Kaj

Kaj

  • Over 15 years of wide-ranging indu­stry exper­tise among others in the auto­mo­tive, plant construc­tion as well chemical indu­stry sectors in Europe
  • Expert in addi­tive manu­fac­tu­ring (metal and synthe­tics) and digital process chain 3D prin­ting (EDM, CAX, 3D Print SW)
  • Loves the balance between hard work and holi­days

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The client’s chal­lenge

  • A company wants to start using addi­tively manu­fac­tured compon­ents in a bott­ling plant for the first time. The focus is on compon­ents made of metal, as well as plastic for the fittings. In case of damage, and also when intro­du­cing new bottle formats, the latter is likely to suffer a shor­tage when quick avai­la­bi­lity is required. The goal there­fore lies in redu­cing the costs of repla­ce­ment parts as well as mini­mi­sing down­time in main­ten­ance and product laun­ches.
  • By impro­ving machine tech­no­logy and deve­lo­ping mate­rials or opti­mi­sing mate­rial proper­ties, the boundary of cost-effec­tive usage of addi­tive manu­fac­tu­ring shifts from proto­ty­ping towards an indu­strial use in the final product, both for the small-scale produc­tion of complex func­tional compon­ents and for repla­ce­ment parts.
  • The company is there­fore no longer faced with the questions of which compon­ents to manu­fac­ture addi­tively and how to iden­tify these. Criteria include options for inte­gra­ting features and an esti­mate of 3D prin­ting costs vs. current compo­nent costs along the entire value chain (deve­lop­ment, manu­fac­tu­ring, and supply chain).
  • Inno­va­tive approach

    • To be able to effi­ci­ently iden­tify compon­ents with the employees, the team received a day of trai­ning on the topic of addi­tive manu­fac­tu­ring before­hand. Aside from learning about the basics, tech­no­lo­gies, and special aspects of produc­tion-ready design for 3D prin­ting, they were also shown specific examples and price indi­ca­tions.
    • In a subse­quent work­shop on compo­nent iden­ti­fi­ca­tion, after preli­mi­nary sorting with the enter2net design engi­neer and the client’s employees, the compon­ents were analysed and evaluated in a CAD system to deter­mine manu­fac­tura­bi­lity. The control­ling depart­ment was also included in this.
    • Based on these analyses, the requi­re­ments in terms of mate­rial quality, compo­nent size, and volume were able to be derived and factored into a make-or-buy deci­sion.
    • Impact and results

    • Of the nume­rous compon­ents iden­ti­fied during the work­shop, three were prio­ri­tised for addi­tive manu­fac­tu­ring and rede­si­gned to be produc­tion-ready. The compon­ents were improved in weight, stabi­lity, and addi­tive feasi­bi­lity by means of topo­logy opti­mi­sa­tion.
    • On the basis of valid price calcu­la­tions based on bench­mar­king studies, a renowned service provider created the compon­ents. Aside from impro­ving func­tion, a cost reduc­tion of 8-17% was achieved along the entire value chain while simul­ta­neously attai­ning faster avai­la­bi­lity (only 3-5 working days instead 2 months like before).
    • In addi­tion to the accom­panying simpli­fi­ca­tion in crea­ting and adapting these compon­ents, the client obtained their own exper­tise in addi­tive design and produc­tion. After­wards, they purchased an afford­able 3D printer to inde­pendently produce simple fitting parts and moun­ting aids.
Kaj

Kaj

  • Over 15 years of wide-ranging indu­stry exper­tise among others in the auto­mo­tive, plant construc­tion as well chemical indu­stry sectors in Europe
  • Expert in addi­tive manu­fac­tu­ring (metal and synthe­tics) and digital process chain 3D prin­ting (EDM, CAX, 3D Print SW)
  • Loves the balance between hard work and holi­days

Want to get to know Kaj?

Get in contact

Still curious?
There is more to see here:

All impulses