VW starts testing 3D-printed structural parts

Automaker teams with Siemens, HP to make lighter components, with goal of 100,000 annually by 2025

Volkswagen has begun certifying prototype 3D-printed structural components, with the aim of producing 100,000 parts annually by 2025. 

VW is teaming with Siemens and HP to industrialize 3D printing of structural parts, which can be significantly lighter than equivalent components made of sheet steel. 

The automaker will use an additive process known as binder jetting to make the components at its main plant in Wolfsburg, Germany. HP is providing the printers and Siemens will supply the manufacturing software.

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Shell to enable digital warehouse by 3D Printing of spare parts

Shell, the British-Dutch multinational Oil and Gas Company, is leveraging spare parts 3D printing to foray into digital warehouse. The company aims to focus on the revolutionary 3D printing technology to optimise its repair and replacement strategies and ultimately enable a digital warehouse approach to spare part management.

Shell believes the technology can reduce the costs, delivery time and the carbon footprint of spare parts and so it is collaborating with industry leaders to push the innovation of 3D printing for the energy sector.

Spare Parts 3D printing

Shell’s in-house 3D printing capability started in 2011 with a metal laser-printing machine to fabricate unique testing equipment for laboratory experiments at the Shell Technology Centre Amsterdam (STCA). Today, Shell has about 15 polymer, ceramic, and metal printers located at its technology centres in Amsterdam and Bangalore.

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New Pentagon policy to accelerate use of 3D printing amid fresh cyber concerns

Defense Department officials want to accelerate the adoption of additive manufacturing to solve frontline and logistical challenges alike under a recent policy change, even as the department’s watchdog raises new concerns about how the military secures its 3D printing systems.

In June, DoD issued its first additive manufacturing policy. The publication follows closely on the heels of DoD’s first-ever additive manufacturing (AM) strategy, released in January.

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Huisman scales up 3D printing

Cranes manufacturer Huisman said it has successfully tested four new 3D printed 350mt crane hooks under the supervision of the independent certification authority Lloyd’s Register.

The hooks are approx. 170 by 130cm in size, almost nine times larger than the first Huisman 3D printed crane hook, the company said. They have a weight of 1,700kg each and a loading capacity of 350mt. Each hook exists of approx. 90 kilometers of welding wire.

(Photo: Huisman)

Huisman has been employing the 3D printing technique ‘Wire & Arc Additive Manufacturing’ (WAAM) to produce mid-size to large components with high-grade tensile steel. According to the company, an important benefit of using this technique for crane hooks is the significant reduction in delivery time at a cost that competes with forgings and castings, and a more consistent quality level.

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Big Oil’s digital pivot marks the beginning of a new era for the industry

The oil and gas industry is embracing new technologies to save time and costs and, most recently, to reduce the carbon footprint of its supply chain as the energy sector is under increased pressure to reward shareholders while helping to fight climate change.  Along with artificial intelligence, machine learning, digital twins, and robotics, the world’s biggest oil and gas firms and oilfield services providers are betting on 3D printing, also known as additive manufacturing, to streamline operations, cut costs and save time, and reduce emissions from spare parts manufacturing. 

Over the past decade, some of the biggest oil and gas firms in the world have turned to 3D printing to procure parts and create digital warehouses to procure and manage the supply of necessary equipment. 

One such example is supermajor Shell (2.60%), which believes that additive manufacturing technology can reduce the costs, delivery time, and the carbon footprint of spare parts. Shell has ongoing projects with other industry players, including Baker Hughes (3.06%), to push the innovation of 3D printing for the energy sector, say Nick van Keulen, Supply Chain Digitalisation Manager and Angeline Goh, 3D Printing Technology Manager at Shell.  

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The 3 transformative trends powering manufacturing now

IN order to move towards a broader and in-depth proliferation of enhanced technologies in the manufacturing industry, it is of utmost importance for the international community of manufacturers to exemplify leadership in employing Fourth Industrial Revolution technologies. Uplifting factories, supply chains and business models, aiming to minimise operational costs, maximise profits and fortify manpower development are the targeted ideals of this unified front.

This is a crucial move to embark on as the global manufacturing market is trailing behind in the engagement of Fourth Industrial Revolution technologies, as more than 70 per cent of companies have not made considerable progression.

[…]

ADDITIVE MANUFACTURING

As another form of technological innovation, 3D printing or additive manufacturing can be momentarily engaged to ease the pressure on supply chains amid fluctuations in demand, as demonstrated by the Covid-19 pandemic.

Last year’s supply chain turbulence forced numerous companies to drastically relook their manufacturing and design tactics.

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Additive Manufacturing as bridge production and other uses

In a presentation at Virtual Engineering Days, Joe Cretella, applications engineering manager at ProtoLabs, offered technical examples about how multijet fusion (MJF) can best be used, while Brent Ewald, solutions architect from HP, talked about developing strategies for using MJF and encouraged companies to think about how the technology can complement their more traditional manufacturing efforts.

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Cretella began by noting that the ideal applications for multijet fusion can include prototypes and end-use parts; complex geometries requiring hinging or light weighting, high strength, and temperature resistance; jigs and fixtures, brackets, clips; and component housings.

He cited a recent case study that ProtoLabs did with a university in France and its German counterparts to produce reusable face shield. Cretella said they were able to optimize the design so that it could be printed as a single component. “So it could fit a large number of those face shields into a single build,” he explained. “And that’s really going to be key on thinking about designs, especially as we’re getting into talking about the parts, we want to be able to fit a high volume.”

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BASF’s Replique venture partners with Miele for on-demand 3D printed spare parts

Replique, a venture born out of chemical company BASF’s business incubator Chemovator, has partnered with German home appliance manufacturer Miele to produce and ship 3D printed accessories via its decentralized production network. 

Through the partnership, Replique’s 3D printing platform will be integrated into Miele’s online shop to enable the company to provide its customers with new 3D printed accessories and spare parts both quickly and cost-effectively.

3D printed coffee clip in two sizes, valuable separator, and borehole cleaner Material: Polyethylene terephthalate, Glycol modified (PETG). Photo via Replique.

The partners are supposedly the first to implement a Good Manufacturing Practice (GMP) for the 3D printing of polymer parts for food contact applications, beginning with an initial three accessories – a coffee clip, borehole cleaner, and a valuable separator for vacuum cleaner attachments. 

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Alstom slashes spare part lead times by 95% using Stratasys 3D printing technology

Alstom, a France-based rolling stock manufacturer, has adopted FDM 3D printing technology from Stratasys to streamline spare part production for the transport sector.

One of the company’s most recent projects involved producing a set of emergency spare parts for Algeria’s Sétif Tramways, and additive manufacturing was the star of the show. Leveraging Stratasys F370 3D printers, Alstom was able to drastically slash lead times and save Sétif Tramways thousands in manufacturing costs, reducing downtime in the city’s 14-mile transport network.

Algeria’s Sétif Tramways comprise 26 stops across almost 14 miles. Photo via Alstom.

“The agility that 3D printing gives us is critical for Alstom strategically as a business,” states Aurélien Fussel, Additive Manufacturing Programme Manager at Alstom. “Where our customers depend on spare parts to maintain operations, having this in-house production capability means we can bypass our traditional supply chain and respond quickly and cost-effectively with a solution to their needs.”

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Military starts to run with 3D printing and additive manufacturing

Defense and aerospace uses for additive manufacturing range from quick prototyping to spare parts logistics support at sea and in other remote locations.

Even within heavy industries, people often speak of 3D printing in terms of science fiction. With the allure of creating something from nothing, it has been poised to revolutionize prototyping, manufacturing, and resupplying for decades. However, additive manufacturing — another name for 3D printing — also is a reality here and now.

U.S. Marine Corps technicians discuss the process of producing mask frames and face shields for use in the fight against COVID-19.

Numerous 3D printing companies offer ready-made menus of different materials and techniques. Some experts say it’s still the way of the future, while others say no one process (or array of sub-processes) can do all the things 3D printing promises to do. So which is it: practical or over-promised?

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