At a recent trade show, we’ve been asked a question that’s been echoing through the world of manufacturing – “When will 3D printing replace traditional manufacturing?” It’s an intriguing question, but it might not be a matter of replacement. What we’re likely to witness first is the convergence of the strengths of both technologies to create a manufacturing future that combines the precision and performance of machine tools with the innovation of 3D printing.
Machine Tool-Like Precision
Imagine a world where 3D printing exhibits machine tool-like reliability, repeatability, and performance. This is becoming a reality, as we’re already seeing how additive manufacturing (3D printing) is collaborating with subtractive manufacturing methods like CNC milling and injection molding. One example of this synergy is the use of 3D printed tools in injection molding.
For this demonstration, we started by 3D printing a tool with a polyamide carbon fiber material. The resin we used is from our partners at BASF. The 3D printed tool was then machined by a specialized supplier. This machining process not only smoothed the tool’s surface but also created features like the ejector pin. The result was a tool with exceptionally smooth and accurate features, almost akin to machine tool precision.
With these precisely crafted tools, two halves of the mold come together, and plastic is injected to produce a final part. This approach combines the best of both worlds, utilizing the advantages of 3D printing and subtractive manufacturing to create intricate, functional parts.
A New Era of Collaboration
The marriage of additive and subtractive manufacturing is the trend we’re witnessing on factory floors. This union allows manufacturers to leverage the strengths of each technology to optimize their processes. What we’ve observed at trade shows, like the one in 2019, is that the manufacturing world is embracing this collaborative approach.
Our focus is on extrusion-based 3D printing, which we believe has incredible potential for various applications. Extrusion offers versatility and numerous value propositions for factories, making it a valuable tool in the manufacturing toolkit.
Enhancing Surface Finish
While extrusion 3D printing produces parts with relatively smooth surfaces, there’s an increasing demand for parts that match the surface finish of injection-molded components. We’ve been working with partners to address this need and offer solutions that bridge the gap.
One such partnership involves a company called AMT, which has developed a vapor honing technology. This innovative process smooths the surfaces of 3D printed parts, bringing them closer to the quality achievable through injection molding. These refined parts are essential, especially for applications in the consumer space, where aesthetics and surface quality matter the most.
The collaboration of extrusion and technologies like vapor honing is just one example of how the 3D printing industry is advancing to meet the evolving needs of manufacturers. It’s an exciting time for extrusion advocates and all those who recognize the potential of additive and subtractive manufacturing working hand in hand.
If you’re interested in exploring the world of 3D printing and learning more about how these technologies can benefit your projects, keep an eye on these exciting developments. The future of manufacturing is about to get even more interesting.