Informing additive manufacturing technology adoption: total cost and the impact of capacity utilisation. Issue 23 (2nd December 2017)

• Record Type: Journal Article
• Authors: Baumers, Martin; Beltrametti, Luca; Gasparre, Angelo; Hague, Richard
• Is Part Of: International journal of production research. Volume 55:Issue 23(2017)
• Page Start: 6957
• Page End: 6970
• Publication Date: 2017-12-02
• Subjects: rapid manufacturing -- cost estimating -- operational research -- additive manufacturing -- build volume packing -- technology selection; Factory management -- Periodicals; 658.57
• DOI: 10.1080/00207543.2017.1334978
• Languages: English
• ISSNs: 0020-7543

Abstract

Abstract : Informing Additive Manufacturing (AM) technology adoption decisions, this paper investigates the relationship between build volume capacity utilisation and efficient technology operation in an inter-process comparison of the costs of manufacturing a complex component used in the packaging industry. Confronting the reported costs of a conventional machining and welding pathway with an estimator of the costs incurred through an AM route utilising Direct Metal Laser Sintering (DMLS), we weave together four aspects: optimised capacity utilisation, ancillary process steps, the effect of build failure and design adaptation. Recognising that AM users can fill unused machine capacity with other, potentially unrelated, geometries, we posit a characteristic of 'fungible' build capacity. This aspect is integrated in the cost estimation framework through computational build volume packing, drawing on a basket of sample geometries. We show that the unit cost in mixed builds at full capacity is lower than in builds limited to a single type of geometry; in our study, this results in a mean unit cost overstatement of 157%. The estimated manufacturing cost savings from AM adoption range from 36 to 46%. Additionally, we indicate that operating cost savings resulting from design adaptation are likely to far outweigh the manufacturing cost advantage.