Volumes of 500 Units
Kelly turned to a contract manufacturer, Rapid Processing Solutions Inc., which specializes in direct digital manufacturing and makes production parts for various jet manufacturers. Using a 3-D production system from Stratasys Inc. of Eden Prairie, Minn., RPSI was able to build the 500 toroid housings out of a strong, lightweight thermoplastic used in aircraft interiors in a single production run. In the end, Kelly Manufacturing got a final product that had improved dimensional accuracy and required no hand sanding. "The lead time for 500 units has been shortened to three days from order to delivery of parts," says Justin Kelly, KMC president.
In another case, Mission, Kan.-based ScriptPro, a maker of automated pill-dispensing systems for pharmacies, uses a Stratasys 3-D production system to make selected parts for its products. ScriptPro uses the machine to make both the prototypes of the bezels that accept vials for pills, as well as the actual vials shipped to pharmacies. "Not only were the tolerances in line, but there was little to no post production work, such as sanding or painting," says Bill Thomas, vice president of manufacturing at ScriptPro. "We produce the vial bezels, wash them, and install them on the machines."
ScriptPro has found that although the per-part cost is higher using additive manufacturing, the company still reaps an overall savings by eliminating the machining and tooling costs to create new bezel shapes and sizes. Based on its median annual machine-production volume, the company estimates that bezel production would cost $5,100 more with direct digital (additive) manufacturing, but the elimination of tooling would save about $30,000, for a net savings of about $24,900.
With savings like that, it's no wonder additive manufacturing is starting to catch on. And while it may not replace mass production anytime soon, the additive approach has proven to be a cost-effective and efficient way to produce limited volumes of parts.
