5 Questions to Ask Before Using Additive Manufacturing

Are you considering using additive manufacturing (AM) for a project but unsure where to start? Asking the right questions is essential to determine if AM is the right solution for your project’s needs. It’s also the best way to ensure your parts are optimized for quality, efficiency, and cost-effectiveness from the start.

Additive manufacturing (AM) has transformed how we manufacture parts, offering design freedom, faster lead times, and scalable production. However, like any manufacturing method, success begins with preparation. By evaluating your project’s specific requirements, you can avoid bottlenecks that may arrive later in the manufacturing process.

To guide you through this process, we’ve identified five critical questions to ask before integrating AM into your production workflow.

1. What are the pain points with your existing manufacturing method?

Before considering the advantages of additive manufacturing, it’s important to assess the limitations of your current manufacturing process. Are you required to meet high minimum order quantities (MOQs) that result in unnecessary inventory? Are extended lead times delaying your ability to meet market demands or customer needs? Perhaps your designs include complex features, like internal channels or lightweight lattice structures, that are nearly impossible to produce using traditional methods.

Pinpointing these pain points helps paint a clearer picture of where AM can be leveraged to overcome specific challenges. For example, AM eliminates tooling requirements, enabling cost-effective low-to-mid volume production. However, this analysis might also reveal that AM isn’t the right fit for your project’s needs.

This evaluation is vital for setting clear expectations and ensuring AM is applied where it provides the most value. This clarity will set the stage for a successful transition to the next question: what criteria to consider when choosing an AM technology?

2. What criteria should I consider when selecting a technology?

Each 3D printing technology has its unique capabilities that make it a viable option to print a part. It’s important to consider the trade-offs you will experience as a result of choosing a specific technology. The criteria you prioritize should align with your goals. Is speed your main concern? Are you focused on minimizing costs? Do you need a material with specific mechanical, thermal, or regulatory properties? Is your part’s design complexity the driving factor?

For example, if rapid prototyping is a priority, lower-cost technologies like FDM or SLA may be suitable. However, they may not offer the same quality, material properties, or precision as more advanced options like Multi Jet Fusion (MJF) or Selective Laser Sintering (SLS). Cost is another key factor—AM can be cost-effective for low-to-mid-volume production runs (100s and 1000s of parts) but may not always be the best for super high-volume runs (100,000s and 1,000,000s of parts). Prioritizing your requirements will help you more easily determine your scalability requirements.

3. What are your volume and scalability requirements?

Volume and scalability play a significant role in determining the economic feasibility of AM. Consider where your part fits within the product lifecycle. Is it in the prototyping, bridge to tooling, full production, or spare part phase? Understanding these factors helps define your cost break-even and ensure the most economical choice for your project.

Video game controller housing 3D file

For example, Endeavor 3D worked on a video game controller housing using Nylon PA 12, where we compared the cost-effectiveness of Multi Jet Fusion (MJF) versus injection molding. Since MJF uses a build box, the nesting orientation of the parts was crucial to minimize thermal stress and achieve optimal surface quality while balancing cost. By calculating the cost per unit and factoring in the tooling and unit economics of injection molding, we found that the cost break-even point for switching to MJF was around 1,025 units. This analysis helped determine that MJF was a viable option for bridge production, offering flexibility without needing costly tooling investments.

4. Is the part printable or do we need to implement Design for Additive Manufacturing (DfAM)?

Not all designs are immediately ready for 3D printing. Design for Additive Manufacturing (DfAM) principles are often necessary to optimize parts for successful production. Consider whether your part fits within the printer’s build volume or if features like thin walls or unsupported overhangs could cause issues during printing. Additionally, assess whether the part’s dimensions and details can be resolved by the selected technology.

The importance of aligning your internal processes and standards with your customer’s project requirements is particularly imperative during this phase in additive manufacturing. Oftentimes, designs require modifications to reduce the risk of warpage or improve structural integrity. Addressing these challenges during the design phase can prevent costly delays and ensure a seamless transition from concept to production.

5. What secondary processes are required?

Another important question to ask is whether your part(s) requires post-processing such as tumble smoothing, bead blasting, vapor smoothing, or dyeing. These processes can enhance a part’s appearance, functionality, and durability. However, these steps come with considerations.

For example, vapor smoothing can reduce surface roughness, but the heat involved might affect material properties. Similarly, dyeing can enhance aesthetics but may add time to the production schedule. Understanding how post-processing affects the quality and variability of your parts helps you select the most appropriate techniques for your needs.

3D-printed automotive spare parts with textures. Courtesy: DyeMansion

Conclusion

Asking these five questions provides a framework for determining whether additive manufacturing is the right fit for your project. It’s crucial to work with a trusted additive manufacturing partner who can guide you through these questions, provide expert advice, and help ensure your project’s success.