CIOInsider India Magazine
The Future of Additive Manufacturing: Trends and Applications
Bharat Bommai is a leader who wears many hats with a demonstrated history of working in the industrial automation industry. His strengths lie in Capital Markets Advisory, Business Planning, Entrepreneurship, Corporate Advisory, and Investment Strategies.
The global additive manufacturing market is growing at a CAGR of 23.3 percent, as reported by Grand View Research. It further informed that in 2021, 2.2 million 3D printers were shipped around the world. These numbers stand as a testament to the fact that the automotive manufacturing industry is revolutionizing conventional construction methods and has the ability to drive massive economic growth.
Comprehending Additive Manufacturing
Additive manufacturing, or 3D printing, is a technique of creating objects layer by layer from digital models. This technology presents diverse benefits from cost-effectiveness to rapid prototyping. It allows industries to design and develop complex components and facilitates the customization and personalization of products. As a result, with the advancement in technology and software development, additive manufacturing is opening doors to endless opportunities for manufacturing businesses.
Future Trends in Automotive Manufacturing
In cooperation with startups such as Tvasta, the Indian Institute of Technology (IIT) designed India’s first 3D-printed house in 2021. In addition to this, there are diverse future trends and applications of additive manufacturing. Let us take a closer look at them.
Powder Bed Fusion
Powder bed fusion is used primarily for low-volume functional parts across industries and printing components such as jigs, parts, and fixtures. These components created by powder bed fusion 3D printing have mechanical properties. The powder bed fusion technique also supports an array of materials and allows for the simultaneous creation of multiple components. Further advancements in the field focus on enhancing powder purity and reducing size distribution. Selective Laser Sintering (SLS), Electron Beam Melting, and Selective Laser Melting (SLM) are some of the most commonly used methods of powder bed fusion.
Industrial Micron 3D Metal Printing- The industrial micron 3D metal printer, named Precision-100, has been developed by the startup company, Aixway3D. The printer uses an ultra-fine metal power bed, and highly accurate lasers to print metal components. It also includes an accuracy of 2 to 5 microns, supports complex designs, and offers ultra-low surface roughness.
Additive Manufacturing Automation
In the industrial 3D printing sector, automation
technologies are increasingly being integrated into additive manufacturing processes to streamline production. This includes the use of automated part handling systems that reduce human intervention after the components are printed, improving productivity and efficiency. Many startups are developing printer-agnostic designs and solutions that allow manufacturers to integrate automation into their existing production lines. These innovations include advanced software and hardware that enable high-speed component production, on-demand services, and rapid prototyping.
Automated Industrial 3D Printing- By leveraging digital workflows, robotic systems, automated sorting, and autonomous mobile robots (AMRs), these solutions enhance print flexibility, reduce material waste, and optimize the overall manufacturing process. This approach is transforming additive manufacturing by automating various stages, from part handling to final assembly, resulting in faster production cycles and improved scalability across industries.
Vat Polymerization
In the additive manufacturing industry, advancements in liquid polymer-based technologies are enabling more precise and efficient production of micro-electronic components. By utilizing projection stereolithography, manufacturers can accurately print complex parts without the need for expensive tooling typically required in traditional 3D printing. This approach significantly reduces costs and speeds up production, especially in fields like healthcare, aerospace, and automotive applications. As the industry progresses, we can expect further improvements in volume stereolithography, leading to better resolution, efficiency, and overall productivity for manufacturers using vat polymerization techniques.
In the upcoming years, additive manufacturing is bound to appear in consumer products, in the highest-volume segments.
Plasma metal deposition is a specialized method used in direct energy deposition (DED) 3D printing, gaining attention for its ability to produce high-quality metal components. This technology is employed by several manufacturers worldwide, combining advanced plasma welding techniques and proprietary control systems to achieve precise and efficient metal deposition. Capable of working with materials such as steel and titanium, plasma metal deposition systems can achieve deposition rates ranging from 0.5 to 10 kg per hour.
The method has been adopted by aerospace manufacturers for building components at reduced costs, particularly for high-performance applications in challenging environments such as the thermosphere. This technology demonstrates significant potential in various industries by offering efficient material utilization, reduced production times, and enhanced design flexibility.
Material Extrusion
Material extrusion is one of the most economical 3D printing technologies available. It uses fused deposition modelling (FDM) to produce components for small-scale production and construction. It is also a low-temperature process and supports a diverse range of affordable print materials. However, due to the limited nozzle limits, the final quality of FDM-based parts is not refined. To combat this issue, many startups are now focusing on developing high-precision extrusion technologies.
Way Forward
The additive manufacturing companies are continuously evolving and enhancing their performance of 3D printing. They are integrating AI, IoT, and other technologies to enhance the 3D printing processes. In the upcoming years, additive manufacturing is bound to appear in consumer products, in the highest-volume segments. For instance, injection moulding is the only practical application to manufacture plastic parts. However, in the middle-volume segment, such as the electronic industry, 3D modelling has begun to make its way. With that, the additive manufacturing industry presents new opportunities and emerging technologies to help businesses streamline production processes, maintain flexibility, and reduce costs.
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