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The digitalisation of production and development is fundamentally changing the business world. Companies are looking for ways to innovate faster. They want to save costs and remain flexible at the same time. This is where 3D printing technology comes into play. This technology offers decision-makers the opportunity to significantly accelerate product development and reduce costs at the same time. Companies such as BMW and Ducati use 3D printing technology specifically for rapid prototype production. This creates real competitive advantages that can make the difference[2].
Why 3D printing technology is becoming indispensable for modern companies
Additive manufacturing is not just revolutionising individual departments. It is changing entire value chains. Traditional manufacturing processes are reaching their limits when it comes to complex requirements. 3D printing offers alternative solutions.[10] Decision-makers are increasingly recognising the potential of this technology. They understand that 3D printing technology is more than just a manufacturing method. It is a strategic lever for innovative strength and market positions.
Technology is becoming particularly relevant for companies in dynamic markets. Product development cycles are becoming shorter. Customer requirements are changing faster. This is where 3D printing technology shows its strengths particularly clearly.[2] With this technology, changes can be implemented in real time. New designs become reality within hours instead of weeks.
Accelerating development processes through additive manufacturing
New requirements for components arise every day in automotive engineering. Companies like Radford Motors show how it works. They use 3D printing technology to customise luxury vehicles.[2] Such individualisations would not be economically viable using conventional methods.
In design and development, 3D printing technology significantly accelerates product development cycles.[1] Prototypes are created much faster. They can be tested and customised. Production is significantly cheaper than milled parts, for example.[1] Teams can work in shorter iterations. Feedback flows directly into new versions. This creates a continuous improvement process.
BEST PRACTICE at the customer (name hidden due to NDA contract): A mechanical engineering company based in Baden-Württemberg used 3D printing technology to develop new machine components. What used to take six weeks was suddenly possible in three days. The customer was able to print prototypes on Monday and carry out tests on Wednesday. This halved the development time and saved the company considerable costs in product development. The flexibility made it possible to react to customer requirements in a much more agile manner.
Cost efficiency and material optimisation through 3D printing technology
Cost-effectiveness is a key argument in favour of the introduction of additive manufacturing. Small batches are produced without expensive moulds[4], which fundamentally distinguishes 3D printing technology from traditional processes. With injection moulding, expensive moulds have to be produced. These are only amortised for large quantities. It works differently with 3D printing.
The Alpha Precision Group reduces costs and lead times for metal parts by up to 90 per cent thanks to 3D printing.[2] Such savings enable completely new business models. Companies can suddenly work economically where it was previously impossible. This opens up niches and new markets[8].
Material efficiency and waste reduction with 3D printing technology
An important point often overlooked: Material waste. Traditional manufacturing processes produce a lot of waste. Large quantities of material are removed during milling and turning. With 3D printing, material is applied in a targeted manner[1] and there is no unnecessary waste. Manufacturing can produce smaller series much more cheaply and quickly[1].
The Ultimaker S5, for example, is a high-volume desktop 3D printer. It can extrude industrial, abrasive composites and plastics from leading material suppliers[3] and can be learnt to operate within a short training phase. The post-processing time of the prints is marginal[3].
The advantage is particularly evident when it comes to spare parts. Car manufacturers have to keep spare parts in stock for 7 to 10 years[3], which ties up enormous amounts of capital. According to a DHL report, spare parts storage accounts for more than 20 per cent of unused stock.[3] 3D printing technology can be used to produce parts on demand. The digital warehouse replaces physical stocks.
Optimise warehouse management through demand-oriented production
Studies show: By consolidating slow-moving products, companies save up to 17 per cent of storage space[3], which is not just a small cost saving. For companies with limited space, this means real flexibility. There is no need to check and rationalise work in progress and safety stock. Time and resources are saved[3].
Maintenance benefits considerably from the fast and independent procurement of spare parts.[1] Whereas a machine failure used to be synonymous with a production stop, it can now be resolved. A spare part is produced from digital data. This works locally and quickly. Delivery times are eliminated. The machine continues to run.
Opening up new business areas with additive manufacturing
3D printing technology opens doors to completely new business models. Companies that want to occupy niches will find their opportunity here.[8] Small and medium-sized companies in particular will benefit. They can react flexibly to changes in demand. High investments in moulds are no longer necessary. Small batches and customised products can be produced economically[2].
3D printing technology represents a promising opportunity in the food and confectionery trade.[8] Innovative products are being created. Value chains are being completely redesigned. Companies can create collector's items through limited editions. Seasonal variations are easily realised[8].
BEST PRACTICE at the customer (name hidden due to NDA contract): A craft business from Hesse recognised the potential of 3D printing technology for individual customer requirements. Instead of standardised products, the company now produced customised solutions. Large retail chains became customers. Sales rates increased because products finally met real customer requirements. What began as an experiment became the company's new business pillar. Turnover tripled within two years.
Using individualisation as a competitive advantage
The trend towards individualisation and batch size 1 has been on the rise for years.[6] Customers want products that correspond exactly to their ideas. With traditional methods, this is often impossible or far too expensive. 3D printing technology makes it possible. Each component can be customised as required[6].
In mechanical engineering, additive processes enable the creation of complex geometries without expensive tools.[10] Designs that were previously purely theoretical become possible. Designers have more freedom. They no longer have to think within the boundaries of traditional manufacturing techniques.
Aerospace: lightweight construction through 3D printing technology
In industries such as aerospace, 3D printing technology is helping to make components lighter.[9] Weight is reduced. Material costs fall. Stability and functionality are retained.[9] One kilogramme less weight in an aircraft means real fuel savings over its entire service life.
Medical applications show similar potential. Customised implants and prostheses are created[2] and surgical models are printed. Clinical processes are simplified. Patient care is improved.[2] Surgeons train on realistic models before complex operations.
Transforming supply chains with additive manufacturing
The impact on supply chains is enormous. Parts can be produced in line with demand. They are produced quickly and cost-effectively. They can be dispatched within days instead of weeks[7]. 3D printing helps to reduce supply risks. Dependence on individual suppliers is reduced. A product becomes future-proof because spare parts are created from digital data[7].
Groupe SEB, manufacturer of KRUPPS coffee machines, works with 3D printing service providers. This means that the 10-year repair promise is honoured[7] and spare and replacement parts are produced as required. Large, expensive stocks are no longer necessary.
Shorten time to market with 3D printing technology
Time to market is a critical success factor. 79 per cent of new products miss their launch dates.[7] This is a huge opportunity for 3D printing technology. It makes 3D printing the fastest option for short print runs and prototypes.[7] No commitment to minimum orders. No batch size constraints.
Small series are produced in record time. Injection moulding takes months to produce tools. Enquiries to plastics manufacturers are completely eliminated[6] and development teams work more agilely. Speed becomes a real competitive advantage.
Reduce labour costs through automated production
In the past, outsourcing to low-wage countries was standard. This worked because labour costs were low. 3D printing fundamentally changes this calculation.[3] The dependency on this variable decreases. One person can run a small spare parts production directly in the warehouse[3].
Intuitive printer management software such as Cura Connect ensures increased uptime and reliability.[3] After commissioning, the machines work independently. Labour costs per hour are drastically reduced. Material prices are lower. The part is built from scratch, not milled from a blank.
Material diversity and technical possibilities are expanding
The choice of materials is now extensive. Components can be produced for almost any load and any optical requirement[6] In addition to various types of plastic, there is also additive manufacturing with metal components. Flexible materials are possible. Transparent materials work. Ceramic 3D printing has arrived in the industry. Even coloured concrete is being printed[6].
This variety of materials makes 3D printing technology a universal solution. It works in industries that have completely different requirements. A plastic part for the furniture industry. A metal part for mechanical engineering. A ceramic element for architecture. Anything is possible with 3D printing technology.
Realise complex geometries economically
Traditional manufacturing techniques become profitable when volumes increase[7] and the high set-up costs are justified by large production volumes. It is different with 3D printing technology. Complex geometries do not cost more. A simple geometry does not cost less. The costs depend on material and size, not complexity[13].
This opens up completely new design possibilities. Designers think creatively. Assemblies are completely rethought. Several milled or turned components are replaced by a single 3D-printed part. That is lighter. Cheaper. Faster available.
BEST PRACTICE at the customer (name hidden due to NDA contract): An electronic appliance manufacturer from Bavaria reduced the number of construction
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