Additive manufacturing vs. traditional manufacturing?

Due to rapid technological advancements, the manufacturing industry has changed at a rapid pace in recent years. Digital transformation is changing the entire business world, including the manufacturing industry. Manufacturers must adopt new technologies to remain competitive with the increasing demand for smart factories equipped with data collection and analytics systems, artificial intelligence (AI) solutions, and connected devices.

3D printing, or additive manufacturing (AM), has also changed manufacturing dramatically in recent years. The process of creating products by depositing material layer by layer is known as additive manufacturing. In contrast, traditional manufacturing uses subtractive processes such as cutting or milling.

There are numerous types of AM, but they all rely on the same basic principle of creating products from individual layers. AM can create products made of metals, plastics, ceramics, and more. The introduction of AM has significantly impacted the manufacturing industry, and we need to know how it differs from traditional manufacturing. Now let's take a closer look at one of the manufacturing's future vital elements and see how we can utilize it.

Now let's take a closer look at one of the manufacturing's future vital elements and see how we can utilize it.

Manufacturing in a conventional way

Traditional manufacturing processes for plastics, such as injection molding, require different approaches to designing and manufacturing products than AM. Conventional manufacturing processes such as forming and injection molding are better suited for producing larger quantities, while 3D printing can be more cost-effective for smaller amounts.

Injection molding, machining, forming, and joining for plastics manufacturing are four standard manufacturing processes. Each manufacturing process, such as 3D printing, has benefits and drawbacks.

Injection Molding: Injection molding is a method of injecting molten plastic into a mold and cooled to form a solid component. This process allows for mass production with consistency and accuracy, making it ideal for highly demanding applications. However, the start-up costs for an injection mold are frequently prohibitively expensive, making this manufacturing process unsuitable for small batches.

Machining: Drilling, milling, and turning can be used to make almost any material into a part. During CNC machining, a piece of material is clamped into the machine, and a numerically controlled tool removes the material until the part is complete. The material selection is extensive, as with injection molding, and can be tailored to the specific application. Machining tolerances (25 m) are incredibly tight, allowing for the production of exact parts. Producing undercuts or internal features, however, can be complex. CNC milling is frequently used for one-offs, functional prototypes, and engine and machine parts because the material is removed selectively.

Forming (Plastics): Plastic forming methods are classified into thermoforming, vacuum forming, and pressure forming. Each type differs in some ways, but they all heat a sheet of plastic and drape it over a mold, forming the sheet into a shape with air pressure and male plugs. Almost all thermoplastics are available as sheets and can be created with them. However, forming is a one-sided process, so the tool surface can only control one side of the plastic sheet. Forming processes have lower tooling costs than injection molding, particularly for more extensive, simpler objects.

Joining: Plastics joining is the joining of semi-finished parts. Examples include joining, bonding, and welding. The incorporation of latches, hinges, and snaps into the construction of a part and external fasteners such as bolts and screws is referred to as fastening. Bonding is the process of joining two pieces together by using an adhesive (such as epoxy). Welding is the process of joining two parts together using heat and pressure. Because the parts are already semi-finished when they are to be joined, many of the joining process specifications are dependent on how the semi-finished parts were manufactured. Even though the joining process depends on the shape of the part, it can be time-consuming and costly. [1]

In Summary:

• Each manufacturing process, such as 3D printing, has benefits and drawbacks.
• Conventional manufacturing processes such as forming and injection molding are better suited for producing larger quantities, while 3D printing can be more cost-effective for smaller amounts.
• Injection molding is a method of injecting molten plastic into a mold and cooled to form a solid component. For small batches, injection molding is unsuitable due to high start-up costs.
• CNC milling is frequently used for one-offs, functional prototypes, and engine and machine parts because the material is removed selectively. However, it can be complex.
• Thermoforming, vacuum forming, and pressure forming all heat a sheet of plastic and drape it over a mold, forming the sheet into a shape with air pressure and male plugs. Forming is one-sided, so the tool surface can only control one side of the plastic sheet
• Plastics joining is the joining of semi-finished parts. It can be time-consuming and costly.
• Production costs are typically higher with conventional manufacturing. However, you can achieve economies of scale by producing large quantities of products, resulting in much lower unit costs.

Additive manufacturing produces three-dimensional objects from digital files

Additive manufacturing creates three-dimensional solid objects from a digital file by applying material until the maker's desired shape is achieved. There is no distinction between 3D printing and AM. Both 3D printing and AM refer to the same process, and both terms refer to creating parts by joining material from a CAD file layer by layer. AM is sometimes referred to as Direct Digital Manufacturing (DDM) because things are produced directly from a digital design without intermediate steps. [2]

Key takeaways include:

• AM technology has existed for decades but has only recently gained widespread attention and adoption.
• Another reason is that AM offers several advantages over traditional manufacturing methods, including lower costs, shorter lead times, and greater flexibility.
• As a result, more manufacturers are using AM in various applications, from rapid prototyping to custom manufacturing.
• This will enable a broader range of applications, from small-scale prototyping to full-scale production.
• Ultimately, AM has the potential to revolutionize manufacturing and unlock new possibilities for product design and development.
• In addition to its technical advantages, AM also offers environmental benefits.
• By reducing the need for large-scale manufacturing processes and associated materials, AM can help reduce waste and energy consumption.
• In summary, AM is a powerful technology with the potential to revolutionize manufacturing and unlock new possibilities for product design and development.
• It offers several advantages over traditional manufacturing methods, including lower costs, shorter lead times, greater flexibility, and environmental benefits.
• As AM becomes more accessible and affordable, its use in various applications will continue to grow.

Conclusion

To summarize, additive manufacturing is a rapidly evolving technology that offers numerous benefits over traditional manufacturing methods. Because AM does not require the same setup time or level of machining operation as conventional methods, it allows for faster prototyping and design iteration.

You can realize complex geometries quickly and on demand thanks to AM.

Furthermore, customization of parts for specific needs allows manufacturers to produce unique products in less time than traditional manufacturing. Again, allowing manufacturers to decentralize their manufacturing operations with more flexible AM machines can open up new doors for small companies by making required components and parts available in much shorter turnaround times than traditional manufacturing.

TPC assists businesses in becoming more competitive by providing them with state-of-the-art 3D printing and AM technologies. We have a variety of materials and processes available to meet specific needs, and our team will find the right solution for your application. Get in touch with our team today to realize the full potential of AM.