The rapid development of 3D printing technology has greatly benefited a multitude of industries, including aerospace, automotive, healthcare, mold manufacturing and even cosmetics, with faster component production and lower costs.
By 2025, the industry is expected to exceed a commercial value of US$5.5 billion in the Asia-Pacific region.
Many large companies in Asia-Pacific have created mature R&D teams, but the adoption of additive manufacturing technology is still in its infancy. This is likely due to misunderstandings about the additive manufacturing industry.
Misconception 1: Additive manufacturing is suitable for all companies
A decade ago, when 3D printing gained popularity, the technology's limitless possibilities understandably captivated many. 3D printers were considered household appliances, dominated headlines and were considered capable of anything.
Gartner refers to this as the beginning of the “Hype Cycle.” Initial expectations soar with technological advances.
Unfortunately, as time passes, disillusionment with technology grows just as quickly, especially when reality fails to live up to overly optimistic initial expectations. The danger lies in taking the hyperbolic portrayal of 3D printers at face value, assuming that the simple press of a button will print the required items.
In reality, 3D printing technology has thrived in professional industrial applications. It revolutionized manufacturing processes, enabling the production of lightweight, customized individual components.
However, companies must evaluate whether to implement this technology. They must thoroughly investigate how to use it and manage expectations.
Factors such as cost, design, delivery cycles and the impact of 3D printing technology on manufacturing processes must be considered. For parts manufactured using traditional processes and 3D printed components, compatibility issues relating to assembly must be addressed.
Misconception 2: Additive manufacturing is only suitable for prototyping
Rapid prototyping is one of the earliest applications of 3D printing technology and is still widely used today. This application is particularly useful in R&D, where prototypes with the same material properties as the finished product can be tested. Being a toolless process, the technology facilitates quick and easy changes, completing them with minimal additional cost.
However, the belief that 3D printing is only suitable for rapid prototyping is a common misconception. In the early years, the technology was unable to reach its full potential due to the limited performance of computers and lasers.
Today, the desire to revolutionize traditional design and manufacturing methods continues to inspire more solutions. 3D printing technology offers excellent flexibility in the manufacturing process, creating highly customized structures with less material and effectively avoiding the problems of bulky products.
Misconception 3: Additive manufacturing is very expensive
There are two ways to consider production costs: one focuses on short-term unit costs and the other takes a broader view, focusing on long-term costs.
Although 3D printing has made many advances in the last decade, for some industries the technology still lags behind traditional manufacturing methods in terms of component unit costs. However, as productivity increases, unit costs will inevitably decrease.
However, other important aspects should not be neglected, such as the search for disruptive changes in production. Traditional methods are often based on mold production, which can be expensive in terms of price and time.
This is especially true for smaller production quantities, which makes “one-piece production” an almost unattainable demand.
3D printing technology reverses this situation, eliminating the need for molds, thus creating vast possibilities for manufacturing personalized products in small batches. Solutions that were previously considered too expensive now deserve to be reevaluated.
Previously, the NextGenAM 3D printing technology project, a collaboration between Premium AEROTEC, EOS and Daimler, was presented. They used additive manufacturing technology to produce aluminum parts for the automotive and aerospace industries, successfully reducing manufacturing costs.
The manufacturing process was significantly shortened and production lines could be easily replicated to expand workshop capacity.
Misconception 4: Additive manufacturing has no design limitations – “unlimited complexity”
In fact, the design capabilities of 3D printing are “not infinitely complex” and the parts it produces still encounter design limitations. Designers using 3D printing technology need training to fully understand the feasibility and limitations of the technology and learn how to successfully design, optimize, build, and apply 3D printing technology.
There are five 3D printing design rules to follow, including paying attention to wall thickness and gap size. Parts manufactured using 3D printing must minimize aspect ratios and surface resolution to ensure stable production cycles. Therefore, designs should avoid unnecessary complexities and always keep the five design rules in mind.
In summary, compared to the limits faced by current traditional manufacturing technologies, 3D printing still offers a high degree of design freedom, enabling many applications that were previously not manufacturable. This promoted a design-oriented mindset, prioritizing problem solving first and then considering basic manufacturing constraints.
Misconception 5: Additive manufacturing is only suitable for small parts that do not require assembly
This common misconception about 3D printing is the cumulative result of the aforementioned misunderstandings. If people believe that the technology is expensive and only suitable for prototyping, then it's not hard to understand why they mistakenly think that 3D printing is only applicable to small parts.
Of course, the reality is that there are now 3D printers capable of producing large parts, with high-quality plastic parts measuring approximately one meter and metal 3D printing exceeding 500mm.
Regarding the need for assembly, the question to explore is “whether assembly is necessary, and whether it cannot be done”. 3D printing can produce parts that do not require assembly, often with the goal of making parts lighter or reducing assembly costs.
In conclusion, 3D printing will not replace all traditional manufacturing technologies in the future. Its role is to expand production possibilities, allowing manufacturers to create products that were previously unattainable.
As a new technology, companies new to the additive manufacturing sector should establish partnerships with trusted additive manufacturing partners to prepare for a new journey.
