What is AM?

Additive Manufacturing (AM) is a transformative approach to industrial production that enables the creation of lighter, more effective and better performing products. It is a process that builds objects layer by layer, directly from digital models. This contrasts with traditional manufacturing, which often involves subtracting material through machining or creating forms through molding processes.

AM enables unparalleled design freedom, that help us re-think product design and allows for the creation of complex geometries that were previously impossible or too costly to achieve.

What can Additive Manufacturing do for me?

Accelerated Innovation

For decades, AM has been at the forefront of Prototyping and product development operations. It has enabled faster iterations and innovative product designs that are not possible using traditional manufacturing techniques. With the new technologies and materials available, AM allows us to re-imagine what an optimized end use product really looks like.

Supply Chain Efficiency

Increasing global competition and consumer demands requires businesses to look at supply chain optimization to stay ahead. AM allows for highly customizable and agile production processes that are built with the purpose of tackling the challenges of the modern supply chain. With ever increasing productivity and cost effective manufacturing of customer specific products, Additive Manufacturing is unlocking the evolution of supply chains.

Reduced Risk

Over the last few years we have seen how fragile the global supply chain can be, and if you own or manage a business, you’re likely always working to reduce uncertainty in your operations. Digitizing supply chains and on-demand production enabled through the use of AM technologies, help to mitigate uncertainties and risks in your supply chain.

Reduced Cost

There are many ways 3D Printing can reduce business costs. By maintaining a digital inventory and an AM production workflow for on-demand parts, you can minimize facility, material handling, and storage costs. AM also enables consolidation of multiple parts in product assemblies, reducing labor costs associated with assembly processes.

Production Flexibility

Additive Manufacturing provides access to a truly lean and agile method of producing multiple parts and products, cost effectively. Production changeovers from manufacturing one part to another becomes less labor and resource intensive, allowing for reduction in production downtimes while keeping your customers satisfied.

Sustainibilty in Manufacturing

With consumers and governing bodies becoming more environmentally conscious, integration of more sustainable practices such as AM can benefit both your brand perspective and your business operations. By greatly reducing material usage and waste, there are opportunities to reduce carbon footprints while also reducing shipping, material handling and inventory costs.

Fused Deposition Modelling (FDM)

One of the most common AM technologies, FDM works by extruding thermoplastic filaments through a heated nozzle.

Ideal for prototyping, educational purposes, and creating functional parts with moderate mechanical properties.

Stereolithography (SLA)

SLA uses a laser to cure liquid resin into hardened plastic in a layer-by-layer process.

Known for its high resolution and smooth finish, making it perfect for detailed prototypes, molds and consumer products.

Selective Laser Sintering (SLS)

SLS employs a high-power laser to fuse small particles of polymer powder.

Suitable for creating durable, functional parts with complex geometries and excellent mechanical properties.

Direct Metal Laser Sintering (DMLS) / Laser Powder Bed Fusion (L-PBF)

DMLS uses a laser to sinter powdered metal, layer by layer, to create strong, functional metal parts.

Used extensively in aerospace, automotive, and medical industries for producing high-performance components.

Electron Beam Melting (EBM)

EBM is a specialized process that is similar to L-PBF but uses an electron beam as the energy source to melt and fuse metal powder layer by layer. It operates in a high-vacuum environment, which helps to prevent oxidation and contamination of the metal powders.

The cost of EBM is generally higher than other processes and is used in specialized applications such as Aerospace components, Medical Implants and other precision engineering components.

Binder Jetting

This method involves binding layers of powder material using a liquid (glue-like) binder, followed by ‘curing’.

Used for a variety of applications such as Tooling, Sand Casting Patterns, Decorative objects etc. A wide range of materials are available to use such as metal, sand (for casting molds), ceramics and composites as well.

Directed Energy Deposition (DED)

DED uses a high powered laser or electric arc to melt a powder or wire feedstock material into the final required shape, layer by layer.

Ideal for repair of existing parts, (adding material to existing components), and manufacturing large, complex metal parts. Commonly used in aerospace, military, and various other heavy industries.

Material Jetting

Material Jetting is essentially based on the same principle as traditional 2D printing we’ve been using for years now. Droplets of photopolymer resin are deposited onto the build plate which are then hardened using a UV light, layer by layer.

Good for scale medical models, jewelry and prototyping purposes. High resolution multicolor and transparent prints are the main use cases for this AM method.

Multi-Jet Fusion (MJF)

MJF is a printing method developed exclusively by HP. The process is very similar to Binder jetting but includes 2 types of fusing agents for the powder, heat is applied during the process to fuse the powder where binder is present.

HP’s cost effective process enables access to a variety of applications that work well with Nylon and PP materials, such as Custom Prosthetics, Robotic End of Arm Tooling, Consumer goods, Drone frames and more.

Types of Additive Manufacturing

The world of AM is diverse, with several distinct technologies, each suited to different applications. Here are some of the most prominent ones used today:

Materials

The catalogue of materials available for use in Additive Manufacturing processes is growing every day. There are countless companies manufacturing materials for AM, in a variety of forms such as powders, wires, filaments, resins, metal pastes and more.

Polymers

Common forms of Polymers in AM:

Filament, Resins, Powders and Pellets.

PLA (Polylactic Acid)

ABS (Acrylonitrile Butadiene Styrene)

PETG (Polyethylene Terephthalate Glycol-Modified)

Nylon (Polyamide)

TPU (Thermoplastic Polyurethane)

PC (Polycarbonate)

ASA (Acrylonitrile Styrene Acrylate)

PEEK (Polyether Ether Ketone)

PP (Polypropylene)

Metals

Common forms of Metals in AM:

Wires, Powders, Paste

Stainless Steel

Carbon (Mild) Steel

Tool Steels

Aluminum Alloys

Nickel Alloys

Titanium Alloys

Copper Alloys

Cobalt Chrome

Tungsten

Magnesium

Ceramics