Siemens Digital Industries Software has submitted this post.
Written by: Ashley Eckhoff, Additive Manufacturing, Siemens Digital Industries Software
Manufacturing, in general, has moved towards more streamlined and optimized manufacturing operations for decades. Modern manufacturing requires large volumes of complex parts to be manufactured. This often requires a multitude of discrete manufacturing steps be applied on multiple pieces of machinery. But that dynamic has been changing with the adoption and growth of additive manufacturing (AM) technologies which allow for complex geometries to be created on a single machine with a single print.
Unfortunately, the relatively small workable volume associated with most printing technologies has been a limiting factor in expanding the use of additive manufacturing into certain industries. However, the evolution of additive beyond planar printing may completely change what is considered normal for manufacturing—printing bigger and more functional parts while reducing the costs associated with acquiring, using and maintaining multiple traditional machines.
The rush for multi-axis printing stems from many benefits of the technology over standard planar prints; for example, the ability to negate the effect of gravitational forces during print. But much of the financial incentive to switch comes from the change in form-factor, providing expanded capabilities to more industries. This is a switch towards more standardized operations and the ability to implement AM as a module in existing manufacturing infrastructure.
Let’s dive into why these changes are so important to the future of additive manufacturing.
More Industries and Applications
Many printing technologies have been limited by size. The final part had to fit within the footprint of enclosed manufacturing machines, just as the CNC (Computer Numerical Control) machining process is limited by the size of the machine. This has in turn limited the industries that might benefit from AM.
That is not to say large format 3D printing does not exist, but the complexities associated with scaling up planar printing has restricted it to niche applications. Large planar printers require cumbersome gantries with an associated reduction in the precision of the final geometry. Many of the applications for large format additive have been limited to marine, construction and architectural projects, while precision operations were still left to other manufacturing processes.
But multi-axis breaks away from the limitation of printing within a box, while still providing all the previous benefits of the technology. Rather than creating an enclosed printer large enough to contain the largest print, robotic arm-based machines can provide a more flexible printing area with better cost scaling compared to standard planar printing machines. The printable volume can be extended further through track systems that expand the work envelope in at least one of three Cartesian directions.
Eliminating the space constraints associated with planar printing enables printing of larger components for aerospace, marine and a variety of other industries seeking to improve the performance of their products.
Combining Hardware and Software
Utilization of robotics to print at larger scales requires complex software to drive the hardware processes. This necessitates a need for digitalization and an integrated development environment, if one is not already established. Not only are the part sizes quite different compared to enclosed printing operations, but robotic arms also produce a vastly different printing area.
When large format printing is combined with multi-axis machining, the parts produced can even compete with more traditional processes with regards to precision. That precision is derived from the much lighter loads at the ends of industrial robotics—rather than moving large components or counteracting the torques of milling operations, printing is a low-intensity process. Capitalizing on that precision requires a combination of software and hardware. The ability of a software package to define deposition paths that work with the part geometry—rather than against it—combined with the proper hardware controls is what allows for printing to be scaled to large formats while retaining the necessary precision.
The extraordinarily complex deposition paths for multi-axis printing can include a full six degrees of motion, requiring not only precision in the path definition, but also precision in the ability of the hardware to follow that path. A small deviation that is within tolerance in a normal 3D printer can become a large deviation that is far outside of allowable tolerance when scaled to large format machines. Therefore, special software packages have been created to ensure that the deposition paths for large format multi-axis printing are exact.
From that point, it is the responsibility of the hardware to replicate those deposition paths accurately, and many large format printers use industrial controls for this reason. Over decades of use in CNC processes, industrial controls and drives have been proven to have the accuracy necessary for complex three-dimensional motion. Consequently, it is this combination of innovative software and industrial controls and drives that has enabled large-format multi-axis printing.
Standardization Reduces Costs
The transition to multi-axis, large-format printing may bring opportunity to new industries, but using existing robotic arms as a foundation for printing creates a standardized platform from which to innovate. Starting with an off-the-shelf robotic arm has financial benefits both for businesses already deploying robotics, and for Original Equipment Manufacturers (OEMs) looking to diversify their industrial offerings.
Rather than developing a new machine from the ground up specifically for additive manufacturing, some OEMs are creating modular printer heads for robotic arms. Investment can be made on the differentiators of the printing manufacturer, while leveraging the development and expertise in motion from the robotics supplier.
The lower overhead of partnering to create modular multi-axis printers may expand the customer base for additive by reducing the upfront investment costs. Having a spare robot on hand would provide the best incentive, but the cost savings of utilizing established machines will also bring down up-front costs. This may even encourage a compounding cycle of innovation, market growth and investment.
For the end-user, this creates a lower barrier to entry for printing if they have already invested in robotics. But it also lowers the risk for secondary OEMs integrating these modular print heads into their machine, enabling a faster return on investment and cost savings for customers looking to invest in AM.
Bigger Projects, Smaller Investments
The additional functionality afforded by additive manufacturing has been a boon for many industries, but the scale has held many industries from adopting the technologies. Multi-axis printing is what might open the floodgates for investment in AM technologies on a larger scale. Printing larger parts than previously possible will provide additive manufacturing access to a greater number of industries. Meanwhile, the ability of additive machine providers to partner with existing robotics companies to create this next generation of printing will reduce the costs and barriers to entry for many other industries and businesses. However, capitalizing on this shift requires a digital solution to utilize, optimize, and innovate through the complexity that comes with the added degrees of manufacturing freedom.
Learn more at Siemens Digital Industries Software.
About the Author
Ashley Eckhoff has multiple degrees in engineering and has worked at Siemens for over 20 years.
His current role as a member of the Siemens Software Additive Manufacturing Program brings him into constant contact with the companies and people making additive manufacturing an indispensable production technology for the 21st century.