As increasing numbers of additive manufacturing (AM) processes and technologies reach the marketplace, their future place in the metalworking supply chain remains an open question. A study commissioned by the German machine tool builders‘ association (VDW) aimed to make some predictions. Its results were announced at the start of Düsseldorf’s biennial METAV metalworking show in February, which featured a dedicated AM area.
Dr Wilfried Schäfer, executive director of the VDW, says: “Additive manufacturing processes are linked to high expectations. In particular, the vision of entirely new value creation chains, right down to customised production of parts or spares on site, is arousing keen interest.”
The study examined the market for development of additive process, analysed academic studies on the subject, surveyed current AM processes available for metalworking, reviewed case studies of AM for particular components and produced a prediction for technology development over the next five to seven years. This work was carried out by KEX, in conjunction with the Fraunhofer Institutes for Production Technology and Laser Technology.
Dr Myron Graw, a partner at KEX, outlines the major finding: “Additive manufacturing supplements the manufacturing processes available in the metalworking sector. For the time being, there is not going to be any broad-based displacement of existing machining processes, nor the much-cited revolution in industrial production operations.”
Assuming annual growth of 40% for additive processes, less than 1% of production volumes of existing technologies will be replaced by additive processes.
The study found that AM is being held back by higher cost and machining time.
For large components, additive processes are more expensive partly because they are slower than subtractive methods. The cost of AM machines and metal powder materials are also found to be relatively high, although both are expected to abate in future.
Where AM is more cost-competitive is in producing complex customised small components, since it eliminates the need for tools. Substantial added value can be generated by AM when making special structures, such as lightweight components in the aircraft industry, cooling ducts and undercuts, the report finds.
