METAL 3D PRINTING

3D printing is changing things in many industries including Manufacturing and Natural

Resources. It is a game changer in spare parts production. 3D printing is revolutionizing the
manufacture, storage, and shipping of spare parts and hence solving many problems for Asset
Intensive industries that has machinery/equipment that needs to be maintained. With 3D
technology, manufacturers and producers will not have to rely on external spare part
manufacturers suppliers. The technology comes with ease of production that even amateurs can
implement. However, even if a manufacturer of a product chooses to work with an external
spare parts supplier, the process will be more seamless and timely. No delays that cause losses.
By 2022, 85% of spare parts suppliers will embrace 3D printing.
3D technology can save companies money as the production of spare parts can be done
on-site. For example, a company can have a space for the 3D printers within the company hence
save on transportation costs and cut on the cost of expediting. On-site production costs less
money than overseas production of spare parts if you take into consideration transportation,
urgency and delays. Companies can circumvent suppliers to manufacture their spare parts on
their own using 3D printing technology.
Additionally, the goal of 3D printing is to produce on-demand spare parts as opposed to
producing and storing the parts. This saves companies a lot of money since they can only order
spare parts when they need them in the exact quantity they need, therefore no money will be
spent in storage. Also, no expenses will be incurred to replace spare parts exposed to tear and
wear in the warehouses.

Industries that have embraced 3D printing of spare parts

The aviation industry among the pioneer industries to adopt 3D printing technology for
its spare parts. Aircraft and engine manufacturers are investing in 3D printing to reap its
numerous benefits. The automotive industry has not been left behind too. Famous car
manufacturers Mercedes-Benz and BMW are leading the way in embracing 3D printing.
BMW, for example, has set up a 3D metal printing startup while Mercedes Benz lets
customers' print 3D spare parts for their freight trucks. The rail industry is also investing in 3D
printing of spare parts with Deutsche Bahn and Siemens pursuing the
technology.Siemens reports that the ability to print spare parts when it needs them has reduced
costs and decreased dependency on suppliers to manufacture parts.
Advancement in the 3D printing technology to produce spare parts has seen many
partnerships being formed to this effect. For instance, Whirlpool, an American home appliance
manufacturer has teamed up with Spare Parts 3D, a Singapore firm to produce spare parts for
Whirlpool. Among the most significant outcomes of the partnership is cost savings. Whirlpool
will not incur inventory expenses by storing high quantities of spare parts. Once a part is broken
or lost, Spare Parts 3D manufactures a replacement promptly.

Problems facing manufacturers and how 3D printing solves them

The process of making, storing, and shipping spare parts is time-consuming and very
expensive for both suppliers and customers. The good news is that 3D printing solves many of
these problems and has positive outcomes for optimized inventory, decreased costs, and
increased efficiency.
1. Material waste
Material waste is among the areas that are milking product manufacturers dry. When using
subtractive manufacturing techniques such as milling, so much material is wasted. A
manufacturer uses only 30-60% of a block but pays for the entire block. This means that 40-
70% of material goes to waste. This has a cost implication. When making huge parts, the
wastage is massive, and the associated cost is prohibitive. However, 3D printing reduces
material wastage and its associated costs. It reduces material waste costs by 95%. This
means that a company that uses 3D printing for its spare parts will save a lot of money on
huge projects.
2. Inventory storage
Manufacturers across different industries struggle with maintaining and storing spare parts
inventory. They incur huge storage costs that increase their operating expenses and reduce
their bottom line. Labor and maintenance costs contribute significantly to high inventory
costs. With 3D printing, there is no need for spare parts inventory as the company can
produce spare parts only when demand arises.
3. Turnaround time
Traditional manufacturing of spare parts is time-consuming. At times, companies have to
rely on overseas manufacturers of spare parts to meet their demand. In such instances a
company's operations will be sabotaged hugely due to the time it takes for the spare parts to
reach the company if something needs urgent maintenance.
4. Costs
Buying spare parts is costly from material to storage and maintenance expenses. However,
3D printing makes it less costly and hence saving manufacturers in different industries
thousands or even millions of dollars. 3D printing cuts material costs, inventory storage
expenses, and turnaround time. A survey on 38 German industrial firms revealed that using
3D printing technology, spare parts suppliers will save approximately €3 billion annually
which leads to reduced costs for customers as well.

Benefits of 3D printing spare parts

 Reduce lead time: Spare parts can be manufactured easily and quickly within the
company's premises.
 Increase spare parts availability: With 3D printing, firms can always make any spare
part whenever they need it. There's no rarity of spare parts for firms with 3D printers.
 Cut costs: 3D printing will cut costs significantly in the production of spare parts. It will
reduce the costs of producing, transporting, and storing spare parts.
 Increase customer satisfaction: Currently, industries have to rely on spare part
manufacturers to meet their spare part needs. This might sabotage the companies, and hurt
the relationship with their customers due to delays. 3D printing will help companies to
meet customers' needs and hence increase their satisfaction.
 Competitive advantage: Firms that will adopt 3D printing of spare parts will earn a
competitive edge over others who will still rely on third-party suppliers to meet their spare
part needs.

3D technology is disrupting all major industries and it will transform how companies
handle spare parts to a large extent and solve many of its problems. 3D printing helps firms
to cut costs, increase operational efficiency, and optimize inventory. Industrial firms must
embrace 3D printing to scale their businesses.

Metal 3D Printing Technology

1. Sharebot
Sharebot, an Italian-headquartered developer, has worked over the years to bring 3D
printing systems to market and help introduce the technologies into small and medium
businesses. Gradually expanding its product range from desktop machines to more professional
systems, and after years of research have arrived at its first metal 3D printer, which debuted
at MECSPE, a manufacturing trade show in Parma, Italy in spring 2019.

Picture 1. Sharebot

The metal ONE 3D printer is the continuation of a project that has evolved from Sharebot’s
SnowWhite selective laser sintering machine for thermoplastic powders, which the company
launched three years ago. The metalONE also uses a powerful laser (1070μm 200W) to
selectively sinter metal powder (SLS technology) within a print area of 65 x 65 x 100 mm.
Equipped with a group of three filters for the inert gas circuit, Sharebot guarantees the air is
completely free of metal particles. For this reason, and the compact design, the company
believes the system is suitable for universities and research laboratories.

2. HP Metal Jet
Another company that wants to make a name for themselves in the metal 3D printing scene
is no other than HP. During the 2018 International Manufacturing Technology Show (IMTS),
the tech giant unveiled HP Metal Jet, an advanced metal 3D printing technology that is capable
of creating production-grade metal parts at a high volume. HP claims that the new additive
manufacturing system will provide users with up to 50 times more productivity at a
significantly lower cost compared to other metal 3D printing methods. Similar to HP Multi Jet
Fusion technology, HP Metal Jet utilizes voxel-level binder jetting. It offers a print volume of
430 x 320 x 200mm, four times the nozzle redundancy and two times the print bars. This
potentially groundbreaking system will use significantly less binder by weight while delivering
exceptional productivity and reliability.
HP has also partnered with GKN Powder Metallurgy and Parmatech to offer its Metal Jet
Production Service. Allowing customers to order industrial-grade metal parts produced by the
new system, without having to fully invest in their own HP Metal Jet system. As for the
commercial availability of the HP Metal Jet, the company plans to sell the system for under
$399,000. Early customers are expected to receive the metal 3D printing system in 2020, while
broad availability will begin in 2021. You can already pre-order the HP Metal Jet system today.

Picture 2. HP Metal Jet

3. Aurora Labs
Aurora Labs’ Rapid Manufacturing Printer One (RMP1) is the world’s first
Direct Metal Laser Melting (DMLM) 3D printer featuring Multi-layer Concurrent
Printing (MCP) technology. Aurora’s patented MCP technology allows for
direct metal 3D printing at rates much faster than was previously possible with
the established single layer DMLM technology.
Recently Aurora Labs announced the launch of the RMP1 Beta Printer, a fully
operational pre-production 3D printer, bringing Aurora Labs one step closer to
their commercialization goal. They are now gathering valuable feedback from
early customers and tests, and the RMP1 is expected to be released later this
year.
The printer will be more sophisticated than the company’s previous models.
For instance, with a build volume of up to 450 x 450 x 400 mm, the RMP1
Beta is capable of printing parts 10x the volume of the company’s previous
test machine, the Alpha.