3D printing technology: New opportunities for decision-makers and managers

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The digital transformation of manufacturing processes is progressing rapidly. Companies around the world are discovering the potential of additive manufacturing for their business models. 3D printing technology is not only revolutionising the production of prototypes, but is also changing fundamental processes in production, logistics and warehousing.[1] As a decision-maker and manager, you are faced with the question: How do we strategically exploit these opportunities for our company?

Why 3D printing technology is relevant for your business now

The barriers to entry into additive manufacturing have fallen. The technology is now affordable, the expertise is available and the applications can often be implemented more quickly than just a few years ago.[1] For many industries, the question is therefore no longer whether 3D printing makes sense. Rather, it is a question of strategic implementation.

The advantages are particularly evident in complex industries. A car manufacturer can shorten its development cycles by weeks. A medical technology company produces customised implants directly for individual patients. A mechanical engineering company optimises its supply chain through decentralised spare parts production.

However, additive manufacturing also offers real opportunities for SMEs. It reduces costs, increases flexibility and creates new business models. Those who actively shape this transformation will secure long-term competitive advantages.

Cost savings through intelligent 3D printing technology

One of the most important findings for decision-makers: 3D printing technology significantly reduces production costs. Massive savings can be made, especially with small series and complex components.

Take the example of spare parts storage. Large companies often store parts for seven to ten years. According to recent studies, these slow movers account for more than 20 per cent of unused stock.[3] With 3D printing, you can produce parts on demand. This saves storage space by up to 17 per cent[3] while also significantly shortening delivery routes.

In traditional manufacturing such as injection moulding, high costs are incurred through tool production. Changes after the mould has been created cost time and money. With additive manufacturing, you can adapt designs flexibly without creating new moulds[1].

BEST PRACTICE at the customer (name hidden due to NDA contract): A leading machine manufacturer used 3D printing technology for customised cooling concepts in plastic parts. The results were impressive: waste was reduced by 30 per cent, while overall quality increased[8]. At the same time, the company saved considerable monthly warehousing costs because parts were only produced when needed.

Another example from the automotive industry shows the economic power of 3D printing: the use of 3D printing has reduced costs and lead times by up to 90 per cent compared to outsourcing solutions[6].

Optimise material and labour costs

Additive manufacturing utilises material precisely. There is hardly any waste as with traditional milling or turning. This not only saves raw materials, but also disposal costs.

Similar principles apply on the labour cost side. A trained person can operate a small spare parts production facility directly in the warehouse.[3] Modern printer management software also automates processes. After commissioning, the machines work largely independently.

Faster product development through additive manufacturing

Rapid prototyping is a classic of 3D printing technology. But the opportunities go far beyond quick samples. Additive manufacturing shortens entire development cycles.

Design and development benefit directly. Prototypes are created in days instead of weeks. Teams can quickly test, obtain feedback and adapt designs[2], which significantly accelerates innovation.

Freedom of design is particularly important here. With 3D printing, you can realise complex geometric shapes that would be impossible with conventional manufacturing methods.[5] Engineers design lighter, more functional and more innovative solutions.

Iterative processes and competitiveness

Fast-moving markets require iterative development. 3D printing makes it possible to test different solution variants as prototypes.[2] Teams talk together on site and modify the design and material according to requirements.

This is a real competitive advantage. According to studies, 50 per cent of the companies surveyed see 3D printing as a strategic competitive factor.[4] Those who innovate faster gain market share and customer confidence.

An example from medical technology: surgical instruments and templates can be customised to the patient's geometry. The production of customised, high-performance parts reduces complications and improves surgical results[6].

Supply chain transformation with 3D printing technology

3D printing technology is fundamentally changing how companies organise their supply chains. The biggest advantage is that additive manufacturing is not an isolated process. It enables a holistic end-to-end process[3].

Instead of producing centrally and shipping globally, you can produce decentrally and in line with demand. This reduces dependencies on suppliers and lowers the risk of demand forecasts[3].

The COVID-19 pandemic demonstrated this impressively. Companies that used 3D printing were able to keep machines in operation and close supply chain gaps. They produced spare parts on site instead of waiting months for deliveries[6].

Rethinking maintenance and spare parts logistics

Maintenance teams benefit massively from fast, independent spare parts procurement[2]. Instead of waiting for centralised warehousing, you reprint parts as required.

This is particularly valuable for long-term products. A car manufacturer often has to keep spare parts in stock for decades. Digital databases plus 3D printers replace massive physical inventories.

A practical example: A mechanical engineering company used to store hundreds of different fastening parts. With 3D printing, he stores digital designs and produces them on demand. Storage space decreases, availability increases.

Industry-specific opportunities for additive manufacturing

3D printing technology opens up different opportunities in various industries. An overview of sectors that are already benefiting:

Automotive industry and lightweight construction

In the automotive industry, additive manufacturing enables weight reduction without loss of stability. This saves material costs and improves energy efficiency.[5] Complex cooling channels in plastic parts optimise manufacturing processes. Mould equipment and production aids are created quickly and cost-effectively.

Medical technology and healthcare

Customised medical applications are one of the strengths of 3D printing technology.[7] Surgical instruments, implants and templates can be produced specifically for each patient. This improves surgical results while reducing sterilisation and transport costs[6].

Aerospace

Every gram of weight counts here. Additive manufacturing enables internal cavities and complex geometries that save weight and reduce costs.[7] This effect is particularly valuable for expensive materials such as metals.

Implementation strategy: from idea to realisation

The opportunities are clear. But how do you actually bring 3D printing technology into your company? A few tried and tested steps can help:

Make or buy - own machines or external services?

This decision is crucial. External 3D printing services save investment costs for machines, material storage and specialised personnel[2]. The cost structure is transparent and predictable, which makes budget planning easier.

External service providers have large machine capacities and a wide range of materials. They can offer different printing processes and materials until the optimum solution is found[2], which is ideal for explorative phases.

In-house production is worthwhile for high ongoing volumes or strategic differentiation. Then you have immediate availability and can work iteratively on site.

BEST PRACTICE at the customer (name hidden due to NDA contract): A medium-sized electrical engineering company initially used external 3D printing services for prototypes. After successful use and growing quantities, it invested in its own machine. This allowed it to combine flexibility with cost savings. Today, the company produces small batches more cheaply and quickly than was previously possible.

Carry out pilot projects in a structured manner

Not every application is suitable for 3D printing. Start with specific pilot projects that have clear economic goals. For example: reduce prototyping time by 50 per cent, reduce spare parts costs by 30 per cent or enable new product functions.

Measure success transparently. Compare costs, time and quality with previous solutions. Learn from the findings for future projects.

Team qualification and knowledge transfer

3D printing expertise is easily accessible today. Intuitive printer management software makes it easy to learn how to operate[3], but targeted training for design, production and maintenance is still worthwhile.

Important: Communicate that 3D printing technology requires new ways of thinking. Engineers must learn to optimise designs for additive manufacturing. Maintenance must understand how decentralised production works.

Frequently asked questions from decision-makers

For which parts is 3D printing really worthwhile? Additive manufacturing shines when it comes to smaller series, complex geometries and customised products. For mass production of standardised parts, traditional processes are often more cost-effective.

What about quality and reliability? Modern 3D printing materials achieve high precision and resilience. Specialised service providers are definitely the first choice for functional parts[6].

What hidden costs are there? Pay attention to post-processing and quality checks. With modern technologies, these times are marginal,[3] but you should still take them into account in your calculations.

How long does an implementation take? Pilot projects can often start in just a few months. Full integration into processes takes more time and requires patience with learning curves.

Limits and realistic expectations

3D printing technology is not a universal tool. It works excellently for specific applications, not for all manufacturing issues.