Wear and tear on manufacturing equipment leads to maintenance and downtime, which affects production efficiency. 3D printing is a cost-effective alternative for producing replacement components such as brackets, pushers and EOAT on demand.

Think of the pushers in the packaging lines that are used for diverting, sorting, rejecting, inserting, feeding and changing lanes. Replacement pushers can be 3D printed in-house in a matter of hours, resulting in significantly shorter lead times and lower part costs compared to outsourced production. This eliminates the need to wait for shipping and part development cycles, and the production line can be back up and running immediately to avoid costly downtime.

Practical report

From 3D printed components in automation and robotics to a new microLIGHT system as a standard modular system: The path of industrial 3D printing at ASS Maschinenbau.

The high variety of variants and complex geometries led to the search for an alternative solution that could meet these requirements more cost-effectively and quickly. Today, these aluminum components are almost entirely replaced by continuous carbon fiber-reinforced components at ASS Maschinenbau.

The machines in the machine park that are responsible for continuous operation in manufacturing can be brand new or decades old. As machine manufacturers update their product lines and discontinue support for older models, sourcing spare parts for older equipment becomes a challenge, especially if the machine manufacturer no longer exists.

Food and beverage manufacturers can produce the old packaging technology components in-house, reducing the time, cost and complexity associated with external procurement. This option not only supports continuous operation, but also extends the life of the valuable capital equipment.

Disruptions in the global supply chain have led to delays, bottlenecks and higher costs in the procurement of parts, impacting manufacturers' ability to meet demand and achieve their sales targets.

For example, the procurement and manufacture of a small component such as a conveyor belt guide, which uses compressed air to transport products along the production line, currently takes up to 12 weeks. However, manufacturers print the parts within hours or days, restoring the original productivity of the production line.

Additive manufacturing reduces the environmental impact of complex supply chains by decentralizing the procurement process. When an assembly line needs to be retooled for new products, manufacturers simply print a component on the factory floor. Introducing a digital 3D printing platform on the factory floor reduces manufacturers' reliance on distant suppliers and cuts excessive spending on materials, transportation and resources - all of which contribute to a more efficient and sustainable manufacturing process.

Ensuring safety on the production line is critical to both operator well-being and operational efficiency. Manufacturers can face significant fines from safety authorities for non-compliance. This highlights the importance of preventing accidents and implementing protective measures to reduce the risk of injury associated with moving parts. 3D printing can be used to produce protective devices, ergonomic aids and tools. Despite their simplicity, these parts are proving to be both cost-effective and crucial for the safety of operators on the production line.

Engineering and design teams can use in-house 3D printers to develop a customized guard that eliminates a pinch hazard identified on the packaging line. 3D printing offers greater design flexibility compared to traditional manufacturing methods and allows the guard to be seamlessly attached to the existing attachment points of the bundling machine. The design requirements for the part are confirmed using Simulation, Markforged's software tool for validating part strength prior to printing.

3D printing solves common problems in the food and beverage industry. In-house 3D printing technology enables manufacturers to reduce the cost of custom tooling and MRO parts, achieve significant time savings, develop innovative and efficient designs, and extend the life of aging equipment. Additive manufacturing eases the challenges manufacturers face in expanding automation on the production line.