Companies are using direct digital manufacturing (DDM) in substantial and growing numbers. DDM, which is also called rapid manufacturing, is a process that uses additive fabrication technology to manufacture end-use parts directly from CAD data. It is a process that not only promises increased speed and cost reduction, it creates possibilities, practices and opportunities. DDM is an approach to manufacturing that invites innovation in the way products are designed and produced.
Direct digital manufacturing grew out of rapid prototyping technologies. RP has been used for 20 years to develop models for testing and design validation. But along the way, people began to realise that the durable, functional plastic prototypes could actually be used as end-use parts, thus giving rise to DDM.
The individuals that have embraced DDM have been successful because they have changed their way of thinking. They are looking for better alternatives rather than direct replacements of an already successful manufacturing process. This shift in thinking is what innovation is all about, and it is why DDM is being embraced by manufacturers worldwide.
DDM is complementary to, not a replacement of, traditional manufacturing methods like injection molding. It should therefore not be assessed with the same specifications or constraints in mind. DDM is rewriting the manufacturing rule book and giving companies capabilities that were previously unavailable with alternative technologies.
Across a wide variety of industries ranging from aerospace to medical devices to toys, companies are discovering the advantages of DDM. Companies see the most benefit from DDM when it is applied where production volumes are low and the likelihood of design changes or customisation is high. DDM’s ability to produce highly complex designs with no impact on product cost or delivery time is another benefit, and, DDM also has the major advantage of no tooling, eliminating the labour intensity that accompanies it.
DDM in action
Established companies such as Boeing and start-ups like engineering and design firm, Digital Mechanics are using DDM. Another example is a medical device manufacturer, with many custom parts, that uses DDM to build fixtures that hold the pieces during secondary operations. There is a diesel engine manufacturer that also uses DDM for jigs and fixtures. Its manufacturing engineering team cites fast delivery, low cost, lighter weight and less inventory as DDM advantages.
Other DDM successes come from the parts that make custom production, assembly and conveying lines work. A manufacturer of high speed printing and labelling machines uses DDM to make its label applicator pads. Each pad is designed to the size and shape of the customer’s printed label. DDM reduces cost and time for production.
A manufacturer of dispensing equipment uses DDM as an alternative to both injection moulding and CNC machining. Selling hundreds of machines each year, a US$200000 injection mould for a bezel was not justifiable. While CNC was feasible, the company’s shop was swamped with other work. The company now uses DDM to manufacture its bezels quickly and affordably without adding to its headcount.
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Scott Crump is president and CEO of Stratasys GmbH, Frankfurt, Germany. www.stratasys.com
