing offering, the company experienced professional solutions at necessary volumes.

Please contact us today to learn more about our bulk 3D printing service and how we can help you every step of the way for your next project.

The post What Is Bulk 3D Printing? – A Complete Guide appeared first on Shapeways Blog.