The 3 missing dark sides of the chip removal method which you must know to speed up your production
In his small workshop the artist chipped away at the marble with his chisel, and with a delicate touch worked around the shape of the nose, the gluteus, even tracing the veins of the hand.
The statue was freed from its marble prison and, Michelangelo, discovering such harmonious perfection, called it David.
If you missed the article which explained the first 3, you can find it on this link.
You are probably asking yourself what has Michelangelo got to do with your mechanical manufacturing, and why does this sculptural method make your machines slow.
If you have read last week’s article you already know that the artist had distinguished himself, not only for his genius and talent, but also for the sculptural method he used.
His philosophy was that the block of marble already contained the finished form, and the duty of the artist was to remove the material and free the statue:
While all other sculptors were adding, Michelangelo was removing.
Doesn’t this remind you of something?
Exactly, this is a very poetic way of describing the chip removal method, which, without the support of a 3D printer, will eat up your profits and slow down your machines.
Here are the other 3 dark sides which slow down your production by 30% and also slow down your revenue
1)Storage is a burden on your wallet
Even Henry Ford ultimately understood that it was better to reduce storage, given the cost to manage and maintain!
I know it’s impossible to eliminate completely, but it can be done in part: the components you produce with the chip removal method need material, which you must store in a warehouse.
On top of that you can’t predict when a machine will break down, consequently you must keep a stock of components in case of accidents.
So a part of your company is occupied by this monster, which, even if you don’t see it, weighs heavily on your running costs.
With 3D printing you can produce your components ‘just in time’, when you need them, without waiting for days.
The CAD files, which are the project designs of the components you want to produce, adapted for 3D printing., are virtual, so you do not need an actual warehouse to store them, but an invisible digital warehouse.
Managing an invisible warehouse, which like the files on your computer desktop, is virtual, will save you time and a load of money, which can then be used to fatten up your revenue.
You will improve the cost and timing of delivery: instead of relying on external suppliers to produce the components for your machines, you will print them yourself, and you will no longer need to wait for anybody or anything.
2) What weighs more, a component printed in 3D or a component produced with traditional methods?
Components printed in 3D have now surpassed components produced with the chip removal method with regards to weight and strength.
NASA produces the components for its shuttles with 3D printing because they are resistant enough to withstand very high temperatures, and the force of atmospheric pressure; moreover their light weight increases the aerodynamics of the aircraft.
“Ok, they are lighter, but how much lighter?”
Components printed in 3D are 65% lighter than components produced with traditional methods
“How is that possible?”
Whilst with subtractive methods you have to produce solid components, with 3D printing you can produce components with an internal void, eliminating all excess material.
At the same time, even if your components printed in 3D are lighter, they still have the necessary mechanical resistance and strength, because, in fact, they are not really hollow on the inside, but have a lattice structure just like a honeycomb built by bees, making the product as solid as steel.
With subtractive methods you will never be able to produce a component with an internal void:
if you want an internal void, you will have to empty it subsequently, therefore more work, more cost, more days of work building up and more money leaving your pocket.
If components printed in 3D were not resistant, Airbus would not attempt to print a whole aeroplane with this technology.
Today it is still impossible to print a whole aeroplane with 3D printing in one single process, but only single components subsequently completing the whole plane.
3)The chip removal method contributes to pollution
When your grandchildren grow up they will thank you for having contributed to save the planet.
In fact 3D printing, unlike traditional methods, allows you to waste less material and less money.
Whilst with subtractive methods you waste excess material, with 3D printing you can:
- Produce lighter components, with an internal void;
- Exploit topology optimization allowing you to position your material only where it is necessary to maintain the correct geometry of your component;
These are not my words but what John Hornick writes in his publication “3D Printing Will Rock the World”.
Apart from material, the chip removal method consumes too much energy and the bills you will have to pay will be hefty.
Again, according to John Hornick, 3D printers consume less energy and less CO2.
When a machine component breaks, you have to order another one, so you have to pay a supplier and the cost of transport.
With additive systems you print the component you need on the spot, and you reduce your supplier’s carbon dioxide emissions.
Not only do you save on fuel, but also your customers, who buy your components printed in 3D, which are lighter than those produced with the chip removal method.
For example Airbus buys 3D printers so that the components of their aeroplanes are lighter and consume less fuel.
“But don’t lasers pollute more than a milling machine?”
Yes, you are right, but remember that a single laser does the job in half the time compared to traditional machines, as Hornick confirms, therefore on the whole you are polluting less by using additive systems than with subtractive methods.
Concerning pollution, however I have to say a BUT which will make this third point not entirely true.
not all 3D printers are ecological
Dealing with 3D printing for metals and being an expert specialized particularly in steel, I will talk about the environmental damage caused by this technology, if you do not have the correct machinery which avoids polluting the planet.
Once you have printed your mechanical component in 3D, the metal powder remains in the filter, which you will have to dispose of.
It is necessary to know that the filter of a 3D printer is explosive, above all if it contains reactive materials like Titanium and Aluminum.
That filter therefore, as well as being an environmentally hazardous waste, becomes fatal for the life of your workers.
The advice which salesmen of standard 3D printers give you is to soak the filter: if the powder is wet it cannot explode.
The enormous problem with this method is that the powder in contact with water forms a mud: this mud is harmful and polluting and must be disposed of as special –hazardous waste.
These toxic wastes are like giant sacks of plutonium which you have to get rid of.
You certainly cannot throw them into a river and hope that the current will take them away.
How can you dispose of the waste without risking fines, lawsuits and the extinction of our planet?
First of all you must collaborate with a company who deals with this type of waste.
Then you must pay!
The cost for disposal of special -hazardous waste is 1,45 euro, vat included per kg, according to the estimates of INTERCENT of Emilia Romagna.
Every day you will have dangerous toxic and polluting waste which will cost you like gold and which you will have to dispose of.
I have thought about this a lot and after two years research with technical experts by my side:
I have come up with a solution
which has made my 3D printer specialized in steel,
unique in the world
This 3D printer, which my customers call The Blue Bear, exploits a disposal system with a Remark certificate, which allows you to throw away the filter into a container for metals which you already have in your workplace.
You will save on running and disposal costs and you won’t get an ulcer every time you print your component in 3D and have to get rid of the dangerous filter.
Breathe easy, because I don’t want to sell you a 3D printer for steel: I’m sorry;
But since you have followed my articles up to now, I want to give you the opportunity of accessing the only customized system 3D4YOU which will make you understand, with numbers and real data, if it is convenient, or not, for you to buy a 3D printer for steel.
I will sell you the Blue Bear if you are interested, only if you first verify that this 3D printer for steel is suitable for you, giving you the chance to have a special document which will tell you:
1)how much it will cost you, economically and financially, to print your components with a 3D printer;
2)how much time it will take to produce them;
3)If, for your type of production the 3D printer is a bargain, or if it will become a black hole swallowing your earnings,
To your question “but is it really so much faster to produce with a 3D printer?
The numbers will answer for themselves.
Now you can choose:
To continue producing with the old subtractive methods, making do with a slower production than the companies who have already invested in 3D, or if you prefer to save your company now, with the advantage of skyrocketing your revenue.
If you stay where you are today without making a decision, you will risk being squashed byy our rivals who have already applied additive systems, and are producing resistant components for their machines.
According to an estimate by Deloitte University the companies who will install 3D printers in their production chain will grow by 23% just in 2019.
How long will it take before you are squashed by these companies, who are more progressive and faster than you?
You can’t wait much longer, in fact, I already have many requests and the places for 3D4YOU are running out.
You will have to queue up because I can only assist 4 companies a month with care, that is the maximum number for a complete assistance with full credit.
Click on the red button below, fill in the form and be contacted by one of our technicians specialized in 3D printing for steel.