Cost per part in AM – How much does it cost to print a part?
3D Printing has developed from a technology that is mainly used for prototyping to a viable manufacturing technology for end-use parts. Understanding how the costs for printing a part compare with the costs for conventional manufacturing technologies is thus gaining increasing importance.
Understanding the real costs for printing a part is not as straight-forward as it may sound. Even once the best combination of technology, materials and printing parameters has been found, arriving at a definitive number can be challenging. When comparing the costs for sourcing a part from external suppliers, we observe a big price spread.
In the rapidly evolving field of Additive Manufacturing (AM), understanding the cost is crucial for businesses aiming to leverage this technology effectively. Additive Manufacturing, often referred to as 3D printing, has transitioned from a prototyping tool to a viable manufacturing solution for end-use parts. However, determining the cost per part can be complex, as it depends on various factors, including whether the part is produced internally or by an external supplier. This blog post explores the intricacies of cost per part in Additive Manufacturing, highlighting the factors that influence costs and the potential for both direct and indirect savings over the lifecycle of parts.
3D Printing has evolved significantly from its early days as a tool for creating prototypes. Today, it is a powerful manufacturing technology used across various industries, from aerospace to healthcare. Understanding how the costs of printing a part compare with those of conventional manufacturing technologies is increasingly important for businesses considering the switch to AM.
The choice of technology and materials is a primary determinant of the cost per part in Additive Manufacturing. Different 3D printing technologies, such as Stereolithography (SLA), Powder Bed Fusion (PBF), and Material Extrusion (ME), have varying cost structures and capabilities. Similarly, the materials used—ranging from polymers to metals—affect both the cost and performance of the printed part.
Process parameters, such as layer height, print speed, and post-processing requirements, significantly influence the part cost. For instance, finer layer heights result in higher resolution prints but take longer to produce, increasing machine costs.
Production volume also plays a crucial role. While small-batch production may have higher per-unit costs due to setup and calibration efforts, larger volumes benefit from economies of scale. Bulk production can reduce one-time costs for qualification and data preparation and increase efficiency, lowering the overall cost per part.
When comparing the costs of sourcing a part from external suppliers versus producing it internally, a significant price spread can often be observed. External suppliers may offer lower per-unit costs due to economies of scale and advanced production capabilities. However, internal production provides greater control over the design and manufacturing process, which can be crucial for maintaining quality and meeting specific requirements.
Direct cost savings in Additive Manufacturing can be achieved through various means, resulting from less material usage, less manufacturing operations and less complex processes. Unlike traditional manufacturing, which often involves material removal processes that generate waste, AM builds parts layer by layer, only adding material where needed. This brings the potential to save costs especially for complex applications.
Beyond the direct costs, Additive Manufacturing can lead to substantial indirect cost savings over the lifetime of the parts. These savings can come from several areas, including enhanced product performance, reduced maintenance, and improved supply chain efficiency.
For instance, lightweight designs enabled by AM can lead to energy savings in aerospace and automotive applications. Custom medical implants created through AM can improve patient outcomes and reduce healthcare costs. Furthermore, AM allows for on-demand production, reducing the need for inventory storage and lowering supply chain costs.
One of the most significant benefits of Additive Manufacturing is the freedom of design it offers. This design freedom allows for the optimization of parts to reduce costs while enhancing functionality. By leveraging design techniques such as topology optimization and lattice structures, engineers can create parts that are not only lightweight and strong but also cost-effective to produce.
A comprehensive cost-benefit analysis is essential for making informed decisions about Additive Manufacturing. This analysis should consider both direct and indirect costs, including material expenses, production time, labor, and potential savings in product performance and maintenance.
Choosing the appropriate AM technology and material for your specific application is crucial for optimizing costs. Factors to consider include the mechanical properties required, the complexity of the design, and the production volume. Consulting with AM experts and conducting material tests can help identify the best options.
Design for Additive Manufacturing (DfAM) principles can significantly enhance the cost-efficiency of 3D printed parts. These principles involve designing parts specifically for the capabilities and constraints of AM, such as minimizing support structures, optimizing build orientation, and reducing material usage. By incorporating DfAM principles, companies can achieve substantial cost savings and improve the overall quality of their printed parts.
Maintaining quality and consistency in 3D printed parts is a common challenge. Implementing robust quality control measures, such as in-situ monitoring and post-production testing, is essential to ensure that parts meet the required standards. Investing in advanced inspection technologies, like non-destructive testing (NDT), can help verify the integrity of printed components.
Scaling up Additive Manufacturing for mass production involves addressing challenges related to print speed, consistency, and cost-effectiveness. Strategies such as utilizing multiple printers, optimizing print parameters, and automating post-processing workflows can enhance scalability. Developing standardized procedures and adopting automation solutions can further improve production efficiency and reduce costs.
The future of Additive Manufacturing is bright, with continuous innovations poised to expand its capabilities and reduce costs. Advances in materials science, printing technologies, and design software are set to push the boundaries of what is possible with AM. Emerging technologies, such as multi-material printing, bioprinting, and large-scale AM, hold the potential to revolutionize various industries.
As the benefits of Additive Manufacturing become more widely recognized, its adoption across industries is expected to grow. Companies that embrace the freedom of design and invest in AM technologies will be well-positioned to lead in their respective fields. By fostering a culture of innovation and continuous improvement, businesses can unlock new opportunities and drive competitive advantage.
Determining the cost of 3D printing a part involves careful consideration of various factors, including technology, materials, process parameters, and production volume. By leveraging the freedom of design that Additive Manufacturing offers, companies can optimize parts for cost-efficiency and performance, achieving both direct and indirect cost savings over the lifetime of the parts.
For professionals and industrial companies looking to improve their knowledge and capabilities in Additive Manufacturing, understanding and applying the principles discussed in this article is essential. Dive deeper into the world of 3D printing and explore the endless possibilities that the freedom of design in Additive Manufacturing presents.
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Would you like to further increase your 3D Printing knowledge?
You can try out the AM Fundamentals course of the AMPOWER Academy free of charge
Understand the most important topics to get started with Additive Manufacturing
The sinter-based AM (SBAM) technologies have, as the name suggests, the sintering process in common. In this process, the printed green part is consolidated into a dense part and receives its final properties. The green part can be printed in advance using different technologies.They all have in common that metal powder is bound to the desired shape by a binder. The best-known printing technologies include Binder Jetting and Filament Material Extrusion.
In this section, you learn everything about the sinter-based AM process chain and get an overview of the different printing technologies.
This course is aimed at engineers, designers and other professionals that are working closely with sinter-based AM technologies. The goal is to cover the most important aspects that will enable engineers and designers to fully grasp the capabilities and technical limitations of the printing technologies and the sintering process to succeed in technology selection and part design. Besides going through the course from the beginning until the end, this course can also act as a constant source of knowledge while working on AM projects.
The course is structured into the following sections.
This section will start with an overview of the sinter-based AM process chain and its printing technologies, followed by a technology deep dive into the most important aspects of the BJT technology, followed by a closer look at the debinding and sintering step also including sintering simulation .
The second section will provide an overview of the different materials that are available as well as part characteristics that can be achieved with the BJT process and typical methods for quality assurance. Finally, several common defects in the BJT process are presented.
The last section will act as a guideline for designers. Besides generally describing the process when designing for Additive Manufacturing, actionable restrictions and guidelines for the BJT process are provided. The final section will present several design examples from different industries.
Simulation to compensate the deformation during the sintering step, nesting of parts and definition of printing parameters
Through various printing processes, different feedstocks such as metal powders, filaments, pellets or dispersions are processed into green parts
Unpacking of fragile green parts needs to be done carefully and is typically a manual process.
Debinding describes the process of removing the binder which results in a brown part
To reach the structural integrity of a metal part, a sinter process is required. The powder particles fuse together to a coherent, solid structure via a mass transport that occurs at the atomic scale driven via diffusional forces.
The brown part shrinks ~13-21 % in each direction.
The process chain of sinter-based technologies differs from other AM Technologies. Especially the post-printing processes (debinding and sintering) are crucial to achieve the intended mechanical properties.
Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.
The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.
Afterwards the build platform moves downward by the amount of one layer thickness and a new layer of powder is applied. Again, the liquid binder is deposited and hardened in the required regions of the next layer to form the green body. This process is repeated until the complete part is printed. After the complete printing process is finished the parts have to be removed from the “powder cake” meaning the surrounding loose but densified powder. To improve the removal of the excess powder from the green body often brushes or a blasting gun with air pressure are used.
To create a dense metal part the 3D printed green body has to be post-processed in a debinding and sintering process. Similar to the metal injection molding process BJT parts are placed in a high temperature furnace, where the binder is burnt out and the remaining metal particles are sintered together. The sintering results in densification of the 3D printed green body to a metal part with high densities of 97 % to 99,5%, dependent of the material.
In classic Binder Jetting systems such as the ones distributed by EXONE or DIGITAL METAL the liquid binding agent is selectively deposited with a single print head. Meaning the width of the print head does not cover the full width of the powder bed. Therefore, the print head moves multiple times in xy-direction over the powder bed to completely cover the printing area and distributing the polymer binder.
The SINGLE PASS JETTING technology was developed by DESKTOP METAL and HEWLETT PACKARD. The width of the printing head covers the full width of the powder bed. When the printhead passes over the powder bed, binder is released from more than 30,000 small nozzles and the whole powder layer is selectively immersed in binder in one pass. The process is bi-directional which means that the binder deposition takes place in both moving directions of the printhead. With these modifications the printing speed is significantly increased.
A similarly fast technology is the METAL JET process by HEWLETT PACKARD. In a single pass, a liquid printing agent is applied to the powder layer and subsequently partially evaporated to form the binding polymer around the metal powder. After the completion of the print an additional curing to achieve the full green body stability is needed.
3DEO combines the Binder Jetting process with a subsequent machining process. Different from conventional Binder Jetting processes, the binder is not only deposited selectively but onto the entire powder layer. After hardening of the complete layer, the part geometry is shaped through a milling process every couple of layers by cutting the part contour out of the binder powder composite.
Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.
The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.
Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.
The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.
Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.
The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.
Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.
The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.
