Humans have carved things out of rock and wood, or formed parts from metal for centuries. Building up a part is relatively new. While there are some foundations and borrowed technology from casting, powder metallurgy and polymer manufacturing, how we define a layer; how we use energy and how we input feedstock mix together to create this additive approach.
Ultimately, understanding the economics of AM unleashes its potential, but also requires asking and answering a series of questions. What requirements need to be met or what must be true for you to succeed? Are you seeking to save money? Reducing schedule? Improving performance? Can you monetize schedule or performance? These analyses will assist the business case.
Developing a business case for Additive Manufacturing (AM) involves assessing technology, materials, design, economics, quality, safety, and regulatory requirements. Key considerations include the selection of AM processes, material cost and performance, design efficiency, and post-processing requirements. The AM cost model comprises material, printing, and post-processing costs, emphasizing the impact of layer thickness, build speed, and machine productivity on overall expenses. For instance, thicker layers can reduce print time but may affect resolution and downstream costs.
Each AM process has unique cost drivers. Laser Powder Bed Fusion (PBF) incurs high costs in printing and post-processing, while Directed Energy Deposition (DED) varies by feedstock type. Metal Binder Jetting features lower printing costs but requires extensive post-processing. Materials like powders and wires are often more expensive than conventional forms, but AM’s efficiency in material usage can offset these costs. Understanding these cost drivers isn’t a one-time process; new equipment, material types, and methods can change the dynamics at any time.
Economic considerations also include sustainability benefits such as reduced waste, on-demand part production, and optimized geometries.
Business cases must align processes, machines, and people to maximize productivity. AM offers flexibility, but success depends on careful alignment of technology, materials, design, and operations to achieve cost and performance goals.
References: Ries, E. (2011).The lean startup: How today's entrepreneurs use continuous innovation to create radically successful businesses. New York: Crown Business.