Shaping Tomorrow: Mastering Additive Manufacturing

FOREWORD

TOM KELLY

EXECUTIVE DIRECTOR & CEO AUTOMATION ALLEY

Additive manufacturing (AM) will be the vanguard of change in Industry 4.0, a lynchpin of technological advancement, a force in sustainability and a herald of change in manufacturing philosophy. Furthermore, 3D printing’s ability to be more precise and rapidly customizable than traditional machining will ensure its status as more than a trend, but an enduring force in the production landscape of tomorrow.

To call additive manufacturing disruptive is an understatement. Building the additive manufacturing future marks the end in dominance of rigid and inflexible traditional assembly lines, a paradigm that still exists today more than 100 years since its popularization.

Paired with generative design AI, additive manufacturing has already demonstrated its prowess compared to traditional means in the aerospace, automotive and medical industries. After all, NASA isn’t investing in outfitting bricklayers in space suits to build its moon base, it's investing in giant roving 3D printers that can gather moon dust and turn it into a concrete-like substance.

If otherworldly AM applications will not peak industry, perhaps market factors will — SME projected the additive manufacturing market to double by 2028, approaching $40 billion. Additionally, federal initiatives like AM Forward show a willingness by the government and large companies like General Electric Aviation,

PATRICK KWON

PROFESSOR OF MECHANICAL ENGINEERING MICHIGAN STATE UNIVERSITY

Honeywell, Siemens Energy, Raytheon Technologies, and Lockheed Martin to collaborate on advancing AM technology in U.S. supply chains.

In this vein, Automation Alley believes integrating 3D printer applications is imperative for all manufacturers to stay competitive in the Industry 4.0 future. That’s why we are honored to be a pioneer in additive manufacturing with our Project DIAMOnD initiative, in partnership with Oakland County, Michigan, creating the largest additive manufacturing network in the U.S.

We are also honored to bring together leading voices in the additive manufacturing industry, small to medium-sized manufacturers, academic stakeholders and policymakers to advance the conversation and encourage collaboration on additive manufacturing. This combination of public and private forces can affect real change in the industry and beyond.

Though additive manufacturing faces challenges, and requires careful consideration before adopting, we believe this technology is not just a new way of creating parts. It is a collective endeavor; a nexus where brilliant minds and savvy adopters converge to redefine the boundaries of what's achievable in our industry for the betterment of all.

Let’s discover what is possible together in additive manufacturing.

PAVAN MUZUMDAR

RAY PUTZ

ABRO

GARY KRUS

GEORGE CARAVIAS

BEAU EVERITT

STEVE MICHON

PATRICK KWON

DAVID

INGRID TIGHE

PAUL

RYAN ZEMMER

ARAVIND JONNALAGADDA

DAVID BERTRAM

LEON BROWN

MATTHIAS SCHULZ

By Fadi Abro, Global Director of Transportation

Navigating Industry Transformations, Growth Trends, and the Rise of Smart Manufacturing EXPERT INSIGHTS:

UNVEILING THE FUTURE: Additive Manufacturing's Evolution and Opportunities

In 2024, additive manufacturing is not in competition with traditional manufacturing; instead, it presents opportunities for manufacturers in various sectors such as automotive and aerospace. The integration of additive manufacturing into their processes is poised to enhance efficiency, streamline supply chain operations, bolster security measures, and contribute to a reduction in the manufacturing carbon footprint. The synergy of artificial intelligence and automation is further refining additive manufacturing, making it more precise and faster, facilitating mass production of parts, anticipating industry consolidation, enabling additive companies to scale up rapidly, offering a broader range of materials, and providing improved one-stop shopping experiences. While the industry has predominantly focused on hardware, a shift is expected towards a greater emphasis on software and materials. This shift

is likely to broaden possibilities for manufacturers, encouraging them to think more expansively about the potential applications of additive manufacturing.

The industry is currently facing headwinds that are anticipated to pose challenges, particularly in the initial part of the year. This situation is likely to lead to some consolidation within the industry. However, there is a strong position to navigate these challenges. A company that boasts a robust portfolio encompassing hardware, software, and materials, making it easily adaptable and cooperative, will succeed in this climate.

In 2024, significant growth opportunities are anticipated across various industries, particularly driven by advancements in additive manufacturing. The automotive sector is witnessing increased investment in

additive technologies, driven by the imperative to create lighter and more efficient vehicles. The electric vehicle (EV) market, in particular, presents a substantial opportunity for additive manufacturing, with noticeable changes already underway.

In the aerospace industry, several airlines are actively pursuing carbon neutrality goals, extending to the manufacturing of aircraft. Integrating additive manufacturing into their processes is viewed as instrumental in helping them achieve these environmental objectives. Furthermore, the defense industry is undergoing continuous evolution in terms of equipment requirements, spanning from vehicles to the materials used in uniforms. Notably, significant investments from the defense sector are being directed towards additive manufacturing, signaling a continued trend in embracing this innovative technology.

In the upcoming year, anticipations for changes in 3D printing technology revolve around incorporating more automation and artificial intelligence into the processes.

Industry 4.0 will maintain a pivotal role in guiding manufacturers to futureproof their shop floors in the upcoming year. A key aspect involves strategic planning for the changing landscape. With the increasing trend of reshoring and the establishment of plants globally focused on delivering materials and parts at a local level, optimizing space on the manufacturing floor becomes crucial. This shift is already evident in the additive sector, where manufacturers are actively constructing additive centers. These centers not only serve as hubs for prototyping, but also serve as platforms for integration of additive manufacturing into the core of their actual manufacturing processes.

The foresight to incorporate Industry 4.0 principles ensures that manufacturers are well-prepared for the evolving dynamics of the industry, enabling them to stay competitive and adaptable in the ever-changing manufacturing landscape.

In the upcoming year, anticipations for changes in 3D printing technology revolve around incorporating more automation and artificial intelligence into the processes. The focus is on making these technologies smarter, which is expected to significantly enhance the mass production capabilities of additive manufacturing across various industries.

The progress made in the preceding year is acknowledged, but there is a collective aspiration to sustain and amplify this momentum throughout 2024. The integration of advanced automation and artificial intelligence is poised to not only streamline 3D printing processes, but also contribute to increased efficiency and precision, further expanding the applications and potential of additive manufacturing in the manufacturing landscape.

For 3D printing companies to achieve success, a crucial characteristic is a willingness to adapt and fulfill the promises that additive manufacturing holds. While machining and prototyping will continue to be essential aspects of additive manufacturing, demonstrating the capability for mass production is imperative. Companies positioned for success are those that have been proactive in developing end-to-end solutions and have closely engaged with their customers to understand and address their needs. The forefront of success in 2024 will be occupied by those companies that not only embrace change but also prove their capacity to deliver on the potential of additive manufacturing, particularly in the realm of efficient and scalable mass production.

SHAPING TOMORROW:

Mastering Additive Manufacturing

While some Industry 4.0 technologies are more nebulous like Big Data and the Industrial Internet of Things, additive manufacturing (AM) is hands on and visual. You can see a new additively manufactured piece being printed and feel it, from a rocket booster the size of a truck to a micro-lattice part the size of a matchead.

With this power and flexibility, the additive process is redefining the way factories approach and think about the design process. However, the change is not happening overnight.

“We’re talking about transforming a $13 trillion manufacturing industry. That’s not an easy task,” Stratasys Global Director of Transportation Fadi Abro said. “We’re not going to take all of those trillions and put them into additive manufacturing. But if you look at scale, $40 billion is invested in the 3D printing market today.”

For this transformation, it is important to establish a playbook for the journey into a distributed and additive manufacturing future.

It requires a mindset shift, Abro added. “Additive manufacturing is not a single product, solution or material. It is a way of doing things. It’s also about localizing production. We need to have ways to react to supply chain problems, and additive manufacturing can be that answer.”

Embracing Design For Additive Manufacturing

The process of integrating additive manufacturing starts with redefining how engineers design products. Design For Additive Manufacturing (DFAM) is a set of processes that focuses on the design, engineering, and production of components or end products through additive manufacturing.

When designing components or products using DFAM, engineers consider material properties, build speed versus accuracy tradeoff, surface finish requirements, and structural integrity as they would with any regular build. Those elements are critical to manufacturing parts that can perform with quality.

However, additional design rules and considerations also come into play. Designers must consider the part’s geometry (overhangs, internal supports), build orientation on the platform, the laser focus position and angle, type of metal or plastic used for printing (including its properties such as heat capacity or wear resistance), build platform size, and shape. Luckily, most of these configurations can be simplified with software, and in some cases, assisted by artificial intelligence (AI).

“Each [additive manufacturing] machine is unique in its capabilities, and because of their own uniqueness, there is specific software needed to make the system run properly,” said David Darbyshire, co-owner of Cyb Llings Inc. “There is a big push in the industry to allow for an individual CAD software app to push up cloud-type services to make it a more unified experience.”

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The challenge goes beyond a unified cloud-type service as well.

“We also need to have a better knowledge base within organizations to understand what an individual machine is capable of doing from a perspective of what material is being used, slicing process being used, what post-processes, and what each piece of equipment is intended for,” Darbyshire said.

More investment in institutional knowledge in regards to DFAM plays to its strengths, as DFAM implemented correctly speeds up the design process by letting engineers spend their time focusing on the performance of the part rather than its manufacturability across various traditional CNC machines. This makes the process part-focused instead of machine-capability focused.

The Advantages of DFAM

The main advantages of DFAM are that it allows designers to more easily create parts with complex geometries and features while also reducing material waste, cost, and time in the manufacturing process. Both of those are major benefits for companies doing business in today's manufacturing industry, which continues to innovate and evolve at a rapid pace. Adopting DFAM well will allow companies to stay ahead of the competition and offer better quality products or services at a lower cost.

DFAM lets engineers spend their time focusing on the performance of the part rather than its manufacturability across various traditional CNC machines.

DFAM also makes manufacturing more of a digital art focused on the creation of intellectual property through software instead of what the hardware production line allows.

This applies beyond polymer additive manufacturing as well — when parts are designed for 3D metal printing, the design intent is much more “topdown" where designers can easily adapt and scale their designs to fit a wide range of needs or manufacturing capabilities without compromising performance or cost.

In addition to the parts-focused approach, DFAM also makes manufacturing more of a digital art focused on the creation of intellectual property through software instead of what the hardware production line allows.

“We need to make an extra effort in teaching our engineers and designers the limitations of the software of these machines,” Darbyshire said.

Additive Manufacturing in Aerospace and Defense

The capabilities of additive manufacturing are already on display within NASA and the Department of Defense. NASA’s latest 3D printed Rotating Detonation Rocket Engine (RDRE) is lighter than traditionally manufactured rocket engines and reached 5,800 pounds of thrust in a four minute test.

“The RDRE enables a huge leap in design efficiency,” NASA Marshall Spaceflight Center combustion devices engineer Thomas Teasley said. “It demonstrates we are closer to making lightweight propulsion systems that will allow us to send more mass and payload further into deep space, a critical component to NASA’s Moon to Mars vision.”

On the military side of additive manufacturing, the Navy is utilizing laser metal deposition 3D printers for ships at sea to fabricate parts without the need to dock or receive parts from other vessels.

Meanwhile, the Marine Corps spearheaded an intiative to 3D print M1A1 Abrams Tank impellers after facing a supply chain shortage with successful implementation. After 100 hours of wear and tear on the printed part, no difference was found between the OEM and additively manufactured part.

Generative Design in Additive Manufacturing

Generative design is a discipline of AI that conceptualizes products based on predefined parameters and inputs. Using a combination of machine learning, cloud computing, and advanced algorithms, this technology creates innovative solutions that would be otherwise difficult, if not impossible, to produce using traditional methods. The goal of generative design is to fully satisfy the demands of a given context in as optimal a way as possible.

Paired with the advanced technical capabilities of additive manufacturing, generative design emerges as a powerful tool in manufacturing the next generation of products. The duo of generative design and additive manufacturing is utilized by NASA with its “Evolved Structures” that are cheaper, lighter and faster to produce than traditional tooling. In the automotive industry, Divergent also deploys these technologies in unison, reducing the braking system weight of its Czinger 21C hypercar by 40% compared to conventional assembly.

"It is hard to buck traditional mindsets, trying to get people to think 'outside the block.'"

-Ingrid Tighe President, Michigan Manufacturing Technology Center

The Barriers of DFAM Adoption

While the benefits of DFAM prove it's competitive advantage, there are roadblocks to bringing it into the mainstream. Prime among these is cost. The hardware and software for additive manufacturing are still fairly expensive, meaning most companies with limited budgets could struggle to invest in the necessary equipment.

However, when compared to traditional machining, additive manufacturing does have an advantage in cost. CNC machines are often five times more expensive than a 3D printer.

It's also important to remember deploying DFAM requires a new type of thinking in product design — something that many engineers in the field may not be trained for, leading to a shortage of engineers with appropriate experience.

“It is hard to buck traditional mindsets, trying to get people to think ‘outside the block,’” said Ingrid Tighe, president of the Michigan Manufacturing Technology Center.

A survey conducted by Eastern Michigan University on 47 Michigan manufacturers showed training in Design For Additive Manufacturing as the most needed skill to successfully implement 3D printing. Furthermore, more than 50% of respondents said hands-on training on additive manufacturing machines is highly important, underscoring the importance of access to machines in the field.

This issue is something that the federal government recently addressed with the Biden Administration’s Additive Manufacturing Forward Program with funding to develop a curriculum for workforce training among AM Forward participants along with apprenticeship programs in additive manufacturing.

Distributed Manufacturing Networks and AM

A concept that wouldn't be possible without the IoT, distributed manufacturing leverages technology to enable the production of products on a large scale while still keeping production decentralized and localized. The flexibility and deployability of additive manufacturing makes it the perfect vehicle for a distributed network.

“With a distributed community, there is a lower barrier to entry, you can share your best practices, and make things you couldn’t otherwise do,” Tighe said. “It’s also a built in R&D department.”

The key advantages of distributed manufacturing are its scalability and flexibility. With distributed manufacturing, production capacity can be rapidly increased or decreased as needed without having to commit large amounts of capital upfront. This type of setup is also well suited for personalized production, as the decentralized nature of distributed manufacturing makes it easier to tailor products to individual customer needs without sacrificing efficiency.

With additive manufacturing technology, distributed manufacturing networks can produce products with greater complexity or customization than ever before. Automation Alley’s Project DIAMOnD initiative will be instrumental in this effort as the largest connected 3D printing network set up for distributed manufacturing in the U.S.

The flexibility and deployability of additive manufacturing makes it the perfect vehicle for a distributed network.

Barriers to Distributed Manufacturing

Though there is a myriad of potential applications for distributed manufacturing, it isn’t without its challenges.

The first major barrier is security. With this type of setup, companies must rely heavily on digital networks to process orders and deliver products. This makes them vulnerable to cyberattacks from outside parties, as well as malicious internal actors.

According to NIST, manufacturing is the most targeted industry for cyber attacks. And the average cost of a data breach for a small business is $105,000.

Quality control is also a major concern, Darbyshire said.

“There are a lot of variables when entering into this space. Internally, you understand the shelf life of your materials, and who is operating the machine. You understand their certification and the qualification of your equipment. But when you start outsourcing, so much more accountability is needed.”

What the finance model looks like is another question left unanswered, Tighe added.

“If you put in a call for 100 separate companies to make a part, how does the payment work? What is the margin and overhead?”

Even with cybersecurity and quality control issues solved, distributed manufacturing may face its most difficult challenge – the protection of intellectual property among many manufacturers.

“There is a big fear in releasing individual parts to a large network with respect to intellectual property,” Darbyshire said. “Does that open the door for someone to make 100 more parts on the side, or create a different part that can do a similar job that competes with the original part?”

One solution may be having all parties agree to sign an NDA (Non Disclosure Agreement), Tighe said.

According to Darbyshire, all these factors must be defined, and “right now there is not an industry standard for manufacturing in this environment.”

Connectivity will be another challenge, as not every factory currently has the IoT capabilities necessary to connect with a distributed manufacturing network. This will require significant investments in hardware and software for companies that wish to participate.

This is why programs like Project DIAMOnD and the Michigan Economic Development Corporation’s Industry 4.0 Technology Implementation Grant are necessary to help small- to medium-sized manufacturers with getting up to speed on IoT integrated systems and additive manufacturing methods.

Additive manufacturing reduces energy use by 25% and can cut waste and materials costs by up to 90%, compared to traditional manufacturing methods.

Sustainability in Additive Manufacturing

Sustainability is a defining issue of our times, and most agree that businesses are key to driving progress. Manufacturers face a growing amount of pressure to reduce their carbon footprints, consumers increasingly seek out companies that prioritize environmentally-friendly products and practices. Luckily, additive manufacturing offers a sustainable alternative to traditionally wasteful manufacturing processes.

“Additive manufacturing by its nature is more sustainable. You are building only the layers you need, and are not carving out a block and throwing waste into the landfill. Inherently, it is more sustainable for prototypes and tooling than traditional means,” Abro said.

Tighe said “Additive manufacturing is lean manufacturing at its best. There is no scrap and waste. It uses less energy, and there is a reduction in packaging.”

The Department of Energy reported “Additive manufacturing reduces energy use by 25% and can cut waste and materials costs by up to 90%, compared to traditional manufacturing methods.”

This is due in part to the fact that additive manufacturing creates products from the ground up, using only as much material and energy as necessary to produce the desired item. 3D printing also enables manufacturers to create complex parts quickly and easily in one go; not only does this reduce production time but also eliminates the need for excess components or postprocessing steps such as sanding or painting which can further contribute to increased energy consumption and waste.

Pressing Challenges In Manufacturing Sustainability

Although everyone agrees it's a priority, sustainability in additive manufacturing is still in its infancy.

For example, printing with bioplastic feedstocks may be an option for some companies looking to reduce their carbon footprint, but this can come with limitations regarding material strength and durability compared with other plastics used in additive manufacturing.

The comparatively low power requirements of 3D printing make it possible to produce parts using less energy, however that benefit to the planet is limited if the source of that energy is a local coal-fired power plant. According to the U.S. Energy Information Administration, over 75% of power demands for industry are supplied by petroleum, coal and natural gas. Renewable energy sources power only 9% of the U.S. industrial sector.

Climbing from the Trough of Disillusionment

2024 will likely continue to see the additive manufacturing industry maturing past the venture capital and government research phase, delving into the nitty gritty challenge of parts production and real-world implementation.

According to the Gartner Hype Cycle on new products entering the market, additive manufacturing likely sits in the “trough of disillusionment” phase, as scores of additive manufacturing startups are weeded out by market forces or consolidated into firms that deliver on their promises.

Despite this natural contraction, leaders in manufacturing should be aware of and adopt the technology on a small-bets basis, bracing for an additive manufacturing future when the technology reaches its full potential. After all, though the horse and buggy industry may have laughed and ridiculed the idea of a motorcar for years, eventually the car caught up with them.

Final Thoughts

Additive manufacturing's ability to change the production landscape shouldn't be underestimated. As the technology improves and more use cases are deployed, the adoption curve is projected to skyrocket in tandem with other Industry 4.0 forces. Therefore, it is imperative for all stakeholders in the manufacturing value chain to understand this technology, its challenges, and its potential.

As the technology improves and more use cases are deployed, the adoption curve is projected to skyrocket in tandem with other Industry 4.0 forces.

- U.S. Department of Energy

INDUSTRY PULSE

Automation Alley posted weekly polls in January for our LinkedIn followers of over 5,000 professionals in the technology and manufacturing ecosystem on the topic of Shaping Tomorrow: Mastering Additive Manufacturing. This is how the industry responded at a glance.

What general material of 3D printing is most useful for your business?

What portion of your production involves additive manufacturing?

What level do you anticipate investing in additive manufacturing?

What is the main challenge your organization faces when implementing additive manufacturing/3D printing in production?

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KEY TAKEAWAYS

The Importance of Design For Additive Manufacturing (DFAM): Making the switch to an additive mindset isn’t as simple as purchasing a 3D printer and pressing the power button. Engineers will need to learn DFAM, understanding the geometry, build orientation, material properties and build process of products. Once an understanding of DFAM is achieved, engineers focus more on part performance instead of machine capabilities.

Generative Artificial Intelligence Design and Additive Manufacturing:

Generative AI design is already employed in aerospace and the auto industry. The process capitalizes on the build flexibility of additive manufacturing, making these technologies a natural duo. Generative AI-designed parts that are additively manufactured are often lighter, stronger and consume less material than their traditional counterparts. Given AI’s mass adoption by the market at large, this will be a force to be reckoned with in manufacturing.

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Distributed Manufacturing and AM: Distributed manufacturing, facilitated by IoT and AM, allows large-scale production while keeping it decentralized. AM's flexibility and deployability make it ideal for distributed networks, providing scalability, flexibility, and personalized production capabilities.

AM and Sustainability: AM offers a sustainable alternative by reducing energy use (up to 25%) and cutting waste and material costs (up to 90%) compared to traditional manufacturing. Industrial pollution accounts for 30% of greenhouse emissions worldwide. AM provides a route to reduce that number.

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Government Support of AM: The U.S. government introduced the AM Forward initiative in May 2022, aiming to promote 3D printing in industry. It encourages collaboration among major companies to help small- and medium-sized businesses adopt 3D printing technology, creating a more resilient supply chain and boosting the local industrial ecosystem. Locally, Automation Alley's Project DIAMOnD is connecting SMEs via a distributed 3D printing network, allowing them to explore what's possible with AM.

Integrating AM Programs in Education: 3D printing provides a practical learning environment for students, allowing them to develop skills and gain practical experience that prepares them for internships and employment in related fields. Additive manufacturing hubs should be a standard on campuses with engineering programs to provide a space to experiment and study the technology.

Building a Scalable Framework: Navigating the change of a new additive manufacturing climate will be disruptive. A new framework is needed to manage this change. Global ID, Digital Rights Management, Digital Product Recipes, and Quality and Certification will be key to overcoming the disruption.

Recommendations for Industry

3D printing is changing the way we make products and is accelerating the circular economy, linking material, design, and production in a continuous and sustainable loop.

Machines, materials, and software innovations are sparking a renewed interest in additive manufacturing—and all companies should be paying attention, especially as on-demand and customized products made to individual specifications become the norm. With its unparalleled ability to increase speed-to-market, lower costs, reduce waste, and customize specialty parts, 3D printing is changing the way we make products and is accelerating the circular economy, linking material, design, and production in a continuous and sustainable loop.

Industry leaders can pave the way for successful integration of additive manufacturing by investing in R&D, strategically incorporating 3D printing into their supply chains, and prioritizing talent development through targeted training programs. These recommendations set the stage for embracing the transformative potential of additive manufacturing within the manufacturing sector.

Investing in Research and Development

Industry leaders should prioritize substantial investments in research and development to explore and refine the applications of additive manufacturing within their specific production processes. This involves not only adopting existing 3D printing technologies, but actively contributing to the advancement of these technologies.

Decisions on which software to use and its functionality are critical to creating an integrated system that connects 3D printers to the production line and data analytics teams while offering real-time information on part production. This information will increase efficiency by tracking parts during production, reducing error margins, and maintaining the supply of needed materials.

By fostering in-house R&D teams or collaborating with external research institutions, companies can stay at the forefront of additive manufacturing innovations, identifying opportunities for process optimization, material development, and product customization.

Integration of Additive Manufacturing into Supply Chains

Industry leaders should strategically integrate additive manufacturing into their supply chain processes. This includes identifying key areas where 3D printing can add value, such as rapid prototyping, on-demand production,

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and spare parts manufacturing. By incorporating additive manufacturing at strategic points in the supply chain, companies can reduce lead times, minimize inventory costs, and enhance overall operational efficiency

Collaborating with suppliers, logistics partners, and other stakeholders is crucial for a seamless integration of additive manufacturing into the broader manufacturing ecosystem.

Talent Development and Training Programs

To successfully adopt additive manufacturing, industry leaders need a skilled workforce well-versed in the intricacies of 3D printing technologies, especially because 3D printing requires a commitment to design for additive manufacturing (DFAM). Implementing training programs, both for existing employees and new hires, is essential. This includes not only technical training on operating 3D printers but also fostering a deep understanding of the design principles and material considerations unique to additive manufacturing. Companies can collaborate with educational institutions and industry associations to develop customized training programs that align with their specific needs. Additionally, creating a culture that encourages continuous learning and experimentation is crucial for staying innovative in the rapidly evolving field of additive manufacturing.

Recommendations for Academia

An immersive additive manufacturing project can provide students with the practical experience to land internships and employment in related fields upon graduation.

As additive manufacturing makes more significant inroads into the production process, academia must partner with industry leaders and the government to ensure curricula are relevant to the workforce's needs. Additive manufacturing allows for a productive learning environment that uses varying skills and educational disciplines, creating similar environments to the workplace. An immersive additive manufacturing project can provide students with the practical experience to land internships and employment in related fields upon graduation.

Creating on-campus 3D printing hubs dedicated to taking a product idea from conceptualization to completion would allow students to explore integrated curriculum design, prioritize flexibility and continuous learning and collaborate with industry partners through training programs

Integrated Curriculum Design

Academic institutions should collaboratively design and implement integrated curricula that incorporate additive manufacturing concepts across various disciplines. This involves integrating 3D printing principles into engineering, design, materials science, and business courses. By fostering a multidisciplinary approach, students gain a comprehensive understanding of the entire additive manufacturing ecosystem, preparing them for diverse roles in the industry. Collaborative efforts between academia and industry professionals can help align educational programs with the evolving needs of the additive manufacturing sector.

Providing the latest CAD software allows students to explore DFAM to make improvements before the printing phase begins, reducing potential errors and misused resources. Colleges and universities must also work with students to meet their needs and provide cost-effective materials and equipment. Students should conduct research on available supplies, industry use, cost analysis, and sustainability under the supervision of instructors and industry mentors. Selecting materials is also an opportunity for academia to immerse students in studying the international supply chain to learn the costs of various materials from different countries and transportation methods to manufacturing facilities.

Additionally, curricula should include quality testing. Using physics and mathematics, students can use data to determine if a part needs a redesign to strengthen its perimeters. Even the orientation of a part during printing, layer height, print speed, and temperature can affect its strength.

Finally, additive manufacturing is a study in sustainability. According to a survey conducted by Filamentive, 10% of materials used in 3D printing are wasted with failed prints, structures, and test prints accounting for the majority of the waste. Improving those numbers requires tearing down the traditional academic silos and using each discipline to develop creative environmentally friendly solutions. Adding environmental studies majors to a collaborative hub provides a better understanding of available natural resources and biodegradable materials that improve sustainability. A diverse group of disciplines will make a circular economy a productive economic model.

Industry-Driven Training Programs

Establishing partnerships between academic institutions and industry players can lead to the development of industry-driven training programs. Industry experts can contribute valuable insights into the latest trends, technological advancements, and practical applications of additive manufacturing. Internship programs, guest lectures, and collaborative research projects provide students with real-world exposure and hands-on experience, bridging the gap between theoretical knowledge and practical application. Policymakers can incentivize these partnerships through grants, tax incentives, or other support mechanisms to encourage ongoing collaboration.

Flexibility and Continuous Learning

Given the rapid evolution of additive manufacturing technologies, approaches and materials, educational programs should emphasize flexibility and a commitment to continuous learning. Institutions should offer professional development opportunities, workshops, and certification programs to enable individuals already in the workforce to upskill and stay abreast of the latest advancements.

Internship programs, guest lectures, and collaborative research projects provide students with real-world exposure and hands-on experience, bridging the gap between theoretical knowledge and practical application.

Skills needed for Additive Manufacturing Careers

A successful collaboration between academia, industry, and policymakers in the realm of additive manufacturing education requires a holistic approach that integrates diverse perspectives, practical experiences, and a commitment to ongoing learning.

Recommendations for Government

Addressing supply chain disruption has been a key government focus in many industries over the past few years, and 3D printing has been one answer for the industry.

Government plays a major role in facilitating the integration of 3D printing technology within industry, particularly for small- and medium-sized businesses. The U.S. government took a big step in promoting the use of 3D printing in industry through the Additive Manufacturing Forward (AM Forward) initiative in May of 2022, but there is more work to be done.

The supply chain has always been critical to the economy, and while industry leaders understood that fact for decades, the point was hammered home during the COVID-19 pandemic. As shutdowns put a pinch on available parts and materials, manufacturers delayed fulfilling customer orders, stopped production, and laid off workers. Addressing supply chain disruption has been a key government focus in many industries over the past few years, and 3D printing has been one answer for the industry.

Government entities should consider the following recommendations to unlock the transformative power of 3D printing in manufacturing. With strategic policy interventions and forward-thinking governance, we can pave the way toward a more secure supply chain and technologically advanced future.

Investment in Research and Development

According to the U.S. Small Business Association, small firms account for 99% of U.S. manufacturing and provide more than five million jobs. Those are significant numbers, but there are still barriers to those small businesses adopting new 3D technology and innovative materials used in production. Cost is one of the main concerns. Lacking a commitment from customers to purchase parts or products prohibits the investment into 3D technology and worker training, which can be expensive and increase annual budget estimates. The lack of investment causes the small- to medium-sized manufacturers to fall behind their larger counterparts.

Government entities should prioritize funding and support for research and development initiatives focused on advancing 3D printing technologies and materials. By allocating resources to collaborative projects involving industry experts, academic institutions, and manufacturers, policymakers can stimulate innovation, pushing the boundaries of what 3D printing can achieve.

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To even the gap, the U.S. SBA, for example, offers loans and grants to upgrade infrastructure, improve employee training, and purchase new technology. The organization also provides a contract assistance program designed to put smaller firms in contact with businesses and government organizations requiring their products.

This investment should extend to exploring new materials, refining printing processes, and addressing challenges such as scalability, precision, and speed. Yet, testing new materials needed for 3D printing can be costprohibitive for small businesses. Larger manufacturers with bigger R&D budgets can afford to test different metals, new filaments, varying types of plastics, and biodegradables. AM Forward works to coordinate the businesses in the industry to share these advancements to avoid duplicating efforts.

Establishing Ecosystems, Frameworks and Standards

To encourage widespread adoption of 3D printing in manufacturing, governments need to develop clear and adaptable regulatory frameworks. Policymakers should work collaboratively with industry stakeholders to establish standards that ensure the safety, quality, and reliability of 3D-printed products. This involves addressing issues related to intellectual property, certification processes, and environmental sustainability.

A transparent and well-defined regulatory environment will provide businesses with the confidence needed to invest in and embrace 3D printing technologies. On a federal level, AM Forward intends to improve the supply chain and help businesses invest in new technology and materials to keep manufacturing stateside to accomplish the initiative's goals.

Regional manufacturing ecosystems like Project DIAMOnD are essential in maintaining low costs and improving sustainability, which is good for the industry at large. Having parts produced nearby cuts manufacturer's lead times, keeps production lines moving, lowers shipping costs, and reduces dependencies on fossil fuels. Recycling waste materials and faulty units while reusing parts and products is more accessible within a close-knit ecosystem.

Policymakers should work collaboratively with industry stakeholders to establish standards that ensure the safety, quality, and reliability of 3D-printed products.

Educational Initiatives and Workforce Development

Governments should invest in educational programs and workforce development initiatives to cultivate a skilled talent pool capable of leveraging 3D printing technologies. This includes integrating additive manufacturing into educational curricula at various levels, providing training programs for current and future professionals, and supporting research institutions that focus on additive manufacturing. By nurturing a knowledgeable workforce, governments can ensure that businesses have the talent pool required to effectively implement and capitalize on 3D printing in the manufacturing sector.

Governments’ Continuing Role

Governments worldwide and in the U.S. are essential partners with the private sector to continue developing additive manufacturing technology to increase productivity, standards, and practices that improve environmental sustainability. Through collaboration, governments can help keep the smaller firms competitive, which keeps the supply chain resilient and helps every area of the manufacturing industry. To assist the private sector, government and industry leaders must work in unison to establish the best pathways to using 3D printing.

How Governments Encourage 3D Printing Use in Manufacturing

• Help the private sector keep supply chains resilient

• Aid smaller firms with adopting new technology and employee training

• Offer equipment and facility upgrade investment incentives

• Create standards and practices that focus on environmental stability

• Facilitate industry cooperation in sharing new techniques

• Create programs to bring manufacturers and government agencies together

Sean Carlson Deputy County Executive, Oakland County

Revolutionizing Manufacturing: Project DIAMOnD's Journey Towards an Additive Future

Manufacturing has operated with the same strategy for over 100 years. Design engineers conceive products, manufacturing engineers concoct production lines to produce them, logistics through freight or other means take them where they are assembled, and a finished product ships to customers.

We can continue down this path, drumming on the same methods that built the modern world generations ago — rife with supply chain struggles, siloed between competitors, at the mercy of steep hardware investments, and the fickle nature of geopolitics. Or we can dare to accept the reality of Industry 4.0 dictating that the days of this dated model are numbered and lay the foundation for a more productive and equitable future.

Oakland County, Michigan in association with Automation Alley is proud to be the vanguard of this manufacturing mindset change. Through Project DIAMOnD, we’ve distributed state-of-the-art Markforged 3D printers to small manufacturers across the county, placing the power of additive manufacturing in a distributed network of stakeholders.

Digital, Independent, Agile, Manufacturing on Demand

Project DIAMOnD has already seen early success, activating its network of 300 participants to create tourniquets to aid Ukraine in 2022. The first phase of Project DIAMOnD was designed to be an emergency response system to produce PPE in the fight against the Covid-19 pandemic. Project DIAMOnD is driving a transformative shift in the manufacturing industry by developing a demand-based digital platform. Here's how we plan to accelerate the transition in mindset towards additive manufacturing in Phase 2:

We can dare to accept the reality of Industry 4.0 dictating that the days of this dated model are numbered and lay the foundation for a more productive and equitable future.

Pavan Muzumdar

COO, Automation Alley CEO, Project DIAMOnD

The Need for Design for Additive Manufacturing Training

Design for Additive Manufacturing requires engineers to think outside the block and relearn what traditional manufacturing training may have taught them. Project DIAMOnD participating companies will go through an exclusive Digital Transformation Program for additive manufacturing, understanding best practices and design principles of a variety of 3D printers on the Project DIAMOnD network in addition to learning how to recraft their business models and businesses in an additive world.

A Secure Peer-to-Peer Marketplace

One of the greatest challenges of distributed manufacturing is intellectual property (IP) security. To address this, companies can leverage the expertise and resources of their peers via the Project DIAMOnD marketplace. These transactions will be done on a peer- to-peer marketplace designed to eliminate the risk of compromising IP security developed in partnership with Markforged, Inc.

An Additive Manufacturing Center for Training, Testing & Validation

Access and training are also challenges small manufacturers face when adopting the additive manufacturing mindset. To facilitate the network’s success across a variety of applications, Project DIAMOnD members will gain access to training opportunities as well as industrial polymer and metal 3D printers hosted and maintained at the DTC (Digital Transformation Center) in Auburn Hills, Michigan. This way, companies can launch and validate products without the burden of owning and operating complex equipment. This provides a pathway to a democratized manufacturing ecosystem. Leon Brown of Earth Orbit Technologies, a Project DIAMOnD participating company, noted “Project DIAMOnD is a path out of poverty.”

Placing the Power of AM at Your Fingertips

Project DIAMOnD plans to distribute an additional 250 3D printers to small- to mid-sized manufacturers in Phase 2. These Fused Filament Fabrication 3D printers are capable of printing production-ready parts with material strengths similar if not exceeding aluminum, carbon fiber, and much more.

If you are interested in being part of the movement that is going to change manufacturing for good, learn more and connect with us at projectdiamond.org. While it is currently an Oakland County, Michigan initiative, we are hard at work to bring Project DIAMOnD to all of Michigan and beyond.

The additive manufacturing future is coming to upend traditional models. Let’s future-proof manufacturing together.

The additive manufacturing future is coming to upend traditional models. Let’s future-proof manufacturing together.

WITH MICHIGAN MANUFACTURING TECHNOLOGY CENTER

The Additive Advantage in Manufacturing

By Ingrid Tighe, President, Michigan Manufacturing Technology Center

Additive manufacturing is revolutionizing how Michigan manufacturers work in many sectors by making it easier, more cost effective, and faster to produce crucial tools and components. This technology can be applied to various sectors and points in the manufacturing process, from design to production. And as these benefits become more evident, additive manufacturing is catching on: the global additive manufacturing market is expected to grow by more than 20% by 2030, reaching a value of nearly $77B. It’s clear that any expansion of Michigan’s manufacturing capabilities must include additive technology.

Additive manufacturing is commonly used in the automotive, aerospace, and defense industries for rapid prototyping. The ability to create multiple models of parts allows engineering teams to design, evaluate, and redesign quickly, meaning teams can meet the most precise specifications and criteria with far less lead time. Additive prototyping is also a more accessible use of the technology, as it can be integrated without disrupting existing supply chains or production processes—making it an attractive Industry 4.0 entry point for smaller manufacturers.

In recent years, manufacturers in many sectors have made headway producing tools and end-user parts with additive processes—a trend on track to continue. Additive processes can make components lighter and stronger and simplify the assembly process. They can also permit development of designs with complex geometries while maintaining the necessary structural integrity. For example, General Electric Aviation recently 3D printed a jet fuel nozzle with an internal cooling channel to reduce fuel usage, which was 25% lighter than a typical part. In many cases, these innovations are only available because of additive’s capabilities. An example is lightweighting, which often uses tree-like

Scaling additive manufacturing has been a longstanding challenge,

but the tide is turning in this regard.

structures to produce strong yet light components—structures that would be virtually impossible to produce with traditional methods or even other innovations.

Additive technology also facilitates on-demand printing of parts and tools with various degrees of customization. In 2022, the US Navy permanently installed a metal 3D printer on one of its ships to allow real-time creation of replacement parts and panels. Other companies have turned their focus to mass customization—providing highly customized products at low volumes, such as vehicle enhancements, personalized medical devices, or even made-to-order jewelry

Scaling additive manufacturing has been a longstanding challenge, but the tide is turning in this regard, too: In 2022, GM turned to 3D printing to manufacture 60,000 parts and ensure the on-time delivery of its Chevy Tahoe SUVs, and has incorporated additive components into several Cadillac models. At the supplier level, the Michigan Manufacturing and Technology Center’s own client, SCHERDEL Group, significantly improved production time for their automotive and aerospace springs, reduced their environmental impact, and saved money by using a 3D printer to reduce

their dependence on traditionally machined tools. Additive manufacturing offers opportunities for innovation and efficiency to manufacturers of any size or production scale.

Additive manufacturing will drive manufacturing into the future as additional suppliers leverage and evolve this technology. In Michigan, our state's focus on mobility will increase demand for newer additive technologies like binder jetting, which can make extraordinarily light metal components, reducing vehicle weights and improving battery performance in EVs and fuel efficiency in gasoline cars and aircrafts.

Additive technology can also help to promote domestic manufacturing by reshoring the production of parts and tools typically sourced from overseas suppliers. Combining additive tools with other Industry 4.0 technologies, such as automation and artificial intelligence, will help manufacturers achieve even greater efficiencies.

Additive manufacturing has myriad applications and endless potential. The flexibility of this technology means the sky's the limit for the manufacturers creating the components and vehicles that Michigan’s success rides on.

In Michigan, our state's focus on mobility will increase demand for newer additive technologies.

ABOUT:

MISSION:

Automation Alley is a nonprofit technology business association and Digital Transformation Insight Center focused on driving the growth and success of businesses in Michigan and beyond through innovation and automation. With a global outlook and a regional focus, we foster a vibrant community of innovators, entrepreneurs, and business leaders through opportunities for collaboration and learning. Our programs and services help businesses develop the skills and expertise needed to effectively jumpstart or accelerate digital transformation. By bringing together industry, academia, and government, we aim to create a dynamic ecosystem that drives innovation and growth across Michigan.

At Automation Alley, our mission is to help businesses thrive in the rapidly changing digital economy by equipping them with the knowledge, insights, and tools to develop a software-first mindset that leverages the power of automation, AI, and other cognitive technologies. We believe that by working together, we can build a stronger, more innovative, and more competitive economy for the future.

VISION:

Wealth, prosperity and equality through technology.

To find out more about Membership visit: automationalley.com

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Project DIAMOnD

https://www.projectdiamond.org/

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Form Labs - Road to the 3D Printed Car: 9 Ways 3D Printing is Changing the Automotive Industry

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LinkedIn - Metal 3D Printing in Aerospace: Case Studies Showcasing Innovation and Efficiency

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Gildform

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