The AM mindset
A new state of mind to use the full potential of Additive Manufacturing
Additive Manufacturing has the power to transform not just how products are made—but how companies design, deliver, and create value. To fully leverage this potential, it’s not enough to simply switch production methods. It requires a shift in mindset: rethinking products from scratch, reimagining supply chains, and exploring new business models. In this section, we introduce the concept of the AM mindset and walk you through a real-world case study to illustrate how design, logistics, and strategy come together to drive innovation with AM.
What you will learn in this section
Thinking Differently with AM
Learn how the AM mindset enables rethinking products, supply chains, and business models beyond conventional limitations.
Design Beyond Constraints
Understand how to apply Design for AM principles by reimagining components from the ground up—with function and process in mind.
Redesigning Value Chains
Explore how AM can simplify supply chains, enable local production, and unlock new business models based on customization and speed.
What you will find in this section
AM Mindset Definition
Rethink your products, supply chain, and business model to unlock the full value of Additive Manufacturing
Adopting Additive Manufacturing is more than swapping production methods—it’s a shift in how we think. The AM mindset challenges you to redesign parts, reimagine supply chains, and rethink how value is delivered.
"The AM mindset is the ability to completely rethink products, supply chains and business models to use the full potential of Additive Manufacturing."
Design with Purpose
Product Design
- Rethink the part entirely with the user in mind
- Apply design-for-AM guidelines from the start
- Use the freedom of AM for added performance
Simplify the Supply Chain
Supply Chain Optimization
- Eliminate stock with on-demand printing
- Reduce lead times and part count
- Localize production and improve sustainability
Innovate the Business Model
Business Model Innovation
- Enable personalized or short-run products
- Respond faster to market needs
- Create new revenue streams via digital manufacturing
Since our definition requires people to master 3 areas – products, supply chains and business models – people need a broad skillset covering different disciplines in order to be successful with AM. Even though we will describe all areas separately, it is key for employees and organizations to look at all three aspects holistically.
The process from the existing product to the optimized case for Additive Manufacturing is discussed seperated into design, supply chain and business model.
The gripper case study
The Gripper Case Study: A Real-World AM Transformation
This case study showcases how a conventional pneumatic gripper was completely redesigned using Additive Manufacturing. The result: fewer components, reduced weight, faster production—and a more efficient product overall.
Original gripper had 21 components mounted on a metal baseplate
Re-designed gripper has only 2 parts, fully integrated
Weight reduced by over 80% (from 1.6 kg to 300 g)
Production costs lowered by 30%
Lead time cut from ~3 weeks to just a few days
Produced using Selective Laser Sintering (SLS) with PA12 material
Fully integrated pneumatic channels—no assembly required
Design
Step 1: Design with an AM Mindset
Design for Additive Manufacturing is more than applying guidelines—it's about starting with the user’s problem and rethinking the part from the ground up. In this step, we explore how to move from constraint-driven design to purpose-driven design.
Old vs. new gripper design
Key Questions to Ask
🔍 What problem is the end user trying to solve?
The gripper moves components from one machine station to another. Accuracy, speed, and reliability are key to its performance.
⚠️ What are the pain points of the existing solution?
- High weight: Multiple metal parts make the system heavy and slow.
- Complexity: 21 components need to be stocked, assembled, and maintained.
🚀 What would the product look like without manufacturing constraints?
- Lightweight bionic structure with built-in air channels
- Polymer-based design instead of metal
- Printed thread and integrated gripping mechanism—no assembly needed
🧰 What’s the best AM technology and material?
The part was printed using EOS Formiga P110 (SLS) with Polyamide 12 due to:
- No need for support structures (ideal for internal channels)
- Good mechanical strength and flexibility
Supply Chain
Step 2: Optimize the Supply Chain
After improving the design, the next step is to rethink how the part is produced and delivered. Additive Manufacturing simplifies the supply chain by enabling local, digital, and on-demand production—minimizing complexity, lead times, and inventory needs.
Key Questions to Ask
⚠️ What are the challenges of the current supply chain?
- Long lead times: 12-day turnaround can be risky during production downtime.
- Inventory complexity: 21 individual parts must be stocked and sourced.
- Global logistics: Sub-components are shipped across the world, increasing emissions.
🔧 How does the new AM process solve these issues?
- Shorter lead times: SLS prints the part in <1 day with minimal post-processing.
- On-demand production: Only 2 components—significantly reducing inventory.
- Local production: With a single material and simplified design, the part can be printed close to the point of use.
🏭 What is the best production setup?
Parts can be printed in-house or outsourced, depending on:
- In-house AM skills and infrastructure
- Part volume and required turnaround
- Application criticality and sustainability goals
Producing close to the end user can reduce shipping costs, cut lead times, and lower the environmental footprint.
📊 Impact Summary
⏱️ Days to Produce: 12 ➝ 1
📦 Components: 21 ➝ 2
🌍 Localized Production
Business Model
Step 3: Challenge Your Business Model
Rethinking your business model may be the hardest—but most rewarding—step in using AM. By shifting from product-centric to solution-centric thinking, Additive Manufacturing can unlock new customer segments, revenue models, and competitive advantages.
Key Questions to Ask
🔍 Which aspects of the business model are influenced by the current manufacturing process?
- Complex design process: High development costs for custom grippers limit offerings to standard or premium options.
- Long lead times: Conventional processes delay customer responsiveness and customization.
⚙️ How does AM impact these factors?
- Simplified design: With only 2 printed parts, grippers are faster and easier to customize.
- Faster turnaround: Designs can be finalized and printed in days, enabling quicker customer response.
💡 What could a new business model look like?
Instead of relying on standard products or long custom projects, the company could offer fast, personalized grippers on demand.
- Customers create their own designs using tools like Trinckle Paramate
- Designs are automatically printable, reducing manual work
- Parts are produced in-house or through distributed printing partners
- This enables a scalable, customer-driven business model
📊 Impact Summary
🎯 Faster customization: Design to production in days
🧠 User-generated designs: Powered by software like Paramate
💰 New revenue model: Mass customization at scale
The case study in short
Reduced weight, cost and less components
The re-designed and printed gripper has been tested without failure at 5 million cycles. The lower weight and more compact design allows using a smaller handling system. The production lead time could be reduced from ~3 weeks to ~4 days.
The following figures summarize further benefits of the new gripper compared to the old design:
-1300 grams
Reduction of weight by over 80 %
-30 % costs
Reduction of production costs from ~2 700 EUR to ~1 700 EUR
-19 components
Reduction of individual components from 21 to 2
The gripping tips in action
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