Gesa Schneider, Senior Territory Manager for Central Europe for Marforged, highlights the opportunities of on-demand manufacturing, the technology behind it, and the obstacles it needs to overcome.
THE FUTURE OF MANUFACTURING
On-demand manufacturing is already a reality for industries where quick access to spare parts presents the opportunity to gain a potential competitive advantage.
Sectors including rail, defence, and automotive are leading the way, making the most of technologies like additive manufacturing (AM) to localise production by printing spares, tooling, and products whenever and wherever they are needed.
With benefits ranging from de-risking supply chains to reducing waste and saving costs with digital inventories – not to mention customising and creating bespoke products to suit customer needs – on-demand manufacturing is changing the way that industries work.
RESPONDING TO A CHANGING LANDSCAPE
Where a global supply chain once meant greater access to the right materials and technology, current economic and geopolitical challenges have started to turn what were once deemed benefits into obstacles.
While working across borders still has huge benefits when it comes to ideas and innovation, businesses have learned from the past few years that bringing a portion of their manufacturing closer to home can help speed up time-to-market.
With longer supply chains continuing to be vulnerable to delays and risks, on-demand manufacturing circumvents these issues time and time again – keeping things moving on the factory floors.
Companies like Deutsche Bahn (DB) have built on-demand manufacturing into their repair and maintenance cycles to speed up repairs, saving time, costs, and resources. The rail giant produced its 100,000th 3D printed spare part in May 2023 and has a ‘digital warehouse’ containing virtual files of spare components, which DB plans to increase from 1,000 to 10,000 by 2030.
AM is making digital inventories a reality across a range of industries. Technologies like The Digital Forge allow companies to print the parts they need according to demand. This not only helps to speed up repair cycles and response times, but can lower the high economic and environmental cost of long-distance shipping, as well as reduce waste and storage costs.
AGILE DESIGNS AND SUSTAINABILITY
In addition to digital inventories and maintenance, on-demand manufacturing is also changing the way parts and products are designed. Product design can be optimised with greater flexibility in mind – and thanks to AM, it allows for customisation to suit specific customer requirements.
It can also incorporate more complex geometries than traditional manufacturing methods, allowing for stronger, lighter structures, which are especially beneficial in industries such as automotive and airlines when it comes to reducing emissions.
Additionally, the localisation of production through on-demand manufacturing reduces transportation-related carbon footprints and waste, contributing to environmental sustainability.
The digital nature of on-demand manufacturing also encourages collaboration across departments, borders, and industries – enhancing designs and skills, and helping to create a more agile and flexible workforce.
It is thanks to this technology and collaboration that local automotive service centres printing parts on-demand to service cars, hospitals and surgeries creating custom prosthetics on-site, and innovations like bicycle tyres that never go flat, become a reality.
Industries like footwear are also turning to on-demand to create custom designs as well as re-shore their manufacturing and reduce waste by creating fewer shoes – manufacturing for demand rather than stock.
ADDRESSING THE CHALLENGES
It is important to note that while the possibilities and benefits of on-demand manufacturing are clear and far-reaching, it is not suitable for all means of production. Rather than eliminating global supply chains, it serves to make them shorter and less vulnerable, whilst becoming more efficient and innovative.
However, on-demand manufacturing still has a long way to go before it reaches critical mass. Sharing success stories and innovations like those above play a big role in helping to overcome the uncertainty, fear of change, and inertia that slow the transformative power of nearly all new technologies.
In addition to the challenges of behavioural change, there are still obstacles to overcome in the widespread adoption of on-demand manufacturing.
These are highlighted below, along with how technologies are helping to address them:
Scalability and production capacity: On-demand manufacturing works well for smaller scale manufacturing and production, but as demand and volumes grow, it is crucial that their capacity, equipment, and workforce can handle larger orders as well as maintain and deliver consistent quality.
AM can help companies to scale their production volumes up and down, as well as incorporate quality assurance and repeatability.
Digital infrastructure, connectivity, and security: On-demand manufacturing heavily relies on digital technologies and connectivity. Companies need efficient digital infrastructure, including robust computer-aided design (CAD) systems, digital communication platforms, and secure data transfer.
Government initiatives like Building Digital UK and the Digital Economy and Society Index (DESI) in Europe are helping to extend robust, high-speed broadband and infrastructure to ensure greater connectivity for individuals and businesses.
Emerging technologies like blockchain are helping to ensure the safe transfer of files across borders to protect proprietary data and intellectual property. As trust in this security grows, so will the adoption of technologies that power connectivity and facilitate collaboration between the designers, manufacturers, and customers required for on-demand manufacturing to thrive.
Quality control and certification: Product liability and certification need to be addressed before we can see the widespread adoption of on-demand manufacturing – especially when it comes to regulated industries. This requires collaboration between stakeholders, policymakers, and regulatory bodies.
Connected AM platforms like The Digital Forge are integrated with digital tools, including artificial intelligence (AI) powered validation and simulation to help enable a smooth digital workflow and repeatability that is vital for regulatory compliance.
Industries need to develop comprehensive frameworks that balance safety, innovation, intellectual property protection, and environmental sustainability.
Education: Knowledge is power, and while investment in digital skills is taking place, there is still a need for upskilling the manufacturing workforce. Engineers, product designers, and creatives need to collaborate and work across departments to drive innovation.
Industry and educational institutions need to continue to work together through facilities like Print City and iAero, providing the hands-on and business-level training needed to help on-demand manufacturing reach its potential.
“In addition to helping manufacturers save time and resources, and reducing waste and emissions, the true value of on-demand manufacturing lies in its ability to de-risk supply chains and solve problems closer to home”
Gesa Schneider, Senior Territory Manager for Central Europe, Markforged
THE FUTURE OF ON-DEMAND MANUFACTURING
As with any technology advancement, the cost of on-demand manufacturing will decrease as its adoption increases. Ultimately, its success lies in its ability to benefit end users.
In addition to helping manufacturers save time and resources, and reducing waste and emissions, the true value of on-demand manufacturing lies in its ability to de-risk supply chains and solve problems closer to home.
By bringing manufacturing nearer to the customers and markets it serves, on-demand means that products can be specifically developed and tailored to meet the needs of local markets, communities, and businesses.
Its widespread adoption will strengthen manufacturing as a whole, making it more relevant, responsive, and resilient when it comes to solving problems on a local and global level.
