Many managers are experiencing just how essential flexibility is for manufacturing companies on their own shop floors. The issue that has the whole world in lockdown also has many companies firmly in its grip. Even before the pandemic, however, the most flexible manufacturing method was additive manufacturing. While 3D printing is still seen by the general public as a gimmick for producing simple plastic parts, the new developments in the field of additive manufacturing have been so groundbreaking in recent years that there are now virtually no limits to the possibilities. Above all, the wide selection of materials, the high speed compared to other types of production and the extensive possibilities for post-processing and measurement make 3D printing an indispensable tool for creating prototypes and small series.

From ABS to steel: a wide range of materials for 3D printing

The various additive manufacturing processes, be it multi-jet fusion, stereolithography or direct metal laser sintering, have led to a veritable explosion of materials that can be processed using 3D printing in recent years. The spectrum ranges from plastics and elastomers to metals. What all processes have in common is that the workpiece is created layer by layer and in most cases must also be held in place by support structures. However, the wide range of materials also means that prototypes produced using additive manufacturing can be used in almost all industries. Particularly in cases where a prototype is needed as quickly as possible, 3D printing has become a true wonder weapon for industry.

Workpieces made from the particularly heat-resistant metal Inconel 718 using direct metal laser sintering are used in the aerospace industry, for example. Copper shaped using the same process can be used wherever good electrical conductivity is required.

High speed and creative freedom at the same time

In addition to the wide selection of materials, however, the comparatively high speed that can be achieved through additive manufacturing for rapid prototyping is one of the main reasons why 3D printing enjoys such a high reputation within the manufacturing industry. While the injection molding process first requires a mold suitable for injection molding to be created for the respective workpiece and then a lot of time and technological effort must be invested in the production of injection molding tools, the desired part can usually be produced directly using 3D printing without much effort. The only thing to note here is that the respective mould must be optimized for additive manufacturing. If there are overhangs, for example, it is advisable to keep them as small as possible by using obtuse angles. In this way, the required support structures can be kept as marginal as possible and the material required and the resulting costs are lower.