Industrial 3D Printing: From Adaptive Manufacturing to Series Production and Digital Spare Parts

From prototyping tool to production technology – rising demands for flexible supply chains, shorter development cycles and customised products are driving the use of additive manufacturing in the plastics industry. Three current examples show how companies are using 3D printing for adaptive production lines, scalable series production and digital spare parts concepts. Together, they illustrate how additive manufacturing is increasingly becoming part of modern production strategies.

EOS is collaborating with Siemens on concepts for adaptive manufacturing processes that enable production lines to adapt more quickly to varying requirements. The focus is on automated and AI-supported processes for industrial additive manufacturing.

One example is the production of customised sports shoe midsoles that can be flexibly adapted to different usage profiles. The combination of industrial 3D printing, automation and data-driven process control is intended to shorten development and manufacturing cycles and increase process reliability.

Furthermore, EOS uses additive manufacturing for production tools such as robotic grippers or vibratory spiral conveyors. This enables:

• Reduced material usage
• Lead times be shortened
• Components be functionally integrated and weight-optimised

Industrial additive manufacturing is also gaining importance in safety-critical applications. These include, for example, complex plastic components for high-speed drones, which rely on flexible production and supply chains.

1zu1scale is investing in new equipment for industrial additive manufacturing whilst simultaneously expanding its toolmaking facilities for injection moulding. The aim is to make the series production of small plastic components more efficient.

Among the new additions is a system for the direct production of black plastic parts to series production quality. This eliminates the need for an additional colouring step during post-processing. The technology is particularly suited to applications in:

• Electronics
• Mechanical engineering
• Automation
• Robotics

In addition, the company is expanding its toolmaking capabilities to include the production of precision steel tools for higher volumes in injection moulding.

The LEHVOSS Group and MORSAN are leveraging digital spare parts warehouses and industrial 3D printing technologies for the food and beverage industry. Instead of keeping physical spare parts in stock, components are stored digitally and manufactured using additive manufacturing when required.

High-performance materials for industrial FFF/FDM processes are used. The additively manufactured components must withstand high mechanical stresses as well as intensive cleaning processes.

The portfolio includes, amongst other things:

• Conveyor belt sprockets
• Grippers and guide elements
• Sliders and ejectors

According to the company, a key advantage lies in the design freedom offered by additive manufacturing: components can be specifically adapted to real-world stresses and functionally optimised.

These examples demonstrate just how diverse industrial 3D printing applications have become – ranging from automated production lines and scalable series production to digital spare parts concepts. Additive manufacturing is thus increasingly becoming an integral part of modern production and supply chain strategies and remains a key area of innovation for the plastics and rubber industry.