Disruptions in the supply chain have forced many changes and realizations upon small- and medium-sized manufacturers (SMMs), including that they must find new ways to provide additional value and solutions to their customers. They have seen the limitations of pursuing low-cost production. But being innovative and responsive isn’t as easy as it sounds; it involves risks and trade-offs.
For SMMS who need innovative ways to improve processes, reduce costs and improve product quality, 3D printing may now be within reach. The primary use of 3D printing remains in prototyping and product development, but the technology is clearly maturing into a production solution to improve operations, especially for high-margin, specialty work.
The value of additive manufacturing lies in being able to create new processes and new business models. As 3D printers become faster, more reliable and production capable, SMMs should be looking at investing in 3D printing for product development with an eye on future operations.
As 3D Printing Becomes Accessible, In-House Prototyping Will Increase
Traditionally, the barrier to entry for additive manufacturing has been pretty high, which has led many SMMs to outsource their parts that are 3D printed. But a printer similar to one that cost $250,000 around 10 years ago might now be about $80,000, and some desktop versions are even in the $3,000 range.
The investment in 3D printing equipment and developing staff expertise is going to position SMMs to be able to provide value – not only in product development, but also position them for new business and protect their current customer relationships.
The prototyping segment is dominated by 3D printing, which is expected to have more than 55% of market share by 2028. There is nothing better for prototyping a slight variation or a significant makeover for a part than 3D printing. A manufacturer can iterate a change in a part 10 times before a legacy machining development process can generate enough of a change to warrant a price quote.
3D printing optimizes prototyping by speeding iterations through product testing. Designers have the ability to fail fast, produce multiple design iterations quickly, and change a product design overnight to meet deadlines.
Understanding Expectations, Limitations of 3D printing
Many SMMs are impressed by the capabilities of 3D printing but surprised by its limitations. The iteration process for prototyping is made possible by the use of less expensive materials and lower-end machines. This combination produces parts that are not as refined or as strong as traditional machining processes. The “lower resolution” of a part produced in this manner represents a trade-off for the increased velocity realized in the prototyping process.
SMMs often are surprised by how little time there can be between iterations. It is how a “fail fast” philosophy is achieved – through these inexpensive but frequent iterative attempts at the solution.
SMMs considering 3D printing should understand the market and its pros and cons. For example, commodity products have already been developed and refined with low costs. The manufacturing benefits of 3D printing will be greater for custom work with high margins.
3D Printing Capabilities Vary Greatly
Not all SMMs will optimize 3D printing by investing in their own equipment. For many who are looking at new product development, one of the appealing aspects is that you might be able to use simple designs and materials to start and build more expensive prototypes as the product is refined. This would require a variety of equipment and materials, and many specialty vendors cover the spectrum of 3D techniques and materials.
Three factors to consider when vetting a 3D printing solution include:
- Cost: 3D printing is valuable for product development and can be viable for some production. Understand how you will leverage this technology and make an informed decision based on the technology that best suits your needs.
- Resolution: A $50,000 machine is going to produce much higher quality and resolution than a desktop printer. But the type or “style” of 3D printing will also drastically affect resolution.
- Durability: The durability of 3D printed parts is dependent on the technology, but parts generally are not as durable as parts made with traditional methods. Form and fit is the best use case for 3D printed parts, but 3D printed parts can be used for testing as well.
Resources May Be Accessible For Trying Out 3D Printing
Many SMMs still see new product development as being out of reach. One major barrier to entry has been a lack of in-house 3D printing knowledge and expertise.
There is an increasing number of resources available to SMMs. For example, our 3D printing studio at TechHelp on the Boise State University campus does about 20% production work for firms that do not have 3D printing capabilities and 80% consulting work. The consulting work is split among startups and entrepreneurs looking to develop a minimum viable product and manufacturers who embed a student employee in their organizations to help with internal projects and prototype work.
Most of these companies do not have the resources to hire an FTE but see this as an entry into bringing prototyping and design in house. The students (mechanical and electrical engineers and graphic designers) help clients design and build prototypes, doing revisions with production in mind. In addition to the product work, these engagements also develop talent through real-world manufacturing experience.
Success stories include:
- A startup entrepreneur who designed an automatic motorcycle clutch with a student and built it into two different manufacturing businesses.
- A toy company that brought talent and 3D printing in-house when they needed it most.
- A motorcycle company that makes after-market seats for motorcycles, ATVs and other recreational vehicles. The traditional mold process using bondo and fiberglass was labor intensive; digital molds for 3D printing unlocked new opportunities.
Your Local MEP Center Has Experts Available to Help
The MEP National NetworkTM can be your trusted advisor in how to utilize resources and plan for advanced manufacturing and new product development. For manufacturers who need innovative ways to improve processes, reduce costs and improve product quality, connect with your local MEP Center, whose experts provide unbiased and affordable recommendations for applying advanced manufacturing technology to improve your operation.
About the author
Grey Beaudry
Grey Beaudry is the New Product Development Specialist at TechHelp, part of the MEP National Network. He works with manufacturers through all developmental phases, including concept generation, rapid prototyping, mechanical design, marketing materials, and manufacturing assistance.
