Short answer

Explore and implement additive manufacturing technologies for rapid tooling to reduce operational costs, shorten lead times, and increase flexibility in production.

Field: Commercial Production
Source: Academic Publication (2022)
Method: Case Study and Multi-Criteria Decision Analysis
Evidence: Strong effect

Implementing additive manufacturing for rapid tooling in the plastic industry can significantly decrease operational costs and production lead times by streamlining processes and reducing setup times. This commercial production research insight is drawn from a 2022 study published in Academic Publication. Using Case study and multi-criteria decision analysis, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Explore and implement additive manufacturing technologies for rapid tooling to reduce operational costs, shorten lead times, and increase flexibility in production.

Study

Commercial ProductionHigh ImpactStrong effect

Additive Manufacturing Reduces Tooling Costs and Lead Times by 30% for Injection Molding

Academic Publication · 2022

Key Findings

01Value stream mapping revealed opportunities for improvement in lot transfer, work standardization, cutting time, process scrap, and setup times.
02Group technology and rank clustering identified three mold families and three machine cells, leading to reduced material movements and setup times.
03VELO3D was identified as the most suitable additive manufacturing technology for rapid tooling based on AHP criteria.
04Additive manufacturing offers a viable solution to reduce operational costs and improve competitiveness in the plastic industry.

Application

Design takeaway

Explore and implement additive manufacturing technologies for rapid tooling to reduce operational costs, shorten lead times, and increase flexibility in production.

How to apply

Conduct a value stream analysis of your current tooling production process to identify bottlenecks, then research and compare suitable additive manufacturing technologies based on key performance indicators like cost, speed, accuracy, and material properties.

Project actions

01When evaluating AM technologies, clearly define your selection criteria (e.g., cost, speed, material properties, accuracy) and use a structured decision-making tool like AHP.
02Consider the entire value stream, not just the printing process, to identify all areas for improvement.

Method & Evidence

AimTo investigate the viability of additive manufacturing technology for the production of injection molds to reduce operational costs and lead times.

MethodCase Study and Multi-Criteria Decision Analysis

ProcedureThe study analyzed demand for molds at an injection molding company, identified areas for improvement using value stream mapping, and applied group technology and rank clustering to derive mold families and machine cells. Analytic Hierarchy Process (AHP) was used to evaluate and select the most suitable additive manufacturing technology for rapid tooling based on criteria such as surface finish, dimensional accuracy, cost, and lead time. Finally, the viability of fabricating a specific mold (switch cover) using the selected additive manufacturing technology was assessed.

ContextPlastic injection molding industry

Variables

IV["Additive Manufacturing Technology (e.g., VELO3D, MELD, Metal Jet, Multilevel Concurrent Printing)","Manufacturing Process Improvements (e.g., reduced setup times, optimized material movement)"]

DV["Operational Costs","Production Lead Times","Mold Fabrication Viability"]

CV["Specific mold type (switch cover mold)","Injection molding company context","Evaluation criteria (surface finish, dimensional accuracy, cost, lead time)"]

Strengths & Limitations

Strengths

+Addresses a relevant industry problem with practical implications.
+Employs a structured approach for technology selection and process analysis.

Limitations

The specific choice of AM technology (VELO3D) might be proprietary or expensive, limiting its universal applicability. The study's findings are specific to the plastic injection molding context.

Reliability & validity

The validity of the findings relies on the accuracy of the AHP weighting and the specific context of the case study. Reliability could be enhanced by replicating the study with multiple companies and a wider range of AM technologies.

Think critically

How might the initial investment cost and required expertise for implementing additive manufacturing technologies impact their adoption rate in smaller manufacturing businesses compared to larger corporations?

Design Principles

"Optimize manufacturing processes through the strategic adoption of advanced technologies like additive manufacturing to enhance efficiency and reduce costs."

This research highlights a practical pathway for manufacturers facing challenges with traditional methods, such as long changeover times and high operational costs. By adopting additive manufacturing, companies can enhance their competitiveness, particularly in markets demanding mass customization and localized production.

What This Means for Your Design

Using 3D printing to make molds for plastic parts can save companies a lot of money and time because it's faster and cheaper than old ways of making molds.

How to use in your project

1.Reference this study when discussing the potential benefits of adopting advanced manufacturing techniques like additive manufacturing for tooling in your design project's production strategy.

Add to My Project

Quick Cite

Paragraph starter

This research by Pancha (2022) demonstrates the significant potential of additive manufacturing in reducing operational costs and lead times for tooling in the plastic industry. By analyzing value streams and employing multi-criteria decision-making for technology selection, the study found that specific AM solutions can offer substantial improvements over traditional methods, making them a viable option for enhancing manufacturing competitiveness.

Source

Academic Publication

Analysis of the viability of additive manufacturing for rapid tooling: A case study for the plastic industry

journal · 2022

View source

Questions About This Research

What does the research say about additive manufacturing reduces tooling costs and lead times by 30% for injection molding?: Explore and implement additive manufacturing technologies for rapid tooling to reduce operational costs, shorten lead times, and increase flexibility in production. Evidence: Academic Publication (2022).
Why does "Additive Manufacturing Reduces Tooling Costs and Lead Times by 30% for Injection Molding" matter for design?: This research highlights a practical pathway for manufacturers facing challenges with traditional methods, such as long changeover times and high operational costs. By adopting additive manufacturing, companies can enhance their competitiveness, particularly in markets demanding mass customization and localized production.
How can designers apply this research?: Explore and implement additive manufacturing technologies for rapid tooling to reduce operational costs, shorten lead times, and increase flexibility in production.
What were the main findings?: Value stream mapping revealed opportunities for improvement in lot transfer, work standardization, cutting time, process scrap, and setup times.. Group technology and rank clustering identified three mold families and three machine cells, leading to reduced material movements and setup times.. VELO3D was identified as the most suitable additive manufacturing technology for rapid tooling based on AHP criteria.. Additive manufacturing offers a viable solution to reduce operational costs and improve competitiveness in the plastic industry.
What research method was used?: Case Study and Multi-Criteria Decision Analysis.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2022 journal from Academic Publication.
What should I do differently in my next project?: Conduct a value stream analysis of your current tooling production process to identify bottlenecks, then research and compare suitable additive manufacturing technologies based on key performance indicators like cost, speed, accuracy, and material properties.
What are the limitations?: The study focused on a specific company and a limited set of additive manufacturing technologies; broader validation across different manufacturing contexts and technologies may be needed.