Additive Manufacturing Implementation Research Articles

Additive Manufacturing Applicability for Efficient Solid Waste Management

Objective: This study intends to perform a theoretical analysis of Additive Manufacturing applicability and integration with Solid Waste Management practices. Theoretical Framework: The main concepts and theories in Industry 4.0, Additive Manufacturing, Solid Waste Management, Cleaner Production, Reserve Logistics stand out, providing a solid basis for understanding the investigation context. Method: This study investigated two of the largest sustainable companies that develop green products and resources for Additive Manufacturing uses operating in the Brazilian market. The information was collected from portals, reports of results, processes, and green manufactured products, according to literature. Results and Discussion: The study results that Additive Manufacturing implementation generated significantly less waste due to technology applied and its usage of green and efficient inputs. Research Implications: This research provides insights into how the results can be applied in Additive Manufacturing Field. These implications could encompass the waste management area and the recycling methods for polypropylene residues. Originality/Value: This study contributes to the literature by analyzing the relationship between additive manufacturing and waste management with the Industry 4.0 concepts, showing additive manufacturing as an alternative way of more sustainable production.

Development of a fuzzy analytic hierarchy process model, sensitivity analysis, and addressing barriers to additive manufacturing implementation in small- and medium-sized enterprises (SMEs)

Additive manufacturing (AM) is gaining popularity worldwide due to its potential to revolutionize manufacturing processes, improve product customization, and reduce waste. Nevertheless, small- and medium-sized enterprises (SMEs) encounter major challenges when implementing AM technologies. The objective of this research is to utilize the fuzzy analytic hierarchy process (FAHP) to identify and prioritize the critical challenges that impede the implementation of AM for SMEs. The study employs a two-stage methodology. First, a thorough literature review and expert discussions identify 15 major barriers to AM adoption. Second, a systematic model is proposed to establish a ranking of these barriers, which is based on the FAHP. The results are validated using sensitivity analysis to ensure the robustness of the findings. Additionally, potential solutions to overcome these barriers are discussed. The research indicates that the two most significant barriers for SMEs are the high costs of equipment and the scarcity of skilled designers. The model that has been presented is a valuable resource for SME managers and practitioners, as it allows them to make strategic and informed decisions that facilitate the efficient implementation of AM. This research is groundbreaking in its comprehensive analysis of the prioritization and ranking of AM implementation barriers, with a particular emphasis on SMEs. It offers essential insights for future research and practical applications.

Supply chain resilience and improving sustainability through additive manufacturing implementation: a systematic literature review and framework

Additive manufacturing (AM) is rapidly transforming supply chains across various sectors. This study explores the current academic literature on AM applications in the supply chain and practitioner literature to explore the application of AM across various sectors. It then identifies AM’s role in achieving supply chain resilience and environmental sustainability. Key themes addressed in the literature have also been discussed. TCM (Theory, Characteristics and Methodology) framework has been used to identify the research gaps and provide future research directions. The study also proposes a research framework and propositions based on AM characteristics and capabilities required to achieve supply chain resilience and environmental sustainability through AM. This study extends the AM literature to present an integrated approach towards simultaneously achieving resilience and environmental sustainability. The study reveals how the AM characteristics of design freedom, part consolidation and on-demand tool-less manufacturing aid in achieving the twin benefits. The research propositions could be taken by researchers interested in exploring the field further. The findings of this study will enable the decision-makers contemplating adopting AM, in making informed decisions and be better prepared.

Hierarchical analysis of barriers in additive manufacturing implementation with environmental considerations under uncertainty

Notwithstanding additive manufacturing has been gaining momentum in the industry, particularly during the fourth industrial revolution, their widespread implementation as a disruptive production technology has brought impacts on the environment. Considering this issue, the research for this paper was built upon the discussion concerning life cycle assessment (LCA) adoption in implementing additive manufacturing (AM). The capability of LCA to achieve environmental goals is a vivid illustration of why it has given researchers and practitioners an extensive impetus. However, to actualize such an effective approach, it is necessary to identify and face the barriers impeding its implementation in AM. Thus, this research aims to identify, classify, and analyze the most critical barriers hindering LCA adoption in AM implementation. To do so, the fuzzy analytical hierarchy process, along with a comprehensive literature review and thorough interviews with the relevant experts, was used to achieve the research purposes. The results revealed twenty-two barriers within five classifications, where the lack of financial resources to conduct LCA study on AM is the most dominant barrier, followed by the lack of LCA expertise in the AM context and the lack of laws and directives for LCA application in AM, respectively. The findings would be useful to decision-makers to develop suitable mitigation strategies and make more informed decisions with individual and/or cluster concentrations. This study can be fruitfully exploited as a guiding reference since no article has hitherto discussed, identified, or analyzed barriers in the understudied area.

Assessing the effect of supply chain collaboration on the critical barriers to additive manufacturing implementation in supply chains

This study proposes a decision support model to explore the effect of supply chain collaboration on the existing barriers to implementing additive manufacturing in manufacturing supply chains. Based on data from Nigerian manufacturing companies, this study determined the severity of the barriers to implementing additive manufacturing in supply chains and then analyzed the impact of supply chain collaboration initiatives on the investigated barriers. The results indicate that barriers related to the technological category are the most severe as well as pinpoint the systemic relationships among the investigated barriers and determine the supply chain collaboration initiatives that are strongly impacting on the barriers. Furthermore, the study results illustrate that the structural barriers that exhibit the highest sense of priority are lack of infrastructural support, insufficient top management support, inadequate government support, low relative advantage and absence of competitive pressure. Hence, this article presents reliable guidelines to manufacturing firms to be aware of the barriers and ensure the development of proper strategies for successful additive manufacturing project outcomes.

The “V” model for decision analysis of additive manufacturing implementation

PurposeThis study aims to broaden the understanding of the additive manufacturing (AM) body of knowledge, presenting a model better suited to the current level of technological development that supports the decision to implement AM in industries, based on the experience of companies in the industry of orthopedic medical implants.Design/methodology/approachBased on the design-science research, the model for the decision to adopt the AM was designed and submitted to experts from the industry of orthopedic implants in Brazil for refinement. For the empirical test of the final model, interviews were used in a company that was considering implementing AM and in another that was not, to evaluate the model.FindingsThe model considers seven dimensions for decision analysis of AM implementation: legal constraints, financial, technological, operational, organizational, supply chain and external factors, being subdivided into 42 criteria that play a relevant role in the implementation decision. The analysis factor of each dimension and criteria are also presented.Originality/valueThe model seeks to be as complete as possible and can be used by various industrial productive sectors, incorporating the analysis of the requirements of health regulatory agencies, suitable for the analysis of the decision to implement AM for the manufacturing of medical implants, not found in other models.

Make‐or‐buy decisions for industrial additive manufacturing

AbstractMuch of the potential of industrial additive manufacturing (AM) is said to lie in the digital specification of components that can be transmitted seamlessly and unambiguously to partners fostering flexible outsourcing. In industry, we observe nuanced AM supply chain governance structures that result from make‐or‐buy decisions, with a tendency to implement AM in‐house. Thus, there is a discrepancy between what is discussed in the literature and implemented in practice. We apply a multiple‐case study approach to investigate why and how AM impacts the make‐or‐buy decision of manufacturing firms. We identify four decision profiles demonstrating the spectrum of specific governance structures and develop a framework to explain the underlying rationales. We find strong arguments for in‐house AM including firms’ perceived need to protect their digitally encapsulated intellectual property, reevaluation of their core competencies, commitment to internal learning, and senior management's enthusiasm for AM. By using transaction cost economics and the resource‐based view, we contribute to the understanding of how arguments of these general theories are modified by the digital and emerging traits of AM. We reveal contradicting guidance in the theories’ argumentation for the case of AM and provide managers a clear perspective on alternative strategies for their AM implementation process.

Connecting additive manufacturing to circular economy implementation strategies: Links, contingencies and causal loops

Additive manufacturing (AM) is one of the technologies driving the shift to Industry 4.0. This transition reconfigures the supply chain to achieve the circular economy (CE) ideal along with improved resource efficiency. This study aims to explore how AM can be implemented in the CE context and to conceptualise the integration of AM and CE. The conceptual elements are identified through a systematic review and content analysis of the related literature, which consist of 51 journal articles. The content analysis was further enhanced by a contingency analysis and a causal loop diagram (CLD). The study highlights the role of the customer and the maturity of the technology as cornerstones when adopting AM in the CE context. Further, understanding the impact of manufacture location, the rapid prototyping legacy and workforce skill is crucial for achieving sustainability in the long run through AM implementation. Further, the contingency analysis reveals key constructs, which are grouped into five key clusters that need to be considered when implementing AM: (1) supply chain actors, (2) drivers, (3) key AM decisions, (4) CE implementation strategies and (5) operational practices. The CLD illustrates the interconnections between these five clusters, thereby revealing how key AM decisions and drivers mediate the influence exerted by CE implementation strategies and supply chain actors of AM on the operational practices. From a practical viewpoint, this study strives to realise the CE by proposing an elaborated guideline for practitioners to implement state-of-the-art AM technology.

The role of additive manufacturing in industry 4.0: An exploration of different business models

PurposeThe rising interest in the integration of digital advanced manufacturing and production systems in the Industry 4.0 context is one of the main factors in the introduction of Additive Manufacturing (AM). The novel technology might change the way firms operate, and the way they interact with consumers, opening new horizons for an improved profit margin and more sustainable business models. The research presented a comprehensive review on the potent role of AM in adhering to customers’ complicated and unique needs using various technologies and techniques, as it discussed the role of AM in introducing new business models that increase the business competitiveness and profitability through an optimisation of production processes. In addition, AM is grasping with innovative solutions varying from waste reduction to shorter supply chains to longer products lifecycle, incentivising firms to adopt it for the economies realised on materials, energy, and costs. Notwithstanding, AM implementation is still in its infancy and faces technical challenges of capability, IT integration, and outcomes. Design/Methodology/approachThis research is based on a quantitative approach that was administered online by means of a highly structured online survey, which aim was to collect primary data that fills the gaps of the research hypotheses due to the lacking nature of research papers exploring them. Therefore, the literature review was a paramount phase in acquiring empirical knowledge about the problem background and concept boundaries that shaped the topic's core objectives and research questions from the lacking nature of explored areas. FindingsThis research investigated the role of AM in industry 4.0 by exploring its impact and intersection with AM firms’ business models while exposing the limitations and challenges to its adoption within industrial contexts. The study highlighted that the AM positive impacts on companies’ business models on the value chain and turnover. This study also revealed the eco-design prospect of AM that will be helpful for different firms to rethink their business models shaping them to be more cost-efficient. OriginalityThis research gave insight on AM technology through a quantitative survey that mainly aimed to classify knowledge and to investigate the role of AM as a lever in improving firms’ value chains through an exploration of possible intersections with business models and impacts of implementation, possible sustainability scenarios and challenges it may face within Industry 4.0 context.

The Implementation of Additive Manufacturing (AM) in Industries Starting from the Identification of Organizational Cultural Characteristics - A Review

Additive Manufacturing (AM), widely known as 3D printing, is a fabrication process to build 3D parts layer by layer directly from a virtual CAD model. It is an innovative technology, with the potential to revolutionize the manufacturing industry completely. It is possible to manufacture complex shaped parts, shortening production sequence, reducing time to market and allowing mass customization. As one of Industry 4.0 nine pillars, AM has promoted an extensive number of researches. Some of them identify organizational culture as a leading factor affecting its implementation in industries. Like any change within companies, organizational culture can be a decisive factor for the successful implementation of AM. However, few studies have thoroughly explored the subject to find which set of cultural characteristics can guide the whole organization. This research identifies, through a systematic literature review (SLR) based on the PRISMA Protocol, which set of cultural characteristics can guide the transition from conventional to AM technology. The systematic literature review was capable of identifying a set of 41 cultural characteristics, which the company should present to implement AM successfully. Knowing which cultural characteristics can help AM implementation companies will increase their chances of succeeding when moving towards AM technologies within Industry 4.0.

An Evaluation Framework on Additive Manufacturing for Hydraulic Systems in Wind Turbines Focused on System Simplification

The wind energy industry showed rapid growth in the past decade, pushing designs to the physical limits. In the last few years, the exponential growth of the wind turbine sizes capped, and the performance upgrades are reached with optimization processes. The first wave was on major parts, but with time advancing the “cost out” strategies are pushed to minor components. A major problem is service costs and the continuous search for missing spare parts in the market. The main aim of this study is to identify when is the best entry point for the additive manufacturing (AM) technology by the hydraulic manufacturer wind turbine companies. From the commercial application for expensive prototypes, it has evolved to economical home use applications. The newly available machines allow printing parts with competing precision to machining equivalents. The material selections range from plastics to metals with mechanical properties equally good or better. This project aims to provide a comprehensive review of the implementation of AM for hydraulic systems in wind turbines. Application screening was done by desk research and on AM technologies. Scientific research has been found on the topic for benchmarking, viability, and cost models. It has been found that there are still missing data for the mechanical properties of the available materials. The result of the decision-weighted matrix shows that the business could gain a competitive advantage by the AM implementation in terms of resources savings and productivity. Although from the technological and market perspective it is justified to initiate before further action the business should review its organization viability.

The additive manufacturing in road construction as factor of its sustainability in conditions of climate change and hydrological catastrophe

The necessity for technology incorporation has appeared in the construction sector a long time ago. A challenging area in the field of construction touches upon design, build, operation, maintenance, reconstruction and include all the steps of a process. This paper calls into the question of additive manufacturing (AM) application in the construction sector, especially road construction, describing the AM implementation. The model-driven methodology is critical to the success of manufacture. Key challenges that face construction 3D-printing are presented and discussed. The aim of this article was to show exhaustively realistic prospect of AM in road construction as factor of its sustainability, in particular in conditions of climate change and hydrological catastrophe. Furthermore, the experimental simulation was conducted to enable clean insights into the AM process. These insights could be fundamental to further experimental investigations with an eye to estimate the use of traditional already well-established construction materials. The presented opportunities elucidate the demand for on- and off-site CAD integration. The conducted experiment demonstrated all steps of AM.

Assessing industrial barriers of additively manufactured digital spare part implementation in the machine-building industry: a cross-organizational focus group interview study

PurposeAlthough additive manufacturing (AM) has been demonstrated to have significant potential in improving spare part delivery operations and has been adopted to a degree in the aviation and automotive industries, its use in spare part production is still limited in other fields due to a variety of implementation barriers. The purpose of this article is to assess the significance of previously reported barriers in the context of the machine-building industry.Design/methodology/approachAdoption barriers are identified from the literature and formulated as hypotheses, which are verified with a set of focus group interviews consisting of original equipment manufacturers (OEMs), AM service providers and quality inspection and insurance institutions. The results of the interviews are reported qualitatively, and the transcripts of the interviews are subjected to quantitative content analysis.FindingsThe article identifies distrust in quality, insufficient material and design knowledge among stakeholders and poor availability of design documentation on spare parts as the key barriers of adopting AM in the production of spare parts. The three key barriers are interconnected and training engineers to be proficient in design and material issues as well as producing high-quality design documentation will yield the highest increase in AM implementation in spare parts.Originality/valueThe article offers a unique approach as it investigates the subjective views of a cross-organizational group of industrial actors involved in the machine-building industry. The article contributes to the theory of digital spare parts by verifying and rejecting presented barriers of AM implementation and how they are interconnected.

Ranking of Additive Manufacturing Implementation Factors using Analytic Hierarchy Process (AHP)

Ranking of Additive Manufacturing Implementation Factors using Analytic Hierarchy Process (AHP)

Additive manufacturing (3D printing) in superficial brachytherapy.

The aim of this work is to provide an overview of the current state of additive manufacturing (AM), commonly known as 3D printing, within superficial brachytherapy (BT). Several comprehensive database searches were performed to find publications linked to AM in superficial BT. Twenty-eight core publications were found, which can be grouped under general categories of clinical cases, physical and dosimetric evaluations, proof-of-concept cases, design process assessments, and economic feasibility studies. Each study demonstrated a success regarding AM implementation and collectively, they provided benefits over traditional applicator fabrication techniques. Publications of AM in superficial BT have increased significantly in the last 5 years. This is likely due to associated efficiency and consistency benefits; though, more evidences are needed to determine the true extent of these benefits.

Investigating additive manufacturing implementation factors using integrated ISM-MICMAC approach

PurposeThe purpose of this paper is to identify various factors influencing additive manufacturing (AM) implementation from operational performance in the Indian manufacturing sector and to establish the hierarchical relationship among them.Design/methodology/approachThe methodology includes three phases, namely, identification of factors through systematic literature review (SLR), interviews with experts to capture industry perspective of AM implementation factors and to develop the hierarchical model and classify it by deriving the interrelationship between the factors using interpretive structural modeling (ISM), followed with the fuzzy Matrice d’Impacts Croisés Multiplication Appliqués à un Classement (MICMAC) analysis.FindingsThis research has identified 14 key factors that influence the successful AM implementation in the Indian manufacturing sector. Based on the analysis, top management commitment is an essential factor with high driving power, which exaggerates other factors. Factors, namely, manufacturing flexibility, operational excellence and firm competitiveness are placed at the top level of the model, which indicates that they have less driving power and organizations need to focus on those factors after implementing the bottom-level factors.Research limitations/implicationsAdditional factors may be considered, which are important for AM implementation from different industry contexts. The variations from different industry contexts and geographical locations can foster the theoretical robustness of the model.Practical implicationsThe proposed ISM model sets the directions for business managers in planning the operational strategies for addressing AM implementation issues in the Indian manufacturing sector. Also, competitive strategies may be framed by organizations based on the driving and dependence power of AM implementation factors.Originality/valueThis paper contributes by identification of AM implementation factors based on in-depth literature review as per SLR methodology and validation of these factors from a variety of industries and developing hierarchical model by integrative ISM-MICMAC approach.

Factors for metal additive manufacturing technology selection

PurposeThis paper addresses the most important factors for the selection of additive manufacturing (AM) technology as a method of production of metal parts. AM creates objects by adding material layer by layer based on 3D models. At present, interest in AM is high as it is hoped that AM contributes to the competitiveness of Western manufacturing industries.Design/methodology/approachA literature study is conducted to identify the factors that affect the selection of AM technology. Expert interviews and the best–worst method are used to prioritize these factors based on relative factor weights.FindingsTechnology, demand, environment and supply-related factors are categorized and further mapped to offer a holistic picture of AM technology selection. According to expert assessments, market demand was ranked highest, although market demand is currently lacking.Research limitations/implicationsThe composition and size of the expert panel and the framing of some of the factors in light of previous literature cause validity limitations. Further research is encouraged to differentiate the selection factors for different AM implementation projects.Originality/valueThe paper presents a more complete framework of factors for innovation selection in general and the selection of AM technology specifically. This framework can serve as a basis for future studies on technology selection in the (additive) manufacturing sector and beyond. In addition to AM-specific factor weights, the paper explains why specific factors are important, reducing uncertainty for managers that have to choose between alternative manufacturing technologies.

A Conceptual Framework on Implementing Additive Manufacturing Technology Towards Firm Competitiveness

Additive manufacturing (AM) is one of the technologies that revolutionize production operations by developing digital competencies to satisfy changing market demands. The purpose of this paper is to explore essential AM implementation factors from an operational performance point of view. The methodology includes identification of AM implementation factors through past literature and semi-structured interviews with experts to capture industry perspectives. Initially, eighteen AM implementation factors have been identified and validated through nine industry experts from Indian manufacturing firms. We found various dimensions or key terms from transcripts and tried to map those dimensions across AM implementation factors. In the process, four factors found unrelated to the AM implementation process. The novelty of this paper lies in the identification of essential AM implementation factors and suggesting a conceptual model based on the linkage between AM implementation factors and firm competitiveness signifying the structured approach towards leveraging AM for competitiveness.

Economic sustainability of additive manufacturing

PurposeThe purpose of this paper is to investigate additive manufacturing (AM) phenomenon extending previous research results by studying in-depth the economic sustainability of AM technology and bringing out the contextual factors that drive its superior performances in comparison with conventional manufacturing, and justify its adoption in rapid prototyping (RP) from an economic point of view.Design/methodology/approachData have been collected through a worldwide survey. Respondents were from 105 companies adopting the technology from 23 countries worldwide.FindingsThe results of this research show that although AM-based prototyping leads to significant cost reduction, it is not as good as conventional manufacturing in terms of the profitability of investment. It also demonstrates how cost reduction depends on production volume and payback period depends on the types of material and scope of AM implementation after controlling for firm size and experience.Research limitations/implicationsThe performance indicator is measured using a Likert scale; however, more reliable conclusion could be made by real amounts. The research also took into account the economic aspects of performance; however, to evaluate the AM technology more comprehensively, other performance measures such as those of social and environmental ones should be considered.Practical implicationsThe paper provides insightful implications for the adoption of AM. In particular, it reveals the contingent performance of the technology in RP.Originality/valueThis paper contributes to expand the literature by demonstrating how different circumstances affect the performance of AM technologies for prototyping and by linking the operational and organizational factors with its performance.

Study on Arc Welding Processes for High Deposition Rate Additive Manufacturing

Although Additive Manufacturing implementation is rapidly growing, industrial sectors are demanding an increase of manufactured part size which most extended processes, such as Selective Laser Melting (SLM) or Laser Metal Deposition (LMD), are not able to offer. In this sense, Wire-Arc Additive Manufacturing (WAAM) offers high deposition rates and quality without size limits, becoming the best alternative for additive manufacturing of medium-large size parts with high mechanical requirements such as structural parts in the aeronautical industry.WAAM technology adds material in form of wire using an arc welding process in order to melt both the wire and the substrate. There are three welding processes that are mainly used in WAAM: Plasma Arc Welding (PAW), Gas Tungsten Arc Welding (GTAW or TIG) and Gas Metal Arc Welding (GMAW or MIG). This paper studies these processes regarding on their capabilities for additive manufacturing and compares the mechanical properties obtained by the different welding technologies applied in WAAM. Obtained results show the applicability of the technology as an alternative of traditional metallic preforms manufacturing processes, such as casting or forging.