For years, 3D printing technology seemed laden with unfulfilled promise. Early adopters often simply replicated their existing product designs using these new additive manufacturing techniques. The capabilities of 3D printing remained constrained by dated ways of thinking. But through gradual evolution in design philosophies, the full potential of this transformative technology is finally being unleashed.
Beginning With Baby Steps: Early 3D Printing Mimics Traditional Manufacturing
In the early days, 3D printing was primarily used for rapid prototyping. Companies marveled at the ability to quickly create design models and prototypes. However, taking the leap to manufacturing end-use products was another matter entirely.
Early attempts at using 3D printing for production parts often just replicated designs optimized for traditional subtractive manufacturing. There was little consideration given to leveraging the unique benefits of additive manufacturing. Parts were frequently created through 3D printing that likely could have been produced faster and cheaper using legacy technologies like injection molding or CNC machining.
With lackluster results, 3D printing took a backseat as companies struggled to justify its use for end-part production. The technology was pigeon-holed into a niche prototyping solution rather than a transformativeproduction method.
Shifting Gears: Designing for Additive Processes
To truly capitalize on 3D printing, a fundamental shift was needed in design thinking. Rather than adapting existing parts, engineers needed to conceive of completely new designs tailored to additive’s capabilities.
Conventional manufacturing constraints like avoiding overhangs, minimizing tool access points, and designing assemblies in discrete components were no longer necessary. 3D printing enabled unprecedented freedom of form, complexity, and consolidation.
But this generational leap in design thinking did not happen overnight. Legacy methods like subtractive machining and metal forming intrinsically shaped the way engineers conceptualized product designs for decades. Adopting design principles optimized for additive was an evolutionary process.
Overcoming Deeply Ingrained Design Habits
Intellectually, the expanded capabilities of 3D printing in enabling complex geometries and assemblies consolidated into single parts was understood. Yet years of training and experience continued to inform engineering design decisions in subtle ways.
The temptation remained strong to simply make minor tweaks to existing parts rather than embrace additive manufacturing’s true potential. Letting go of familiar legacy design crutches to pursue novel design approaches did not come easy.
For many, venturing outside their comfort zone held little appeal. Why take risks on unproven designs when existing products were satisfactory? Management incentives for short-term gains over long-term innovation provided little impetus for revamping design methodologies.
Gradually Embracing the New Design Freedom
Over time, however, the appeal of fully utilizing 3D printing became apparent. By completely rethinking designs for additive-first principles, significant benefits could be achieved.
Enlightened companies began providing additive manufacturing training for engineering teams. Younger designers joining the workforce came equipped with 3D printing knowledge.
Design for additive approaches like topology optimization and generative design gained traction. Engineers grew more apt at exploiting 3D printing’s capabilities through designs consolidated into single parts, internal lattices, and complex organic shapes.
The long overdue shift towards design thinking tailored specifically for additive manufacturing was gradually gaining momentum.
Unleashing Additive’s Full Potential
Emergent sectors like space, aerospace, and motorsports with high-performance needs were early adopters of additive manufacturing design practices. Unencumbered by legacy concepts, they recognized the performance benefits unlocked by novel designs.
Now, additive manufacturing design has crossed into the mainstream. Forward-thinking companies are retraining engineering teams and rebuilding their design process around additive manufacturing principles.
Rather than incrementally improving on old designs, they are asking: “If we could 3D print this part from scratch, how could we design it differently to achieve maximum performance?” This fundamental change in thinking is enabling the full power of 3D printing to be unleashed.
Making the Mindset Shift: Letting Go of Outdated Notions to Fully Embrace 3D Printing
Transitioning from long-held traditional design methods to new additive manufacturing capabilities requires open-mindedness. Without fundamental changes in engineering team mindsets, 3D printing will never reach its full disruptive potential.
Clinging to the Familiar
For those steeped in legacy design thinking, 3D printing can seem like merely an alternative manufacturing process. The temptation is to make minor adaptations to existing designs to produce them additively rather than rethinking them completely.
This mindset severely limits the value derived from additive manufacturing. It confines engineers to outdated ways of thinking that fail to embrace the new design freedom. Products suffer as incremental improvements prevail over innovation.
Change is difficult. But clinging to the familiar limits our ability to adopt radically improved approaches. We must shake off outdated notions to pursue the new capabilities that technologies like 3D printing provide.
Overcoming the Fear of the Unknown
Transformative technologies inevitably encounter resistance. The uncertainty of new methodologies breeds skepticism. Unproven strategies are perceived as risky, even when great potential upside exists.
This phenomenon slowed the adoption of design for additive manufacturing. Engineers feared straying from proven legacy methods. Management emphasized short-term cost metrics over long-term performance gains.
But the numbers don’t lie. As more companies embraced AM design thinking, performance improved while costs decreased. The benefits became too substantial to ignore.
We must be willing to take calculated risks and experiment with new methods to overcome ingrained notions of how things are supposed to be done. Only then can we discover their true potential.
Adopting an Additive Mindset
Fully embracing additive requires more than just utilizing 3D printers. It requires adopting an additive manufacturing philosophy across the product development process.
Designers must discard conceptions of constraints and limitations inherited from legacy processes. Engineers should constantly ask themselves – how could we redesign this part if additive manufacturing capabilities didn’t exist?
Rethinking existing parts for additive-first principles opens new realms of performance and efficiency. This mindset shift won’t happen overnight for companies with established cultures and processes. But taking steps in that direction sets the stage for unlocking 3D printing’s full potential.
Navigating the Barriers: Why Adopting 3D Printing Has Been an Evolutionary Process
The transition from traditional design thinking to additive manufacturing principles has been gradual. Let’s explore the barriers that slowed 3D printing’s adoption and how they are being overcome.
The Training Gap
For decades, engineering curriculums and on-the-job training ingrained legacy design-for-manufacturing concepts. Very little addressed optimizing designs for additive manufacturing.
Engineers schooled exclusively in milling, molding and casting struggled to break free from that knowledge. Designing products tailored for 3D printing’s capabilities did not come intuitively.
Closing this training gap has been critical in unlocking the power of additive. Both new and experienced talent require education in AM design principles to make the shift.
Resistance to Changing Workflows
Companies develop entrenched processes optimized for legacy production methods. Adopting radically different additive manufacturing workflows faced institutional resistance.
Stakeholders cling to existing processes that have served them well historically. But sticking with comfortable workflows restricted thinking about how 3D printing could enable entirely new approaches.
As AM capabilities advanced, the performance benefits finally began overcoming organizational inertia. Progressive companies started transforming legacy processes to leverage 3D printing rather than forcing it to conform.
The Supplier Ecosystem Lag
Additive manufacturing does not exist in isolation. The associated downstream supply chain ecosystems took time to develop.
Early on, few materials suppliers provided formulations optimized for 3D printing. Part quality assurance techniques and equipment had not evolved either.
As the AM industry matured, high-performance materials developed, software improved, and quality processes were established. This emerging ecosystem finally enabled end-to-end production utilizing 3D printing.
Cost and Speed Considerations
During the early days of adoption, 3D printing struggled to compete with conventional processes on cost and speed for production applications.
Over time, equipment, materials, and design innovations improved productivity and cost-effectiveness. This boosted AM’s viability for end-part manufacturing.
Today, 3D printing is highly competitive for an ever-expanding range of applications. But it took years to improve productivity and reduce expenses enough to cross that threshold.
Charting a Path Forward: How Companies Can Fully Capitalize on Additive Manufacturing
Here are strategies and best practices business leaders can adopt to leverage 3D printing to its fullest potential:
1.Make Additive Manufacturing a Strategic Priority
To fundamentally transform design thinking, additive manufacturing must be a core strategic focus backed by management commitment. Maintaining the status quo won’t suffice.
Develop a future AM vision. Outline the innovations required in processes, training, and culture. Elevate AM as a key competitive advantage rather than a tangential activity.
2.Invest in Additive Manufacturing Education
Provide additive manufacturing training at all levels of the organization – from technicians to engineering leaders. Cover both technology capabilities and design principles tailored for AM.
Foster broad understanding of how AM enables entirely new ways of thinking compared to legacy subtractive methods. Share case studies of AM benefits over conventional processing.
3.Take an Additive-First Approach to New Products
Rather than adaptively redesigning for AM, start all new products from an additive manufacturing perspective. Take advantage of consolidated assemblies, novel geometries, lightweight lattices, and part consolidation.
Challenge teams to utilize AM capabilities early in the conceptual design process rather than applying it as an afterthought. Make AM the default first choice over legacy processes.
4.Re-Imagine Existing Products for Additive Production
Methodically review existing products and redesign sub-assemblies and components optimized for AM production.PHASE these redesigns to manage risk and investment.
Adopt AM-enabled features like conformal cooling, mass customization and part consolidation to incrementally improve legacy products until comprehensive redesigns can be undertaken.
Continually Refine and Optimize Your AM Process
Additive manufacturing capabilities are continuously advancing. To stay ahead, companies must relentlessly refine their AM processes.
Adopt new design software, printing methods, and materials as they emerge. Continually improve workflows and quality management practices. Work closely with partners to take advantage of the latest innovations.
The gradual evolution towards design for additive manufacturing has positioned 3D printing to revolutionize manufacturing. By adopting strategies to unlock its full potential, forward-thinking companies can gain a true competitive advantage.
Leveraging the full benefits of 3D printing requires much more than just purchasing additive manufacturing equipment. It requires transforming engineering mindsets, rethinking established product designs, and integrating AM throughout your organization’s culture and processes. This does not happen overnight. But the effort promises greatly expanded performance potential for companies willing to undertake the journey.