Additive manufacturing, often referred to as industrial 3D printing, has moved well beyond making plastic prototypes. Metal components can now be produced layer by layer directly from a digital design, and the technology is increasingly being explored in engineering, defence, aerospace and other established industries.
For traditional manufacturers, the interesting question is where additive manufacturing provides a practical advantage alongside machining, forging and other proven production methods.
What Is Additive Manufacturing in Practical Terms?
Traditional machining starts with a piece of material and removes what is not required. Additive manufacturing takes the opposite approach, gradually adding material until the finished shape has been created.
This can make a considerable difference when producing a complicated component. Internal channels, unusual curves, and shapes that would require several machining operations may sometimes be produced as a single part.
There can also be less wasted raw material because only the material required to build the component is deposited, although finishing and post-production machining may still be necessary.
Where Can Additive Manufacturing Save Time?
One of the most useful applications is prototyping. Imagine an engineer needs a non-standard component for a new assembly. Traditionally, tooling, machining and several separate processes might be required before the first physical part can be tested. Additive manufacturing can allow a digital design to be produced relatively quickly, checked for fit and altered before committing to a larger production run.
This can also help when an obsolete component is difficult to source. Where the appropriate drawings, materials and approvals are available, producing a small quantity may become more practical than setting up a conventional production process designed for hundreds or thousands of parts.
Does Additive Manufacturing Replace Traditional Machining?
For many engineering components, traditional manufacturing remains highly practical. Standard nuts, flanges, certified bolts and other routinely produced components can already be manufactured efficiently using established processes. High-volume production also tends to favour methods that have been refined over decades.
Additive manufacturing becomes more interesting when quantities are low, geometry is complicated or significant amounts of expensive material would otherwise be machined away.
There are also situations where the two approaches work together. A component might be additively manufactured to create its basic form and then machined to achieve the required threads, sealing faces or dimensional accuracy.
What Happens When Components Need Certification?
This is particularly important in industries such as oil and gas, petrochemical, power generation and heavy engineering, where component specifications can relate directly to safety and reliability.
Producing a part in the correct shape is only part of the job. Manufacturers may also need to demonstrate the material used, manufacturing conditions, mechanical properties, dimensional accuracy and inspection results.
That matters for certified fasteners, pressure-containing components, and other safety-critical parts. Additive manufacturing has its own quality-control and certification requirements, and organisations such as TWI have developed qualification processes specifically around metal additive manufacturing.
The same principle applies when purchasing conventionally manufactured certified bolts. Documentation and traceability help establish that a component meets the required specification rather than simply confirming that it has the correct dimensions.
At Canmec, we manufacture certified components to recognised standards including ASTM, ASME, and API.
How Could Additive Manufacturing Change Spare Parts?
One particularly useful possibility is reducing the need to physically store rarely ordered components. Instead of keeping an unusual spare part on a shelf for years, some businesses may eventually maintain approved digital designs and manufacture components when they are required. The UK Government has already identified supply-chain flexibility as one of the potential advantages of additive manufacturing.
For critical parts and certified fasteners, however, digital storage does not remove the need for controlled materials, manufacturing procedures, inspection, and certification.
Where Does Additive Manufacturing Fit into Traditional Industry?
The most realistic future is likely to involve a mixture of manufacturing methods. Machining, forging and conventional production remain well suited to many industrial components. Additive manufacturing adds another option, particularly for prototypes, low-volume parts and complex designs.
FAQs
What Is Additive Manufacturing?
Additive manufacturing creates a component by building material layer by layer from a digital design. Industrial systems can work with metals and alloys as well as polymers.
Is Additive Manufacturing Suitable for Metal Components?
Yes. Processes such as metal powder bed fusion and laser metal deposition can produce metal components, although the appropriate method depends on the material, design and intended application.
Can Additive Manufacturing Produce Finished Parts?
It can, although some components require additional machining, heat treatment, surface finishing or inspection before they are ready for service.
Why Is Certification Important for Industrial Components?
Certification can provide evidence that materials, manufacturing processes and finished components meet the standards specified for an application. This can be particularly important in safety-critical environments.
Will 3D Printing Replace Traditional Manufacturing?
It is more likely to complement established processes. Conventional machining and other methods remain efficient for many standard and high-volume components, while additive manufacturing can offer advantages for complex shapes, prototypes and smaller production runs.
