The 3 biggest questions for additive manufacturing in 2018

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The additive manufacturing industry made great strides in 2017, with new technologies coming to market, new applications being discovered and new 3D printing materials being developed. However, in a space that has always been tied to elevated levels of hype, there are still key questions facing the technology, its applications and potential growth. Let’s take a look at the three biggest questions facing additive manufacturing that we hope to find answers to in 2018.

Will metal 3D printing have a breakout year? 

In 2017, we saw that while there was increased interest in metal 3D printing, there was a lack of design-for-manufacturing knowledge, which delayed adoption of this technology. In response, there has been a push among manufacturers to help educate their customers on best design practices. This year, we’ll see a greater understanding of designing for this process. 

There are more positive signs that point to a breakout year for metal 3D printing. This includes growth in key niche applications such as the automotive and medical industries, which are using the technology to gain a competitive advantage. In the automotive sector, weight reduction is paramount. New high-strength steels, along with composites and adhesives, are helping to reduce weight and increase strength in modern vehicles. Metal 3D printing can also help with weight reduction in order to increase miles per gallon and hence decrease emissions. Right now, the biggest opportunity for 3D printing is for lower-volume production runs for higher-end custom vehicles. Within the medical sector, custom models and parts can be built cost-effectively without sacrificing strength. 3D printing has found applications in dentistry to create crowns and bridges, and is moving toward the ability to create permanent restorations in dental composites. 

With increased knowledge and applications, the last ingredient for metal 3D printing to go mainstream is the technology itself. To move beyond niche applications, the speed and cost of metal 3D printing both need to be lowered. A major milestone in 2017 was the announcement of the Desktop Metal Production System. If the cost-per-part and quantity volume meet the company’s claims, it’ll be able to meet full-scale production speed requirements and quality at a fraction of the current cost. However, the system won’t ship until 2019, so this is a question that may not be answered this year. 

There is no doubt that 3D printing technology is trending up. However, many of the companies currently utilising metal 3D printing are doing so in trial applications to see if they can replace traditional practices. The results of these trials will be an important factor to determine whether 2018 is the year of metal 3D printing.

Can hybrid additive become cost-effective? 

Hybrid additive manufacturing, which combines both additive and subtractive manufacturing technologies, offers an exciting avenue for engineers who seek to push the limits for design complexity and efficiency in manufacturing. German tool supply manufacturers are leading the way in the deployment of these technologies. According to DMG MORI, a build rate 10 to 20 times higher than powder bed fusion machines can be achieved with its LASERTEC 65 3D. The machine combines laser metal deposition and milling processes on one machine and has demonstrated outstanding performance in various applications. This includes machining of complex-shaped parts for aircraft and medical components, and repair or coating on parts for corrosive wear protection. The MPA technology from Hermle is a versatile tool for generative creation of large-volume components offering a widespread field of applications. It is especially beneficial in the field of injection moulding and die casting tools where the MPA technology can play to its strength. The Hermle MPA40 can create hollow structures and undercuts using a water dispensable filler material.

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The benefits of combining multiple processes into one is quite appealing to manufacturers worldwide. The chance to streamline operations and better utilise floorspace can pay large dividends. However, hybrid machines also cost more than having independent machines linked via a pallet system so there are greater upfront costs required for the manufacturer.

Will the need grow for on-demand manufacturing? 

There has been buzz that the future lies in service-based companies, which can offer individual customisation over product-based companies, which offers an array of products as they are. Service-based manufacturers whose key strategy is to support build efforts and sales for customers have already found some success. This has been led by manufacturers that want to increase customer loyalty and aftermarket opportunities. By 2021, Gartner predicts that 20 percent of the world’s top 100 consumer goods companies will use 3D printing to create custom products. 

Imagine if a major footwear company made the leap to offer shoes fully customised to the feet of the end-user. This would create major demand for on-demand manufacturing. The reality is that this may not be that far off in the future, with companies like adidas, Nike, New Balance and more already integrating 3D printing into their manufacturing strategies. As more companies look to shake up their traditional product-base, there will be a growing need for on-demand manufacturers. 

2018 may certainly prove to be another good year for additive manufacturing. The feeling within the industry is that we are on the precipice of some major breakthroughs. There is still much to learn about the technology and what it will take to reach its full potential. However, the increased adoption of 3D printing by specific niche industries, the new technologies entering the market and the increased focus on customisation of products bode well for additive manufacturing. The question is now whether 2018 is the year we take another giant leap forward.