Direct Digital Manufacturing Technology
DDM technology is one that manufacturers have dreamt about for decades, but has just recently become a reality. Additive fabrication technologies that until recently have been relegated to rapid prototyping applications, have entered into the manufacturing realm. The use of additive fabrication procedures is what distinguishes direct digital manufacturing (DDM) from the other conventional manufacturing techniques, and it is from DDM technologies that unique opportunities and advantages arise. Straight from 3D digital data, a part is manufactured, layer-by-layer, without molding, casting or machining. .
DDM is a unique, new alternative for the manufacture of end-use items. Having little in common with conventional manufacturing methods, the distinctiveness of DDM overturns old principles, creates new criteria and changes the decision-making process. The main benefit of DDM is that it eliminates limitations imposed by traditional manufacturing procedures, for example die casting or injection molding. DDM essentially changes many of the principles and “facts” that govern conventional manufacturing enterprises. Because DDM is an additive procedure that eliminates tooling, there are several benefits that are not available with traditional procedures.
DDM CONCEPTS AND ROLE
To understand what DDM can do for manufacturing companies, an appreciation of the basic changes that it imparts is essential. With DDM, time-to-market is no longer restricted by the lead-time for tooling. Because DDM eliminates tooling, a product can be manufactured on the same day that the design is completed. This enables companies to react faster and to do so with a lesser amount of initial cash outlay for tooling as well as capital equipment.
DDM is defined as a procedure that is used to carry out one of the following manufacturing functions:
· Create tooling for the casting, forming or molding products: This application can be either the indirect formation of tooling from a pattern, which is made from an additive fabrication technology or the direct production of tooling.
· Manufacture sellable, end-use goods: The manufactured items are the subassemblies and components and go into the goods that companies sell to their customers.
· Produce end-use items which are used by the manufacturer: Instead of making a company’s products, the procedure is used to produce devices that help in the manufacture of the sellable products. These assembly and fabrication tools include fixtures and jigs.
The shift away from the phrase rapid manufacturing is because of two factors. First, and most significantly, DDM offers a lot more than a hastening of the manufacturing procedure. An emphasis on “rapid” can cause an oversight of the many benefits delivered all through the manufacturing process. DDM isn’t a simple modification of existing manufacturing techniques that makes the procedure faster. It is a drastic departure that fundamentally alters manufacturing. Second, many conventional processes have begun using the term “rapid manufacturing” to describe the activity whether or not it incorporates additive fabrication technology. This has rendered the term somewhat meaningless. Second, with this huge shift come new processes, modified workflows, innovative procedures and new ways of thinking. DDM offers a radical departure that enables manufacturers, engineers and designers to do what was previously impossible or impractical. DDM has opened the door for new markets, new business models and new product designs: It is a new method that affects more than manufacturing engineering and design. It has broad effects throughout the whole organization. For these reasons, DDM has been labeled as the next industrial revolution
ADVANTAGES OF DDM
Rapid Deployment – After a part’s design is finished, manufacturing can start immediately. The lead-time for first articles of completed products is now measured in hours and minutes, not months, weeks or days. Immediately after the CAD data is finished, manufacturing can start since there is no delay in production as you wait for tooling. Rather than waiting 6 to 12 weeks to finish tooling construction and design, a company can export the CAD data as an *STL file and start production. The brief cycle time for delivery of manufactured items helps in lessening time-to market and also preserves on-time delivery if last minutes challenges occur.
Low Capital Expenditure – Doing away with tooling not only lessens time-to-market, it also lessens the manufacturing cost. Traditional manufacturing techniques demand dies and tools that are costly. With DDM, there’s no requirement for tooling. Consequently, the initial cash expenditure to increase manufacturing is significantly reduced. In addition, other capital investments, like those for new assembly lines, manufacturing lines or specialized manufacturing equipment can be minimized or avoided. By lessening the initial expenditure, a company can safeguard their cash flows, finance new products and justify products for markets with low yearly demand.
Liberty to Redesign - Equally significant to the design liberties presented by DDM are the newfound liberties to redesign a part at any point during the lifecycle of a product and as frequently as desired. Because tooling has been done away with, there is completely no extra cost for product redesigns. A part can be revised without production delay or added manufacturing expense.
Limitless Complexity - DDM encourages the designing of parts that perform optimally. Because DDM makes parts using the additive fabrication procedure, the complexity of the design is unlimited. Not only is design complexity unlimited, it is also free. There is no extra cost to manufacture intricate, complex designs and sophisticated. In addition, the time to produce a complex part is no different from that for a simple design.
Short-Run Manufacturing - For nearly all conventional manufacturing techniques, economic order quantities (EOQ) control capacity planning and production scheduling. Considering set-up and teardown, these manufacturing procedures yield the least manufacturing costs when manufacture runs surpass the predetermined minimum production quantity.
The FUTURE OF DDM
For DDM, the opportunities seem boundless. Actually, any limits that arise appear to be self-imposed. The advantages and implementation of DDM are limited only by our imagination, innovation and creativity. DDM is in its initial stages, and there are several advancements waiting for us in the future. DDM is viable today. Each day, companies are taking steps toward this future, and they are receiving instant benefits. It will take some time for DDM to be full embraced; it will need agents of change and will demand open mindedness for industry to shift to this new reality in manufacturing. Direct digital manufacturing will bring fundamental changes and sweeping advantages. For this to happen, advancements and improvements are required in areas such as equipment, materials, science and technology.
DDM is a unique, new alternative for the manufacture of end-use items. Having little in common with conventional manufacturing methods, the distinctiveness of DDM overturns old principles, creates new criteria and changes the decision-making process. The main benefit of DDM is that it eliminates limitations imposed by traditional manufacturing procedures, for example die casting or injection molding. DDM essentially changes many of the principles and “facts” that govern conventional manufacturing enterprises. Because DDM is an additive procedure that eliminates tooling, there are several benefits that are not available with traditional procedures.
DDM CONCEPTS AND ROLE
To understand what DDM can do for manufacturing companies, an appreciation of the basic changes that it imparts is essential. With DDM, time-to-market is no longer restricted by the lead-time for tooling. Because DDM eliminates tooling, a product can be manufactured on the same day that the design is completed. This enables companies to react faster and to do so with a lesser amount of initial cash outlay for tooling as well as capital equipment.
DDM is defined as a procedure that is used to carry out one of the following manufacturing functions:
· Create tooling for the casting, forming or molding products: This application can be either the indirect formation of tooling from a pattern, which is made from an additive fabrication technology or the direct production of tooling.
· Manufacture sellable, end-use goods: The manufactured items are the subassemblies and components and go into the goods that companies sell to their customers.
· Produce end-use items which are used by the manufacturer: Instead of making a company’s products, the procedure is used to produce devices that help in the manufacture of the sellable products. These assembly and fabrication tools include fixtures and jigs.
The shift away from the phrase rapid manufacturing is because of two factors. First, and most significantly, DDM offers a lot more than a hastening of the manufacturing procedure. An emphasis on “rapid” can cause an oversight of the many benefits delivered all through the manufacturing process. DDM isn’t a simple modification of existing manufacturing techniques that makes the procedure faster. It is a drastic departure that fundamentally alters manufacturing. Second, many conventional processes have begun using the term “rapid manufacturing” to describe the activity whether or not it incorporates additive fabrication technology. This has rendered the term somewhat meaningless. Second, with this huge shift come new processes, modified workflows, innovative procedures and new ways of thinking. DDM offers a radical departure that enables manufacturers, engineers and designers to do what was previously impossible or impractical. DDM has opened the door for new markets, new business models and new product designs: It is a new method that affects more than manufacturing engineering and design. It has broad effects throughout the whole organization. For these reasons, DDM has been labeled as the next industrial revolution
ADVANTAGES OF DDM
Rapid Deployment – After a part’s design is finished, manufacturing can start immediately. The lead-time for first articles of completed products is now measured in hours and minutes, not months, weeks or days. Immediately after the CAD data is finished, manufacturing can start since there is no delay in production as you wait for tooling. Rather than waiting 6 to 12 weeks to finish tooling construction and design, a company can export the CAD data as an *STL file and start production. The brief cycle time for delivery of manufactured items helps in lessening time-to market and also preserves on-time delivery if last minutes challenges occur.
Low Capital Expenditure – Doing away with tooling not only lessens time-to-market, it also lessens the manufacturing cost. Traditional manufacturing techniques demand dies and tools that are costly. With DDM, there’s no requirement for tooling. Consequently, the initial cash expenditure to increase manufacturing is significantly reduced. In addition, other capital investments, like those for new assembly lines, manufacturing lines or specialized manufacturing equipment can be minimized or avoided. By lessening the initial expenditure, a company can safeguard their cash flows, finance new products and justify products for markets with low yearly demand.
Liberty to Redesign - Equally significant to the design liberties presented by DDM are the newfound liberties to redesign a part at any point during the lifecycle of a product and as frequently as desired. Because tooling has been done away with, there is completely no extra cost for product redesigns. A part can be revised without production delay or added manufacturing expense.
Limitless Complexity - DDM encourages the designing of parts that perform optimally. Because DDM makes parts using the additive fabrication procedure, the complexity of the design is unlimited. Not only is design complexity unlimited, it is also free. There is no extra cost to manufacture intricate, complex designs and sophisticated. In addition, the time to produce a complex part is no different from that for a simple design.
Short-Run Manufacturing - For nearly all conventional manufacturing techniques, economic order quantities (EOQ) control capacity planning and production scheduling. Considering set-up and teardown, these manufacturing procedures yield the least manufacturing costs when manufacture runs surpass the predetermined minimum production quantity.
The FUTURE OF DDM
For DDM, the opportunities seem boundless. Actually, any limits that arise appear to be self-imposed. The advantages and implementation of DDM are limited only by our imagination, innovation and creativity. DDM is in its initial stages, and there are several advancements waiting for us in the future. DDM is viable today. Each day, companies are taking steps toward this future, and they are receiving instant benefits. It will take some time for DDM to be full embraced; it will need agents of change and will demand open mindedness for industry to shift to this new reality in manufacturing. Direct digital manufacturing will bring fundamental changes and sweeping advantages. For this to happen, advancements and improvements are required in areas such as equipment, materials, science and technology.
