Traditional manufacturing vs. Additive manufacturing
Articles · September 20, 2022
3D printing makes it possible to produce a metal product with a geometry of almost any complexity in a few hours, having a high material utilization rate at the same time. But with all the advantages, additive manufacturing has never sought to take the place of the classical method, its task is to expand the technological capabilities of production, ensure economic efficiency and increase production capacity in various industries.
Traditional manufacturing
Raw materials are supplied to metalworking enterprises in the form of metal blanks (ingots, sheets, blanks or other semi-finished products). Later by the use of casting, forging, stamping, turning or milling methods, they are shaped into future products. Products also undergo heat treatment: annealing, normalization, hardening or tempering. For the final surface treatment of products, mechanical (grinding, polishing) or electrophysical and physicochemical methods are used.
Due to the variety of methods, traditional manufacturing makes it possible to produce both universal and complex, highly specialized products with predetermined properties. The raw materials used in the production of metal products have a relatively low cost, however, some methods of manufacturing parts require the use of expensive equipment. Also, tooling can be expensive, and its creation can also take a great deal of time.
Additive manufacturing
Additive manufacturing is a technology for creating three-dimensional objects by depositing material, layer upon layer. Here, finely dispersed powder from various metals and alloys is used as a raw material. The 3D printer, based on the 3D-model data, distributes the material over the build platform, where it is laser-fused layer upon layer. This process is called selective laser fusion technology or Laser Powder Bed Fusion) (commercial names for this technology from individual printer manufacturers are SLM, DMLS, DMP, DMLD, etc.).
Additive products have a high cost largely due to expensive equipment and depreciation. The cost of a 3D printer can exceed several million dollars. The build chamber of the additive installation is limited in size, at the moment the largest printer in our Center has a build zone of 500x500x500 mm, so it is still impossible to create truly large products without welding. With the exception of blank dimensions, a 3D printer can print products of almost any complex geometry, including those with generative and bionic designs. Additive manufacturing significantly reduces the production time of products and can significantly reduce their weight.
Comparison chart of additive and classical methods
| Additive manufacturing | Traditional manufacturing | |
| Large-series and mass production | – | + |
| Аverage-scale production | +/- | + |
| Low-rate production | + | + |
| Fast production time | + | – |
| Low cost of materials | – | + |
| Complex geometry and bionic design | + | – |
| Post-processing needed | + | + |
| Кeady-made metal product meet all quality indicators | + | + |
| Small amount of waste | + | – |
3D printing makes it possible to produce a metal product with a geometry of almost any complexity in a few hours, having a high material utilization rate at the same time. But with all the advantages, additive manufacturing has never sought to take the place of the classical method, its task is to expand the technological capabilities of production, ensure economic efficiency and increase production capacity in various industries.
Traditional manufacturing
Raw materials are supplied to metalworking enterprises in the form of metal blanks (ingots, sheets, blanks or other semi-finished products). Later by the use of casting, forging, stamping, turning or milling methods, they are shaped into future products. Products also undergo heat treatment: annealing, normalization, hardening or tempering. For the final surface treatment of products, mechanical (grinding, polishing) or electrophysical and physicochemical methods are used.
Due to the variety of methods, traditional manufacturing makes it possible to produce both universal and complex, highly specialized products with predetermined properties. The raw materials used in the production of metal products have a relatively low cost, however, some methods of manufacturing parts require the use of expensive equipment. Also, tooling can be expensive, and its creation can also take a great deal of time.
Additive manufacturing
Additive manufacturing is a technology for creating three-dimensional objects by depositing material, layer upon layer. Here, finely dispersed powder from various metals and alloys is used as a raw material. The 3D printer, based on the 3D-model data, distributes the material over the build platform, where it is laser-fused layer upon layer. This process is called selective laser fusion technology or Laser Powder Bed Fusion) (commercial names for this technology from individual printer manufacturers are SLM, DMLS, DMP, DMLD, etc.).
Additive products have a high cost largely due to expensive equipment and depreciation. The cost of a 3D printer can exceed several million dollars. The build chamber of the additive installation is limited in size, at the moment the largest printer in our Center has a build zone of 500x500x500 mm, so it is still impossible to create truly large products without welding. With the exception of blank dimensions, a 3D printer can print products of almost any complex geometry, including those with generative and bionic designs. Additive manufacturing significantly reduces the production time of products and can significantly reduce their weight.
Comparison chart of additive and classical methods
| Additive manufacturing | Traditional manufacturing | |
| Large-series and mass production | – | + |
| Аverage-scale production | +/- | + |
| Low-rate production | + | + |
| Fast production time | + | – |
| Low cost of materials | – | + |
| Complex geometry and bionic design | + | – |
| Post-processing needed | + | + |
| Кeady-made metal product meet all quality indicators | + | + |
| Small amount of waste |
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Traditional manufacturing vs. Additive manufacturing Articles · September 20, 2022 3D printing makes it possible to produce a metal product with a geometry of almost any complexity in a few…
