Making a critical metal 3D-printing component easier to manufacture
Lower costs and virtually no lead time
In metal 3D printing, every component in the process must do exactly what it is supposed to do. Especially when the machine is used for applications where quality, configuration and repeatability are tightly specified. A small deviation can then have major consequences for the final result.
A manufacturer of metal 3D printers was struggling with a critical component in the printing process: the recoater that distributes each new layer of powder evenly. The component was purchased externally, but did not fully meet the required dimensions. As a result, additional operations were needed to make the component fit, time after time.
The challenge
The existing component caused unnecessary machining time, additional dependency and a long lead time. Lead time therefore increased to three to four months. To prevent supply problems, the client had to hold additional stock.
For a process where repeatability and consistent quality are essential, this was not workable. The component needed to be right. Not only technically, but also in terms of availability and cost.
The approach
We carried out a full technical review of the component. We looked not only at its existing shape, but above all at function, tolerances and manufacturability. What does the component need to do? Which dimensions are critical? Which machining operations are required? And how can the product be manufactured more intelligently with consistent quality?
Based on this, we redesigned the component with greater control over dimensions and availability.
The result
The component is now produced on an ongoing basis by Coolen Engineering. This gives the client a continuous supply without additional machining. Costs fell by around 30%. Lead time dropped from three to four months to almost immediate availability. This gave the client greater control over the process and more time to develop new products.
- Costs around 30% lower
- Lead time from three to four months to almost immediate availability
- Continuous supply without additional machining
