How 3D-printed spare parts are revolutionizing a print shop

Founded in 1891, Vogel Druck und Medienservice GmbH is one of the leading web offset and media service providers in Germany with 350 employees and sees itself as an innovative system supplier with a high level of vertical integration. The company is part of the Bertelsmann Marketing Services and specializes in the production of magazines and catalogs.

Like many other sectors, the printing industry is also facing major challenges. Digitization and rising prices for paper and materials require ever more cost-efficient working methods.

Jörg Kuchenmeister, Managing Director of Vogel Druck und Medienservice, has witnessed numerous developments in the industry over the past 20 years. The company has always responded to these changes with innovations. For example, the company has been completely climate-neutral since last year.

One negative development is the enormous cost of spare parts for older machines. Exorbitant prices for simple wear parts that quickly run into hundreds of thousands of euros. To counteract the enormous costs, Jörg Kuchenmeister saw a possible solution in 3D printing.

It all started with a collaboration with a 3D printing service provider.
The first components were printed by this service provider on a Markforged 3D printer and the tests were promising.

However, the process was not dynamic enough for Jörg Kuchenmeister. He wanted to move from planning to doing and build up the expertise in his own company.

As part of Formnext 2021, a Markforged Mark Two is purchased and Stefan Kemmer, responsible for quality assurance, also becomes a 3D printing officer. He learns how to design in CAD automatically and starts a success story together with the entire team.

The coherent system of material, software and hardware made it easier to get started with the new technology. However, the operating technicians at Vogel Druck und Medienservice were initially somewhat skeptical about the new technology, but quickly came to appreciate its added value.

Around three weeks after purchasing the Markforged Mark Two 3D printer, the first acute case arose in production that prompted a rethink. Shortly after the start of the shift, a part broke in a machine. Production came to a standstill. The delivery time for the replacement part from the supplier was six to eight weeks. The operating technician sought help from Stefan Kemmer. He saw the solution in the new Markforged 3D printer. Without further ado, he designed the component in Fusion 360 and sent it to the printer. After just four hours, the plant technician had the freshly 3D-printed spare part in his hands. The spare part was installed in the same shift and the machine was up and running again.

This was followed by other parts on the machines and units that could be replaced quickly without having to dismantle the machine. Machine parts made of POM material are particularly suitable, but in some cases aluminum or steel parts are also suitable. The components were designed and printed in a very short time. The utilization of the 3D printer continued to increase.

Two areas are covered by industrial 3D printing: 
- Machine spare parts
- Improvements such as fixtures or brackets

The current status is to be maintained for the time being. Further components will be substituted and costs will continue to be saved. Depending on capacity utilization, an investment in another Markforged 3D printer is not ruled out.

A partner company from the USA has also already decided to invest in a Markforged 3D printer. This means that the possibilities of Markforged technology can also be used profitably in the USA and experience can be shared across locations. Jörg Kuchenmeister is confident about the future.