Transforming Prototyping: Additive Industries Leverages Metal 3D Printing to Slash Development Costs and Accelerate Production

Additive Industries Private Limited is a startup from Bengaluru that specializes in providing technical solutions to various premium industry sectors. Initially a proprietary firm, they transitioned to a private limited company in 2021 and have since earned the trust of their customers by offering End-to-End Digital Manufacturing services. Today, they cater to sectors such as aerospace, automotive, engineering, dentistry, and various other branches of the medical industry. Their customers prefer Additive Industries as a single-window solution for their rapid prototyping needs, including 3D scanning, 3D CAD modeling, re-engineering, dimensional analysis, non-destructive testing, and solutions tailored to modern manufacturing challenges.

Challenges

In today’s fast paced manufacturing world, customers’ demands are as well evolving in optimizing the product development from conception stage itself in sustainable manner. Having inhouse capabilities to tap in the potential of partnering with their customer in new product development or re-designing the parts, remains core strength. The mutual targets posed are to shorten the product development lifecycle and reduce the cost of product development.

Starting from in house specialties like 3D CAD modeling, 3D Scanning, dimensional analysis and re-engineering etc. Additive Industries were well equipped. But when it came to producing the prototypes, the organization was dependent on external service providers with traditional manufacturing practices like casting, milling, turning, and drilling etc. While these subtractive manufacturing processes are cost-effective for mass production, they often fall short in three key areas for prototyping:

1.????? The design freedom, due to limitations of conventional manufacturing processes

2.????? Development lead times, due to many manufacturing steps involved

3.????? Overall cost-effectiveness

?Mr. Anand Kumar Venkataswamy, the Managing Director of Additive Industries, shares these were the key limitations they faced in meeting the demands of large clients, including government bodies and private sector entities. These challenges are typical in large-scale prototyping for critical sectors like aerospace and automotive.

Solution?

A chance meeting with TRUMPF team at a client’s premises introduced Mr. Anand to TRUMPF’s metal 3D printing technology.

In this manufacturing technology a workpiece is built up gradually in a powder bed. To do so, a laser melts down the metal powder in material layers precisely at the points specified by the component's CAD construction data. And this sounded like a natural fit in the product development chain to Mr. Anand. The compatibility of this manufacturing technology complements the downstream and upstream processes in prototype development.

The process is optimally suited for series production of geometrically complex parts with delicate internal channels and cavities that cannot be produced using conventional processes such as turning or milling or can only be produced ineffectively. Recognizing its potential to handle volumes and bring significant design freedom, Additive Industries decided to integrate TRUMPF's machines into their operations.

Implementation

After in-depth assessment of part requirements from focused industry segments like automotive and aerospace, typically bigger parts sizes, Mr. Anand and his team chose to go with TruPrint 3000 machines from TRUMPF. These machines have been rigorously used for all their customers across prototyping and quick-production needs.

While producing parts for aero engines and other research activities for aerospace, TruPrint 3000 has significantly boosted the overall efficiency and part quality. Traditional methods were costly for frequent design changes and slower in production as they involved many steps, while TruPrint 3000 facilitated rapid prototyping and production at much lower costs.

In the automotive sector, it has been extensively used for conformal cooling needs, enhancing the quality of mass-manufactured plastic parts. The precision and efficiency of machine allowed for immediate cooling channels, improving the manufacturing process, and drastically reducing waste. The TruPrint 3000 can print parts of size up to 300 mm diameter and 400 mm height. That serves requirements of most of the Additive Industries’ customers.

Along with design freedom, faster lead times and cost efficiency, the TruPrint 3000 has enhanced service capabilities of Additive Industries to handle more complex applications like functional integration in parts and customization. This has resulted in more satisfied customers and an expanded customer base.

Testimonial

?Mr. Anand shares, “Unlike challenges in adopting new technology in existing production setup, TruPrint 3000 was an easy integration in to our business. Due to its capabilities, ease of operation and support offered by TRUMPF team in India, our machines started printing complex parts and expanded our business in no time.”

He adds, their clients including research institutions and players in aerospace and automotive industries, have consistently appreciated the quality and precision of the 3D printed parts produced on TRUMPF’s machines, meeting stringent requirements, and delivering consistent results. Mr. Anand confidently recommends TRUMPF to other businesses in the industry.