3D printing optimisation: How to secure competitive advantages now

"`html

Modern production calls for innovative solutions. The 3D print optimisation opens up completely new possibilities for companies. It reduces material waste and significantly lowers production costs. At the same time, it enables faster development processes and greater flexibility. Companies that utilise this technology secure decisive competitive advantages. In this article, we will show you how 3D print optimisation drives your business success[1][2][3].

Why 3D printing optimisation is crucial for your company

Additive manufacturing is revolutionising the industry. Traditional manufacturing methods are reaching their limits. They require expensive tools and long development times. The 3D print optimisation fundamentally changes this paradigm[1].

Companies report significant cost savings. Material costs are reduced by up to 30 per cent. Development time is reduced by more than 50 per cent. These figures are not the exception, but the rule[3].

The advantage is particularly evident in mechanical engineering. Complex components are produced faster and more cost-effectively. At the same time, their quality improves noticeably. This is the key to better profitability.

Material efficiency through intelligent 3D printing optimisation

Intelligent material distribution is at the centre of modern production. 3D print optimisation uses mathematical algorithms and artificial intelligence. Software calculates exactly where material is really needed[1].

Traditional methods such as milling or drilling produce waste. Up to 80 per cent of the material ends up as waste. 3D printing completely avoids this waste[2].

This advantage is particularly utilised in the aviation industry. Brackets and components are created with organic structures. They are lighter and more stable than conventional parts. Every gram less saves fuel and reduces emissions[5].

BEST PRACTICE at the customer (name hidden due to NDA contract) A mechanical engineering company optimised its injection moulding tools through topology optimisation and 3D printing. The weight of the moulds was reduced by 75 per cent. Cycle times were reduced by 40 per cent. At the same time, the surface quality of the injection moulded parts improved considerably. The investment was amortised after just six months.

Cost reduction: The economic advantage of optimisation

Companies are constantly looking for ways to reduce costs. The 3D print optimisation offers measurable savings here. All cost components are positively influenced[2].

Save direct material costs

Less material means lower raw material costs. A kilogramme of plastic or metal costs significantly less if it is saved[3].

This is clearly evident in medical technology. Prostheses and implants are produced in a material-efficient manner. One company saved 35 per cent on raw material costs by optimising designs. At the same time, the biocompatibility of the implants increased.

Energy efficiency and print optimisation

Shorter printing times mean lower energy costs. Less material requires less printing time. This saves electricity and reduces the carbon footprint[2].

A robotics company used 3D print optimisation for grippers and format parts. The production time per component fell from four hours to two hours. This corresponds to an energy saving of around 40 per cent per part[4].

BEST PRACTICE at the customer (name hidden due to NDA contract) An automotive supplier optimised its plastic components for 3D printing. Topology-optimised designs reduced the printing time per part from three hours to 1.5 hours. Material waste was reduced to less than five per cent. Over the course of a year, the company saved over 120,000 euros without compromising product quality.

Faster prototype development and time-to-market

In fast-moving markets, speed is the key to success. The 3D print optimisation dramatically shortens development cycles[3][8].

Classic development takes months. Tools have to be built before the first component is produced. 3D printing works differently. Ideas become reality within hours.

Iterative improvements without delay

Engineers quickly recognise weak points. They optimise the design on the computer. The improved model is printed immediately. Further tests follow immediately.

A medical technology company developed a new diagnostic device. Using traditional methods, this would have taken twelve months. With 3D print optimisation functional prototypes were available after three weeks. The company brought its product to market six months earlier.

Minimise sources of error through digital processes

Digital designs enable precise simulation. Problems are recognised before production. This saves on expensive faulty series and rework[4].

An electric motor planner used simulation software for topology optimisation. Motor components were tested virtually. Only then was 3D printing carried out. Failure rates fell by 60 per cent.

Creative freedom and innovative product designs

Traditional manufacturing limits creativity. Tools, machines and material flow systems restrict design. 3D printing frees engineers from these chains[2][5].

Complex geometries now feasible

With 3D print optimisation organic shapes are created. They look unusual, but are physically perfect. Cavities, grooves and outlets are seamlessly integrated[1].

Dentistry demonstrates this impressively. Braces and implants are individually optimised. Each piece fits the patient perfectly. This would be impossible with conventional manufacturing.

Lightweight optimisation for higher performance

Less weight means more power. A robot with lighter components can work faster. At the same time, energy consumption is reduced[4].

BEST PRACTICE at the customer (name hidden due to NDA contract) An aerospace supplier designed brackets for cabin interior parts. The original aluminium design weighed 850 grams. After topology optimisation and 3D printing from fibre-reinforced plastic, the new bracket weighed just 210 grams. The load capacity remained identical. Over 30 kilograms were saved per aircraft, resulting in enormous paraffin savings for thousands of aircraft.

Sustainability through resource-saving production

Environmental protection is not only an ethical imperative, it also makes economic sense. The 3D print optimisation actively contributes to sustainability[2][3].

Waste reduction and circular economy

Additive manufacturing produces no waste. Material is used specifically where it is needed. Leftover plastic parts can be recycled[2].

A plastics processor integrated 3D printing optimisation into its production. Material waste was reduced by 95 per cent. Surplus material was fed back into the printing process. The company needed 60 per cent less raw material.

Reduce CO₂ emissions

Lighter products are more efficient to transport. A lighter container requires less fuel. Shorter manufacturing processes save energy[1].

A logistics company printed its containers and boxes with an optimised design. The weight per unit was reduced by 40 per cent. For 100,000 units, this meant over 4,000 tonnes less transport weight per year.

Practical application examples from various industries

Automotive industry: Lightweight components for better efficiency

The automotive industry is 3D print optimisation intensively. Engine parts, brackets and ventilation ducts are optimised[4].

A major car manufacturer produces fan blades with a topology-optimised design. The weight was reduced by 35 per cent. Efficiency increased by 25 per cent. This saves drivers around two litres of fuel per 1,000 kilometres per vehicle.

Medical technology: Individualised solutions

Medical devices benefit enormously from customised designs. Every patient is different. 3D printing enables customised products to be produced in industrial quantities[3].

A dental company prints customised dental splints. Each splint fits the patient's teeth perfectly. The treatment time is reduced by 20 per cent.

Robotics and automation: customised parts

Grippers and format parts are produced without expensive moulds. Small and medium-sized companies can now produce robotic parts cost-effectively[4].

An automation supplier develops grippers with an optimised design. The speed increased by 30 per cent. The costs per gripper fell by 45 per cent.

Practical steps for implementing 3D printing optimisation

The changeover requires planning and patience. But with the right steps, every company can succeed.

Step 1: Analysing existing production

Which components are expensive? Which ones require long development times? Where do large material losses occur? These questions help to select the best candidates[3].

Step 2: Qualification of the team

Employees need knowledge about 3D print optimisation. Training courses and workshops are essential. Software training enables rapid progress.

Step 3: Start pilot projects

Start with a project. Experiences from the first successful project