3D printing in logistics – supply chain layer by layer

3D printing is becoming increasingly popular in industry. In the meantime, not only prototypes but also very small series and large quantities are being produced using additive manufacturing processes. It will also have a lot of influence on the logistics industry. This article aims to provide information on these and other questions about the possibilities that already exist and what is still in the planning stage.

Why is 3D printing so popular in the industry?

Additively manufactured objects can have both simpler and more complex designs with no problems during manufacturing. Both hollow and solid shapes can be manufactured with this technology without having to worry about how they will be assembled later. The parts can even be optimized to the desired shape. Design engineers, for example, can produce prototypes without machining skills, just as marketing managers can print brochures. All you need is the appropriate software and file and, of course, the appropriate 3D printer including filament. Some providers also specialize in 3D printing a wide variety of objects and offer these services to other companies, as well as individuals.

In the meantime, however, not only prototypes and very small series but also spare parts can be produced using additive manufacturing technologies. For example, it is possible to produce some spare parts for Audi, Ford and VW vehicles using these technologies. French home appliance and cookware manufacturer SEB and housewares retailer Boulanger also rely on on-demand printing of spare parts. For example, Boulanger maintains the Happy3D.fr website, which provides a variety of open-source design files of hard-to-find spare parts. These spare parts can include, for example, battery covers, nozzles and a wide variety of handles. If these break, the otherwise still functional products are often disposed of up to now, whereas the parts can now be replaced without any problems. Based on these examples, it quickly becomes apparent that considerable resources can be saved through the use of 3D printing.

3D printing enables small series and spare parts production directly on site

Just-in-time inventory management is now used in many sectors. However, it also quickly falls out of mind again. Customized formats are often still manufactured in large quantities and then stored with an intermediate supplier, who then delivers the objects piece by piece as needed. Of course, sufficient space is needed for storage, and transport routes and times to the customer must also be considered.

However, more and more companies are now ordering spare parts and small quantities of their designs from the major 3D printing suppliers or producing them themselves, depending on their needs. Start-ups have the opportunity to delay larger investments – for example in production – and still be able to offer their customers prototypes and small series of various objects through the production of 3D prints by appropriate service providers. Some also choose to go all in on 3D printing. In general, however, it is important to find ways to do this that make it possible to simplify the business processes between saving the respective design file and delivering the finished object.

Additive manufacturing makes it possible to shorten the supply chain. At the same time, it closes the gap between procurement, manufacturing and distribution. For small quantities, the customer can also become a co-designer. This makes it possible to carry out modifications and adaptations to the design almost within production for a small number of units, provided that the need for conversion is low. Since the objects are manufactured in a single piece, there is no need for assembly.

Barriers to 3D printing of components

3D design files are not available for every component – especially older ones. Here, the available originals must either be scanned or the models must be recreated on the computer. A major obstacle is the heterogeneity of the equipment that will be used for 3D printing. There are no standard API's here yet.

There is also the question of the service life of materials to be used for additive manufacturing. At the same time, the question arises as to whether the additively manufactured parts meet the various industrial safety standards. Other important criteria are cost transparency and possible outsourcing.

Some companies will be manufacturing spare parts on site in a few years. For example, it is conceivable that Airbus spare parts could be printed directly in airport maintenance hangars. Transport that can sometimes take hours can thus be avoided.

Leading logistics service providers rely on 3D printing

Logistics service providers are always looking for ways to become more efficient, but also more locally focused and also better connected on a global level. They also make use of additive manufacturing for this purpose. These service providers include the most important specialists in logistics and supply chain management, such as DHL, DB Schenker and UPS, among others.

DB Schenker has been pushing the development of digital business models in recent years and sees additive manufacturing as an important part of its warehousing and delivery services. At the same time, the company is helping to maintain the competencies available within the DB Group. This expands the logistics portfolio with numerous options. Spare parts production is now recognized as a service with a clearly defined lead time.

Amsterdam-based DiManEx is also dedicated to optimizing supply chains through digitalization. With 3D printing, potential savings are to be exploited and improved cost management achieved at the same time. Through their own research, company employees found that about 80 percent of products in stock are sold only twice a year. So far, this has resulted in numerous write-offs and scrappings and does not contribute to the conservation of resources. Thus, the cost of warehousing hardly corresponds to the high effort and the corresponding production and storage costs. It makes more sense to order the parts directly on site, if necessary, or in specialized manufacturing centers that exist not too far from the recipient.

DiManEx aims to identify spare and old parts in an already existing database, thus enabling remanufacturing by means of additive manufacturing. One DiManEx customer has even managed to reduce nearly 80 percent of its total cost of ownership by using 3D printing.

Logistics company UPS has already established an on-demand network in the U.S. that can send data to 60 different UPS Store locations spread across the country. This would allow a significant reduction in inventory of slow-moving parts, as well as cost-effective customization of products during the production process. Designers and engineers also benefit from significantly faster delivery of the high-quality spare parts or prototypes.

DHL – the world's largest logistics company – is also increasingly relying on additive manufacturing. For example, DHL conducted extensive research to compare the quality of 3D printed spare parts with those produced using injection molding technology. The results showed that the 3D printed parts were almost equal to or even better than the quality of the objects produced using conventional injection molding technology. DHL continues to analyze the possibilities of 3D printing in all areas of logistics. Decentralized and on-demand production will also play a prominent role here.

Better customer service

3D printing in logistics not only has a positive effect on the costs incurred, it also has numerous other advantages. This allows companies to provide better customer service by ensuring greater parts availability. With this technology, there are significantly fewer transport and waste costs.

Conclusion

The range of possibilities for using 3D printing in logistics or in the supply chain is enormous. As a result, the process can significantly reduce manufacturing lead times and greatly accelerate the time to market for new designs. Customer service can also be significantly improved with this technology, as the components can be printed directly on site or commissioned from 3D printing service providers. This will also significantly reduce the number of spare parts that have to be produced in stock. 3D printing can also be used for the faithful restoration of old technical equipment or vehicles, provided that the corresponding files are available or have been created on the home computer. To obtain a digital image of an existing part, the use of a 3D scanner is recommended.