From warehouse to digital file
The industrial revolution brought about by 3D printing continues to gather pace. What was once primarily intended for prototypes is now part of series production – especially in industries such as aerospace, medical technology and mechanical engineering. Additive manufacturing is not only changing production processes, but also global logistics. Instead of physical products, files are sent. The supply chain is becoming a platform.
But what does it mean for the industry when components can be manufactured where they are needed? And how relevant will transport across continents remain? These questions were addressed on Wednesday in three presentations on the topic of ‘3D printing and its impact on global transport’.
One thing is certain: the market for additive products is growing rapidly. According to market research company Additive Manufacturing Research (AM Research), the market was worth 10.1 billion US dollars in 2019 and is expected to reach 14.7 billion US dollars by 2023, representing an annual growth rate of 13.5 percent. According to forecasts, the 3D printing markets will generate sales of 58.7 billion US dollars in 2030.
Applications range from spare parts production for small series production of Alstom trains to parts for an automotive manufacturer and castings for MAN. Components can now be printed in industrial quality and are available even in the event of supply chain disruptions costing millions. Because, as Max Siebert, CEO and founder of Replique, says, ‘The most expensive part is the one that's missing.’
One of the advantages is that no initial investment is required. Prototyping costs can be reduced by 60 percent and development time by 30 percent. High storage costs for spare parts or the disposal of brittle or corroded parts are eliminated. What's more, additive manufacturing can be completed within five to ten days on average.
However, access to additive manufacturing is also required. After all, in addition to the design, the right material and technology must also be selected. Further process steps include production, storage and integration, as well as distribution, which are offered by 3D printing service providers such as Replique.
At logistics service provider Seifert Logistics, the spare parts logistics business was the starting point for exploring 3D printing processes. ‘Many of our customers in the automotive industry are facing a planning dilemma,’ reports Fabian Frommer, team leader for data science and digitalisation at Seifert Logistics. They are contractually obliged to maintain stock, but it is difficult to estimate exact requirements. ‘If too little is kept in stock, expensive re-production is necessary; if too much is kept, it has to be scrapped.’
For Seifert Logistics, this results in two disruptive potentials for the entire logistics sector: ‘On the one hand, we can replace parts of physical warehousing with a digital warehouse,’ explains Frommer. Instead of storing components in the traditional way, a digital twin – i.e. the CAD (computer-aided design) model of a component – is now stored digitally. If the part is needed, it can be manufactured on demand, just in time, using 3D printing and delivered directly.
The second disruptive potential lies in transport logistics: physical data traffic can be partially replaced by digital data traffic, reducing transport. ‘We wanted to exploit this potential and are working on this with our customer Daimler Buses, a bus manufacturer for whom we regularly produce spare parts,’ says Frommer.
In addition to spare parts logistics, Seifert sees further potential in component printing. Here, the logistics company is working with a manufacturer of steam cleaners for whom a very special nozzle with several channels has been developed that is important for the cleaning process. This nozzle can eject steam in one go and then draw it back in again. ‘The part is ideal for 3D printing because it is very complex in shape and difficult or very expensive to manufacture using conventional production processes, which makes it a business case for us and our customer,’ explains Frommer.
Seifert not only supports its customers in the design phase, but also handles 3D printing production and delivers the finished parts – a classic production and delivery process. However, this business area will become really exciting when additive manufacturing and classic logistics services are successfully integrated. The aim is to develop an integrated premium offering.
In addition to warehousing and transport, value-added services such as assembly are also becoming increasingly important. ‘The roles in the supply chain are shifting,’ says Frommer. ‘Logistics service providers are increasingly taking on production-related tasks. This makes the supply chain more transparent and efficient for customers.’
Seifert sees further potential in process optimisation – for example, through defined scanner locations for forklift drivers, which result in measurable time savings over the course of a year. However, optimisations directly at the customer's site are particularly interesting. One example comes from the automotive industry, where there was a risk that a defective component could be installed during an error-prone assembly step – with potentially serious consequences, ranging from production downtime to incorrect delivery. The solution: a specially developed clamp that prevents incorrect installation. ‘The part costs only a few pence, but can prevent millions in damage,’ explains Frommer.
The fourth and final area of potential is the production of complete end products. Seifert has set up its own small profit centre for this purpose, which focuses specifically on small batch sizes, complex component structures and digital warehousing. Here, too, the combination of manufacturing and logistics can open up new business models – if implemented consistently. (cb)
