Beginning the AM Journey: An Uphill Battle
Faster machines, cheaper feedstocks, new standards — with all of these advances, why is additive manufacturing still “an uphill battle” for so many?
Notional diagram of the potential impact of AM on performance, cost, and schedule as a company progresses on their journey. Photo Credit: Tim Simpson
So why the uphill battle? It largely happens because the tendency is to begin with AM as a process substitution, reproducing an existing part made via conventional means with AM. T
To gain traction with AM and begin the uphill climb, consider modifying the part, or MfAM as I now call it (thanks David Dietrich and the team at Honeywell for bringing this to my attention). MfAM is a succinct way to avoid the unwanted costs of AM that I discussed last month, and its application is just as important as the more exciting things that people talk about when designing for AM (e.g., topology optimization, lattice designs, biomimicry, and such) as I discussed two months ago. Unfortunately, the full freedom to apply design for AM (DfAM) may not be possible until somebody can “clean sheet” a part or completely rethink an existing part for AM. Few established firms begin there, and they have to endure the earlier stages and chart an uphill course to maximize AM’s benefits.
The uncertainty around the potential upside of future parts designed for and made with AM clouds this view, making the journey all the more difficult. Add the baggage one carries when basing the initial AM business case on process substitution that simply reproduces an existing part with AM, and it is clear why it is an uphill battle. The benefits often don’t add up, weighing one down from the start. Worse, it can derail the AM journey entirely as the costs add up.
But there is hope, as DfAM and MfAM are the “ying and yang” of a successful AM journey. DfAM drives value while MfAM avoids costs, and both are critical to making AM viable.
When redesigning a part for AM, begin with MfAM and apply DfAM to the best extent possible. Conversely, when designing a new part from scratch, begin with DfAM and apply MfAM to reduce costs. Not surprisingly, the end points from each of these endeavors is not the same, nor is the starting point. As such, the benefits differ as well. MfAM improves producibility and viability with AM, advancing one up the hill on their initial journey. As the path forward becomes clear, DfAM increases the benefits and helps one reach the peak. From there, the horizon comes into much better view. Fighting the uphill battle is worth it when looking back on all that has been learned along the way.
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