For many years, 3D printing was primarily associated with prototyping, but its role has significantly evolved. In recent times, additive manufacturing has become a viable production method, particularly for components that are difficult to source, such as those needed in isolated environments like ships or space missions. Today, 3D printing is increasingly seen as a legitimate option for full-scale production, especially in industries with high standards and rigorous requirements, such as healthcare.
At MD&M Minneapolis, Carl Douglass, CEO of DI Labs, will discuss the advancements of 3D printing in production during his session, Additive Manufacturing for Production: Product Management, Economic & Technical Considerations, scheduled for Thursday, October 17, from 11:15 AM to 12:00 PM. Douglass will explore the advantages and challenges of using additive manufacturing for producing end-use components.
The Shift from Prototyping to Production
According to Douglass, the primary goal of 3D printing in production is to develop, launch, and manage products more efficiently, particularly in sectors like healthcare. “3D printing has long supported the improvement of product development, and in the past decade, it has played an increasingly important role in product introduction phases,” said Douglass. He emphasized that the flexibility 3D printing offers—such as personalization and the ability to make real-time iterations—is what makes it so valuable in industries that require constant innovation.
Additive manufacturing allows companies to produce on-demand parts, reduce startup capital requirements, and enable rapid product iterations. However, Douglass cautions that implementing 3D printing for production isn’t as straightforward as some printer manufacturers might suggest. There are still technical hurdles and learning curves to overcome, particularly when scaling up production.
Scaling Additive Manufacturing for Production/h3>
During his session, Douglass will share lessons learned about the challenges and opportunities of scaling 3D printing for production. He will discuss how additive manufacturing can be applied in various industries, from medical devices to aerospace and consumer goods. One key takeaway is that while 3D printing can handle production volumes ranging from tens of thousands to even 100,000 parts, it is most valuable for components that cannot be made using traditional methods like injection molding.
“Most of our business—about 80%—is in producing tens of thousands to hundreds of thousands of parts annually,” Douglass explained. Although 3D printing is typically more expensive than injection molding, it excels at producing parts that are either too complex or impossible to mold. This flexibility has made it a critical tool for sectors that need customized or low-volume components.
The Role of Mass Customization and On-Demand Production
One of the most exciting developments in additive manufacturing is the ability to create mass-customized parts. According to Douglass, the technology is ready to handle this kind of personalization in large volumes, but the challenge lies in the digital infrastructure. “The hardware is there, but manufacturing isn’t set up to manage infinitely variable SKUs,” Douglass said, pointing to the need for software solutions to handle mass customization efficiently. As artificial intelligence becomes more integrated into manufacturing processes, he believes that the industry will achieve direct-to-customer volume production.
In industries such as healthcare, 3D printing has already proven valuable for rapid real-time iterations. Douglass noted that many medical clients use 3D printing during clinical trials to quickly make and test adjustments. This agility, paired with the speed of on-demand production, allows companies to make modifications and validate them without the need for costly and time-consuming tooling.
Lessons in Managing Additive Manufacturing for Success
Douglass emphasized that success in 3D printing for production requires a shift in mindset from traditional manufacturing practices. Unlike injection molding, where parts are consistent and repeatable, 3D printing introduces more variability. “The parts don’t always come out the same,” Douglass said. To overcome this, companies need a solid process for feedstock management, process control, and inspection to ensure quality and consistency.
He also highlighted the importance of rigorous management practices, stating that 3D printing requires more oversight than traditional manufacturing to ensure the success of production workflows. The paradigm shift from traditional methods to additive manufacturing necessitates a greater focus on process control and product management to ensure the reliability and success of the final product.
