3D Metal Printing: Dark Art or Modern Blacksmith?
NEW YORK, Jan. 15, 2018 /PRNewswire/ -- "Metal AM is so unlike other manufacturing processes that whole new qualification methodologies must be developed to enable certification in these critical applications," says Richard Grylls, SLM Solutions NA, Inc. "The parts that are already in production have been the result of years of labor to prove that the manufacturing process is capable — this must change to 'months of labor,' and eventually 'weeks of labor,' for the full capability of metal AM to be realized.
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Work is ongoing around the world, including at SLM Solutions, to overcome these challenges and enable parts to be qualified on an SLM system quickly, affordably and, above all, with absolute confidence of performance in the component in the critical application."
Metal AM is so unlike other manufacturing processes that whole new qualification methodologies must be developed to enable certification in these critical applications.
—Richard Grylls, SLM Solutions NA
In addition to standards, the ability to produce multiple parts consistently across machines, operators, and manufacturing facilities requires improved process monitoring and measurement tools. Research is ongoing concerning dimensional and thermal metrology methods for real-time, closed-loop control of AM processes. Meanwhile, a growing number of metal AM system vendors have introduced process monitoring options for their equipment.
For example, FIT AG has recently installed computer tomography (CT) to its in-house QA department. FIT is able to increase process stability for its manufacturing systems via non-contact and non-destructive measurement and analysis of inner structures.
The CT system allows identification of cavities, aberration, fissures, form deflection, pores, displacement, shape distortion, etc. Evaluations such as design versus part comparison or analysis of wall thickness are visualized in color and serve as proof of specified product requirements.
Renishaw and Dassault Systèmes have partnered in the increasingly vital area of process control software. For Renishaw, it is said to be part of a wider goal of offering to end-to-end solutions for innovative manufacturing and support the managed integration of AM into the production workspace.
If these developments live up to their potential, the impact on the 3-D printing industry and manufacturing industry as a whole could be significant. In 2016, BCC Research estimated total sales of 3-D metal printers, metal feedstocks, related software and services at about $995 million, or approximately 27% of the global 3-D printing market.
In BCC Research's recent report, IAS102B Global Markets for 3-D Printing, the metal printing-related segment of this market is projected to reach $3.3 billion by 2021, which if realized would represent a CAGR of approximately 27% between 2016 and 2021.
"BCC Research believes that widespread adoption of the technology innovations described in this report could drive the future growth to almost 37% per year," said Andrew McWilliams, Market Analyst.
"At this rate, the market could be worth more than $4.7 billion by 2021."
Metal products produced by additive manufacturing had an estimated value of about $210 million in 2016, a tiny percentage of the over $10 trillion global manufacturing market. By 2021, the new SLM software could drive this figure to as much as $2.1 billion, still a small fraction of the global manufacturing market but more than twice the level that could be expected without the software.
Widespread adoption of the technology innovations described in this report could drive the future growth to almost 37% per year. At this rate, the 3-D printing market could be worth more than $4.7 billion by 2021.
—Andrew McWilliams, Market Analyst
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