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How to produce complex components in a short time at a very low cost

How to produce complex components in a short time at a very low cost

How to produce complex components in a short time at a very low cost

What you are about to read is not magic

Even if this seems to be an article about some obscure art, I am, in fact, referring to the mechanical sector and the objects I am going to talk about are components which you probably deal with every day in your company.

I am talking about: mechanical complex shapes, tubes, channels with internal cooling systems or simply a circular shape or a component with different trajectories. These objects with their complex geometrics are impossible to produce with traditional methods in a short space of time and in one single phase.

Unfortunately for you, to produce a multiple dimension component with different shapes, using the chip removal method, you must first produce each single piece and assemble the pieces subsequently, losing operative working days at a great expense.

According to the McKinsey Global Institute Report, in order to survive, companies must focus on productivity, that is, more earnings in less production time; automation can help achieve this objective.

Increase in productivity thanks to automation will raise your annual growth rate by 1.4%, bringing benefits at a micro-economic level: what does it mean for you and your company?

This data might seem like boring economic jargon, but in fact it is saying that: above all in countries where the percentage of workers is falling, due to the fact that there are more old people than young (example Italy), automation will help you not to experience this crisis because you will need less manpower, and also less working time to earn the same amount of money, or more, than you are earning now with resources which you could save.

Be careful however! While automation can substitute 60% of professions, a 3D printer does not eliminate the operator, but it lightens the workload, reduces the phases to complete and allows you to achieve components with features that, as you will see in detail below, you will never obtain with the chip removal method.

With a lighter workload your operator can carry out various duties at the same time and catapult your company productivity sky-high.

Moreover, if your operator works with a 3D printer specialized in only one material, like the 3D4STEEL Blue Bear, which is specialized only for steel, he will work more efficiently and faster. If you want to know more, I have written an article which will enlighten you.

Read also the article in Tom’s Hardware on the benefits of having a 3D printer specialized in only one material.

To be able to produce impossible geometrics in one single phase, that is all those complex components which are now sifting away your money and your precious time, is the proof that with a 3D printer you can speed up your production immediately.

Do not be misled, however, by what you read in newspapers regarding the production of impossible geometrics with additive systems because, while what you read is targeting all sectors, from the fashion to the medical sector, and always cites examples of  gazillion dollar companies, you must always ask yourself how you can relate the data you read to your situation as a small and medium sized mechanical company.

This is how a 3D printer will allow you to produce components which will be the envy of your competitors

Conduits like labyrinths, shapes which intersect, join, and when they meet merge.

And more ..

Tunnels

Overlapping structures

components with multidirectional trajectories and with curved shapes: it sounds as if I am talking about the work of Maritius Cornelis Escher, instead, I am referring to those components which, to produce with subtractive systems, cause you to cut your throat, waste time dividing the work up in more phases, and wait days and weeks to cash in chickenfeed.

Complex geometrics remind us of the work of the Dutch engraver and graphic artist Maritius Cornelis Escher, who produced some three dimensional lithographs, which created evocative optical effects.

If you look at the Waterfall, for example, at first sight it looks like a normal three dimensional image: the flow of water falls from above and activates the mill which pushes the water into a twisty canal which joins up with the waterfall; in actual fact this optical effect represents an impossible image to produce.

Impossible geometrics however are possible and easy to produce, but only with a 3D printer.

It is not worthwhile to produce impossible geometrics with traditional methods, not only from an economic point of view and in terms of production times, but also because of the impossibility of obtaining the quality that each of your components MUST have.

You will be surprised therefore by the benefits that only a 3D printer can guarantee:

1.If you want to produce a component with an internal hollow, such as a conduction pipe, with traditional methods, you will first have to make the object and then dig out the material.

From the quality point of view your component will not be lightweight and resistant, as with additive systems, because the operator can never be as precise as a 3D printer.

Additive systems allow you to produce components with an internal hollow, guaranteeing the certainty of achieving both the lightness necessary for your kinematic machines, and the resistance to support mechanical stress.

This is not magic, but pure geometry: you must be aware that 3D printing exploits geometry calculations (topology optimization) for material layout only in points strategic to maintain solidity, and avoiding layout where it is not needed.

Thanks to topology optimization you will have the mathematical certainty that your components will be light and resistant

But there’s more…

Resistance is guaranteed also by another small trick that you can exploit only with additive systems.

To say that with 3D printing you can obtain components which are completely hollow inside is an inaccuracy.

Your components will not be hollow, but internally they will have a lattice structure like the honeycomb of bees, which assures resistance without making the component heavy.

It is not by chance that additive systems have solved one of the biggest problems of aeronautical manufacturers: how to make the components of aircraft lightweight but resistant.

In short this is what you are missing out on by continuing to ignore 3D printing to speed up your production:

1)you won’t be able to produce impossible geometrics, objects which, as you have seen, are the daily bread and butter of a mechanical company: hollow pipes, structures like cooling conduits, intersecting shapes and non-linear trajectories;

2)you will lose time producing components piece by piece which, with 3D printing, you can produce in one single phase: losing time in the world of business means lagging behind light years compared to your more technological competitors and risking extinction like all the companies who have not been able to adapt to change;

3) you will lose tons of money because a slow production and all the hidden costs will eat up, not only the company coffers but also your personal wallet. Goodbye Caribbean holidays, leather seats and villas with sea views;

4)Your components will not be lightweight as they would be if printed in 3D.

Instead of having resistant pieces in steel, light as aluminum, you will have components which have cost manpower and extra time and, if they are lightweight, risk crumbling like potato chips or, if they are resistant will be as heavy as lead;

5)you will have a standard production which does not distinguish itself from the competition.

Instead of producing unique objects, with special features in a short time and without draining your company coffers, with the chip removal method you will have to be content with giving your customer non personalized components when CUSTOMIZATION is becoming the rabbit out of the hat of many successful companies.

Nike for example, thanks to 3D printing, has become the favorite shoe company of all sportspeople, because it produces shoes which adapt to the feet and the specific needs of the customer-athlete.

Customizing your production thanks to 3D printing could be the ace up your sleeve to beat the competition and become the number one in your sector, earning mind-boggling sums of money.

However, just as a 3D printer does not work magic, so no manufacturer of 3D printers is a magician who can foresee with certainty, without carrying out tests on YOUR production, if a 3D printer is worthwhile for you on an economic level or not.

Luckily for you:

You have the opportunity of accessing the only customized system which will allow you to have mathematical data showing you whether a 3D printer for steel is worthwhile, WITHOUT having to buy one

Without having to buy one means that you won’t have to fork out millions to install a 3D printer in your production chain, which you don’t know how to use and without even having the certainty that you will become rich or speed up your production.

With 3D4YOU you will have:

  1. Data on how much it will cost you on an economic and financial level to print with a 3D printer for steel only: finally you will really know how rich you can become and with that money buy a villa by the sea and spend your summers in the heavenly tranquility of the Tropics;
  2. Data on how much time it will take the printer to produce your components; you will know by how much your production times will beat your competitors;
  3. The opportunity of printing YOUR components;
  4. A detailed analysis of your specific case which will allow you to discover if 3D printing is suitable or not for your production;
  5. A team of experts will assist you so that the entire course will be easy and without stress or worries to add on to those you already have for your work;
  6. A complete training course on how the 3D printer works; this course is worth 840 euro which will be gifted to you!
  7. And much more…

The icing on the cake is that if you are not satisfied with the course, if you realize that, for whatever reason ,you have had second thoughts or that 3D printing is definitely not for you:

You will have a super zero risk guarantee which will allow you to have all your money back

now all you need to do is get informed about this amazing course and outsmart YOUR competitors who, because they are frightened, are not going to venture into the dark forest of additive systems and that when they do, will be devoured by the false promises of manufacturers of standard 3D printers, by risky investments and other mortal traps for the company coffers.

Get smart: arrive first: click here and watch the video which will dispel any doubt which still grips you.

P.S: since 3D4YOU is a customized system I can only assist 4 companies a month, therefore you should check the timer below the video to find out if you have missed the train to riches.

Ivano Corsini

Fondatore e CEO di 3D4STEEL. Creatore del metodo CorSystem - il metodo definitivo per produrre più velocemente e guadagnare di più con una stampante 3D per acciai. Imprenditore 4.0

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