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The Future Looks Bright for Additive Manufacturing

Thu Nov 30 00:00:00 EST 2017

As more companies embark on their digital transformation, they are increasingly reevaluating their manufacturing processes. They're exploring how 3D printing can enhance and augment traditional manufacturing methods.

Additive manufacturing is a powerful force within digital manufacturing, bringing new applications and markets into focus. In the future, the additive manufacturing market is predicted to reach $55.8 billion by 2027, according to a recent report by Smithers Pira.

Here is how we think the future of 3D printing will enable this journey:

Traditional versus Additive Manufacturing: A Seismic Shift

Traditional manufacturing processes such as machining and injection molding have emerged as industry standards for high-volume mass production over the past half century. These methods make perfect sense due to their low cost and high quality, while 3D printing has been relegated to rapid prototyping and low-volume production runs. 

Currently, only 29 percent of manufacturers are using 3D printing for production parts, according to a recent survey sponsored by Jabil. But as 3D printing becomes more efficient and the material offering expands in the future, we expect this figure to climb. 

Siemens predicts that 3D printing will be 50 percent cheaper and up to 400 percent faster in the next five years. Therefore it should come as no surprise that 93 percent of manufacturers expect to grow their use of 3D printing for production parts in the next three to five years, according to the Jabil-sponsored 3D Printing Trends survey

Download the Whitepaper: 3D Printing Trends

Distributing the Manufacturing Process

Distributed manufacturing is changing how companies are incorporating 3D printing into their digital strategy. Instead of considering a centralized solution, distributed manufacturing enables companies to decentralize production so they can manufacture the final product closer to the customer. 

With 3D printing, manufacturers can better connect the physical supply chain with a digital thread and manage products more efficiently from concept to end-of-life. Manufacturing can be distributed to any location that has digital manufacturing systems in place simply by sending a file. This decentralization enables a more collaborative, transparent, and efficient supply chain orchestration

Three Ways Additive Manufacturing Will Disrupt Industry

According to a PwC survey of manufacturers, the most disruptive effects of 3D printing will be:

  • The Restructuring of Supply Chains: Incorporating additive manufacturing to existing processes may require a great deal of time and effort for companies to digitize and restructure their supply chains. But that's not holding back companies from starting their digital journey. According to Jabil's Digital Transformation Survey, 90 percent of manufacturers are in the middle of their digital transformation efforts, however only 23 percent have a corporate-wide strategy. 
  • Threats to Intellectual Property: Additive manufacturing may increase cases of infringement on patents, copyrights and trademarks. Whereas the early 2000s marked the height of piracy in movies, TV shows and music, the future of piracy may be in computer-aided product design (CAD) files. These threats to intellectual property may result in time-consuming and expensive litigation.  
  • Changed Relationships with Customers: Customer relationships evolve as companies go through the digital transformation. As 3D printers become more ubiquitous and shoppers have new ways to purchase products, companies will need to focus on the customer-centric strategies. 

 

Widespread Additive Manufacturing Adoption is Expected Soon

Sixty percent of manufacturers expect 3D printing use to at least double in two to five years, according to the 3D Printing Trends survey. As more companies use 3D printing in production, the budgets allocated for additive manufacturing will also grow. Fast Radius reports that 40 percent of companies expect their 3D printing budget to increase by more than 50 percent in the next 12 months. 

Applications for 3D printing in existing markets will continue to increase in the future as today's production applications will be expanded by the capabilities of additive manufacturing. Industries such as aerospace and automotive have already begun adopting 3D printing to produce better performing parts while minimizing costs. But it's not just industrial markets that bring opportunity. New markets such as food, fashion products, eyewear and textiles are all set to be disrupted by 3D printing. Imagine the following scenarios:

  • Nutrition customization may be improved by printing meals using specific food cartridges based on dietary restrictions, allergens and other preferences,
  • Printing the perfect outfit for a night out or interview with a 3D printer, using your exact measurements for clothes that fit you perfectly every time,
  • 3D printing your eye wear, with access to better quality and thousands of options. 

New Opportunities Will Drive More Investment

With so many opportunities on the horizon, companies will have to focus which initiatives they'll invest to utilize additive manufacturing. The top three initiatives for investment include: 

  • designing new parts for production, 
  • on-demand production 
  • and reducing time-to-market. 

Developing a new production part can require multiple iterations and prototypes before the customer's needs are met. 3D printing enables rapid prototyping, which can reduce the time it takes to build a prototype from weeks to just 48 hours. This rate helps new parts move more quickly through the design cycle to production.

Producing a part on-demand with 3D printing enables manufacturers to print parts as needed instead of pulling the part from a supply warehouse. On demand production will help companies realize huge reductions in inventory and storage costs. In the automotive industry, for example, spare parts inventory could be reduced by 90 percent with 3D printing, according to a report from MIT.

Time-to-market is critical for brands that want to beat their competition to the store shelf, especially in New Product Introduction (NPI). With 3D printing, the manufacturing process can speed up significantly, helping brands design, manufacture and distribute products to consumers faster. 

Breakthrough Technologies in Additive Manufacturing

Several new markets and technological advancements are helping drive a 3D-printed future:

  • Continuous Liquid Interface Production (CLIP): Continuous Liquid Interface Production (CLIP) was recently introduced with the promise of advancing the industry beyond prototyping to 3D manufacturing. The process differs from other methods in that it grows parts instead of printing them layer-by-layer. By combining oxygen and UV light, CLIP grows objects from a puddle of resin. The process produces commercial quality parts that are consistent, predictable and 25 to 100 times faster than traditional 3D Printing.
  • Soft Robotics: Soft Robotics is a 3D printed synthetic muscle that is three times stronger than natural muscle. This human-like material enables soft robots to be untethered and mimic natural biological systems. It can be used in a number of applications including patient-customized orthotics and prosthesis.
  • Manufacturing Production Components for Aerospace: From rocket engines to turbine blades, 3D printing enables production components to be produced in large scale and at the highest quality. For complex aircraft, reducing the material weight of parts and components is critical for maximizing efficiency.

Healthcare: A Market Ripe for Disruption

Healthcare is one industry in particular that will continue to be transformed by additive manufacturing. Use cases such as prosthesis manufacturing, bioprinting and medical implants are pushing the healthcare 3D printing market forward towards an expected $2.2 billion by 2024, according to Global Market Insights.

Traditional prosthetics have often been expensive and unflattering, with some costing as much as $100 thousand. Thanks to the evolving 3D printing technologies, these costs can be reduced by 99 percent or more. Personalized prosthetics can actually be more affordable for those who need them most. 

Prosthetics are only the beginning for the healthcare 3D printing market. Researchers have been experimenting with bioprinting cartilage and bones using bio-ink containing stem cells. Considering the complications and complexity in organ transplants, as well as the mere shortage of donors, using stem cells to bioprint fully-functioning human organs open doors to a world of possibilities. Although we may not be there just yet, the future is bright.   

Consider medical implants, another area 3D printing can transform the healthcare experience. Implants can often require complex shapes. With 3D printing, doctors can take a scan of the patient to develop a customized implant with the perfect fit. The whole healthcare experience can be personalized down to each patient. Dentists and hearing aid manufacturers have already been utilizing 3D printing to their advantage, but the true value of additive will show when we can truly transform the industry. 

What is the Future of Additive Manufacturing?

The future of additive manufacturing looks bright. In the future, 3D printing will position itself more prominently in the manufacturing landscape. As costs continue to reduce and processes become more efficient, the possibilities for use-cases will expand considerably. 

Download the Whitepaper: 3D Printing Trends