Summary: This case study explores the cooperation between Niedersachsen ADDITIV and 3D Spark, showcasing a real-world example of how collaborative innovation has supported the manufacturing sector in Lower Saxony. Emphasizing 3D printing technologies and initiatives like Niedersachsen ADDITIV's '3D Printing Practice Check', alongside the extensive capabilities of the 3D Spark platform, it underscores the critical role of digital innovation in enhancing manufacturing efficiency, reducing costs, and achieving sustainability.

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Introduction: Manufacturing is challenged by the need for economic and environmental sustainability. Long delivery times of new and spare parts put a pressure on the industry, and especially affect small and medium enterprises (SMEs). Niedersachsen ADDITIV and 3D Spark cooperation aims to maximize the benefits of 3D printing technology, leading the industry towards more flexible, faster, economical, and environmentally friendly manufacturing practices across Lower Saxony.

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The Challenge: The manufacturing landscape is inherently complex, marked by an ongoing quest for efficiency, cost-effectiveness, and environmental sustainability.

Specific challenges for SMEs include:

• High costs and inefficiencies in prototype development.
• Limited flexibility in production methods.
• Prolonged manufacturing times and increased waste.
• Complexity of comparing different production options and selecting the best design and technology in terms of cost, manufacturability, lead-time and carbon footprint.
• Lack of resources to evaluate and implement new manufacturing approaches such as 3D printing.

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Solution: Niedersachsen ADDITIV’s 3D Printing Practice Check Initiative: The 3D Printing Practice Check initiative by Niedersachsen ADDITIV invites businesses to explore the integration of 3D printing into their operations, aiming for technology adoption that is both technically sound and economically beneficial. This initiative ensures businesses from Lower Saxony are supported throughout the process, offering free guidance and access to a variety of additive manufacturing equipment for feasibility studies and prototype production.

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Cooperation with 3D Spark: Niedersachsen ADDITIV teamed up with 3D Spark to tackle the challenges in manufacturing and improve the region's various industries by strategically using 3D printing technologies. 3D Spark, with its B2B Manufacturing & Procurement software tool, complements the "3D Printing Practice Check" initiative by providing an extensive suite of features aimed at optimizing manufacturing outcomes. This cooperation ensures that businesses have access to:

• A comprehensive analysis of thousands of production options,
• Detailed cost, lead-time, and sustainability assessments for each manufacturing route,
• And deep insights into manufacturability, helping decision-making from design to production.

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Real-World Impact: AK Regeltechnik: The collaboration's value was underscored by a project with AK Regeltechnik, aiming to enhance the flexibility of their hydraulic control valve prototype production through 3D printing. This shift from traditional methods to additive manufacturing was designed to optimize resource use and streamline production.

Previously manufactured through subtractive processes, these prototypes underwent a redesign to exploit the benefits of 3D printing fully. The cost-effective case study using the 3D Spark platform played a crucial role in this transition, offering quick manufacturability checks, build time estimations and cost analyses after each design cycle.        

The platform's analysis  proved vital in identifying and overcoming manufacturing challenges, such as ensuring that the designs met all technical requirements for wall thickness, gaps size, support removability and size. Based on these analyses, the most advantageous redesign could be identified quickly.

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3D Spark also analyzed the cost drivers in detail and pointed out to further potential cost savings. In this case, printing time turned out to be the most significant cost driver, which might be decreased for example with machine parameter optimization.

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The project achieved remarkable outcomes:

·       Manufacturing Time Reduction: 3D printing saved time and material compared to the standard subtractive approach.

·       Printing Time Reduction: The redesign of the part saved an additional 40 hours in the printing process (selective laser melting).

·       Cost Reduction: More than 50% lower costs associated with additive manufacturing demonstrate the economic advantages of adopting 3D printing.

·       Weight Reduction: Two-thirds weight reduction was achieved for the newly designed hydraulic valve compared to its traditionally manufactured counterpart, enhancing performance and material efficiency.

These results highlight the project's innovative approach to redesigning components for additive manufacturing, significantly impacting manufacturing time and costs while ensuring compliance with functional requirements.

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Benefits: Niedersachsen ADDITIV and 3D Spark have collectively introduced a suite of benefits for businesses exploring 3D printing:

·       Simplified Entry for SMEs: Making it easier for small and medium-sized enterprises to adopt 3D printing with tailored recommendations based on economic viability.

·       Rapid Feasibility Checks: Enabling quick assessments of new projects without the need for extensive preparatory work.

·       Informed Decision-Making: Assistance in choosing between additive manufacturing and traditional methods based on detailed cost analyses, manufacturability, environmental impact, and timelines.

·       Transparent Process Mapping: Clear visualization of process steps and time requirements, making the benefits of any production technology easily understandable.

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Conclusion: Niedersachsen ADDITIV, with the support of 3D Spark, is enhancing the ability of Lower Saxony's industries to adopt and benefit from 3D printing technologies. By offering faster, more comprehensive, and transparent evaluations, businesses can now navigate the technical and economic aspects of 3D printing more confidently. This initiative not only underscores the potential of additive manufacturing to revolutionize production processes but also aims to position Lower Saxony at the forefront of industrial innovation.

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More About Niedersachsen ADDITIV: Niedersachsen ADDITIV, a collaborative effort initiated by the Laser Zentrum Hannover e.V. (LZH) and the Institute for Integrated Production Hannover GmbH (IPH), has been at the forefront of advocating for the widespread adoption and integration of 3D printing technology within the industry. Funded by the Lower Saxony Ministry for Economic Affairs, Transport, Building, and Digitalisation, its mission is multifaceted: to democratize access to 3D printing technology, foster innovation, and equip businesses with the necessary tools and knowledge to embrace this manufacturing approach.