7 key advantages of 3D printing for end-of-line automation. The TMG case

In light of these requirements, TMG began to consider using 3D printing alongside traditional manufacturing. In 2019, it began its journey into the world of Additive Manufacturing by exploring new manufacturing technologies.    

In early 2020, TMG turns to 3DZ to have the first 3D printed prototypes manufactured and then tested. From the second half of the year, it already started installing 3D printed parts as end-use elements in its automation plants.   

In 2021, it decided to internalise 3D printing, choosing, with the support of 3DZ, Markforged’s X7 printer with CFR filament printing technology. 3DZ then took care of the machine installation and staff training.   

The strength of Markforged’s X7 printer is its ability to print components reinforced with continuous Carbon Fibre, Kevlar, Glass Fibre and High Temperature Glass Fibre. The use of these fibres offers the possibility of obtaining parts as strong as aluminium but with a much lower weight.   

TMG makes equipment that has to handle heavy parts, and many components are exposed and not underbody. It therefore needed to provide its customers with parts that were extremely robust but also aesthetically pleasing. One of the main features of CFR printing technology is that it can produce components with continuous fibre reinforcement to achieve parts that not only have a very strong structure but also a very good surface quality. The X7 printer was therefore the most suitable choice.  

Since the introduction of Additive Manufacturing at TMG, the balance of printer utilisation and achievements is extremely positive:   

𝟭. 𝗠𝗔𝗫𝗜𝗠𝗨𝗠 𝗣𝗥𝗢𝗗𝗨𝗖𝗧𝗜𝗩𝗜𝗧𝗬

In just one year, the X7 printer made 1450 parts and printed 6500 hours. This is 75% of the hours available in a calendar year: TMG is a true example of using the 3D printer for continuous part production.   

𝟮. 𝗙𝗥𝗢𝗠 𝗧𝗛𝗘 𝗣𝗥𝗢𝗧𝗢𝗧𝗬𝗣𝗘 𝗧𝗢 𝗧𝗛𝗘 𝗙𝗜𝗡𝗔𝗟 𝗣𝗔𝗥𝗧

Going from the initial idea of using 3D printing for prototyping to using that prototype directly in production was a very quick transition.   

𝟯. 𝗣𝗥𝗢𝗗𝗨𝗖𝗧𝗜𝗢𝗡 𝗧𝗜𝗠𝗘 𝗥𝗘𝗗𝗨𝗖𝗧𝗜𝗢𝗡 (-𝟴𝟬%)

“We went from drawing a bottle by hand and making prototypes with cardboard, with not entirely accurate answers, to having a 3D printed part ready to test in a few minutes and that, if validated, we can send straight into production. Having a 3D printer in the company has made it possible to reduce production times considerably: the time for many parts has been cut by 80%. 

𝟰. 𝗜𝗡𝗗𝗘𝗣𝗘𝗡𝗗𝗘𝗡𝗖𝗘 𝗙𝗥𝗢𝗠 𝗘𝗫𝗧𝗘𝗥𝗡𝗔𝗟 𝗦𝗨𝗣𝗣𝗟𝗜𝗘𝗥𝗦

3D printing has enabled TMG to overcome the difficulties associated with the long lead times and procurement of raw materials in recent years and the unavailability or late delivery of suppliers of certain mechanical components. For example, it designed a pulley that was not available on the market, and then printed and produced it in-house using additive manufacturing.   

𝟱. 𝗢𝗣𝗧𝗜𝗢𝗡 𝗧𝗢 𝗠𝗔𝗡𝗔𝗚𝗘 𝗖𝗢𝗠𝗣𝗟𝗘𝗫 𝗚𝗘𝗢𝗠𝗘𝗧𝗥𝗜𝗘𝗦

The high variability of the products manipulated by TMG implants did not allow traditional technologies to achieve mechanisms that would guarantee a suitable grip.    

3D printing proved to be much more versatile, allowing TMG to create complex geometries and find effective solutions for even the most complex requirements.     

𝟲. 𝗥𝗘𝗗𝗨𝗖𝗘 𝗧𝗛𝗘 𝗡𝗘𝗘𝗗 𝗧𝗢 𝗔𝗦𝗦𝗘𝗠𝗕𝗟𝗘 𝗠𝗨𝗟𝗧𝗜𝗣𝗟𝗘 𝗣𝗔𝗥𝗧𝗦

TMG replaced parts previously composed of 4/5 separate parts, which were purchased from external suppliers and assembled with different machining, with parts moulded in one piece.    

Redesigning a complex part into a single element makes it possible to   

– reduce the barcodes to be managed   

– eliminate assembly operations by freeing up manpower   

– simplify all processes in both the purchasing department and logistics.  

𝟳. 𝗥𝗘𝗗𝗨𝗖𝗧𝗜𝗢𝗡 𝗢𝗙 𝗪𝗛𝗘𝗜𝗚𝗛𝗧𝗦 𝗔𝗡𝗗 𝗘𝗡𝗘𝗥𝗚𝗬 𝗖𝗢𝗡𝗦𝗨𝗠𝗣𝗧𝗜𝗢𝗡

Thanks to the extremely strong but lighter printing materials, TMG was able to achieve a 30 to 50 per cent reduction in the weight of the gripping equipment. 

This has also made it possible to reduce the installed power while maintaining productivity.