Getting into additive manufacturing

Additive manufacturing (AM) is becoming increasingly popular in the metalworking industry. Incorporating 3D printers and hybrid machining centres is a smart decision for large production shops that have the capital to invest in this technology. However, additive machines may be out of reach for the job shop. Frank Defalco, former senior program manager of Canada Makes, discusses the technology, programs, and incentives to help job shops access additive manufacturing.

CM: What is Canada Makes, and how does it serve the additive manufacturing industry?

Frank Defalco: Canada Makes, part of the Canadian Manufacturers and Exporters (CME), was developed in 2014 because we identified a need for some leadership to offer help and direction to companies looking to adopt additive manufacturing as part of the process.

Canada Makes can help put together the information that shops would need that isn’t just hype. There was quite a bit of hype around the sector. There is still a little bit, but I think that’s tempered somewhat now, which is good. We still have a need to help identify where companies can use the technology today and be profitable at it. So that’s one of the main reasons that Canada Makes functions, and I’ve always looked at it as being important to help develop Canada’s additive supply chain.

One of the important components is the Metal Additive Manufacturing Demonstration Program, which is managed by CME Canada Makes with funding from NRC-IRAP. The program was designed to provide participating SMEs guidance, advice, and an opportunity to explore adopting metal AM. At the beginning the technology was new to me and many of the customers we were speaking with, and we had a hard time even finishing 10 projects in the first round. However, as the program was refined, we were able to show possible cost savings of adopting the technology and how companies can take advantage of the sweet spots of AM. It’s a real reflection of what the sector was facing.

This March we are completing the fifth round with over 60 projects. We also noticed that more companies in the tooling sector, particularly tool-, die-, and mouldmakers, are exploring conformal cooling, which is made possible through AM. These companies are asking the right questions and putting significant time and effort into understanding if AM is the right process to help them.

CM: What are the barriers small job shops face when trying to break into the metal AM market?

Defalco: Cost is one of the biggest barriers of finding, understanding, and designing for AM. Canada Makes has introduced a number of tools, such as the interactive process and design guides, to help provide information. Finding skilled workers is always a challenge, particularly when it comes to workers who understand what exactly the technology can do. Shops often have a hard time getting over sticker shock. We provide information to help determine if and how using AM can save money.

SMEs are really starting to take advantage of metal AM. They are beginning to investigate and understand the technology and use this data for low-production runs, high-value parts.

Canada Makes has worked with over 250 SMEs in the last few years. We help them engage with over 100 AM companies to help produce the 60 projects that we have undertaken. A majority of the SMEs we work with are located in and around Windsor, Ont., particularly because of the mould and die industry there. We work with companies nationwide, but there is certainly a concentration in Ontario and Quebec. We see some significant interest in Alberta. There is also some work in British Columbia. Like I said, we reach every province.

Calgary-based Onstream Pipeline Inspection developed a gauge, currently being field-tested, that includes seven parts made by AM.

CM: What industries or market sectors are the companies and projects focused in?

Defalco: Aerospace is one of the biggest users of AM technology. Canada Makes has done several projects with companies producing aerospace components, as well as projects within the energy sector in Alberta. We’ve had some real winning projects over the years. One in particular was with a Calgary-based company named Onstream, a manufacturer of pipeline inspection gauges. The company was interested in AM but was unsure about the quality of the metal. They participated in our program and were really impressed with the technology. They have now gone through field tests and entered production.

It is really a winning formula. We are able to take steps into AM with short production runs for highly complex parts requiring lightweighting. It is a perfect fit.

Like I said, we see a lot of opportunity in aerospace, energy, and, of course, the medical sector. We haven’t done a lot of medical projects, but we see a lot of medical component manufacturers looking into it. So those three areas are huge, and of course the tool and die industry is another.

CM: What trends are you seeing in the metal AM market, and what challenges do you see the industry facing?

Defalco: The goal of the program is not to encourage companies to go out and buy an additive machine. In some cases that can be the worst thing they could do. Some of the companies are still looking for a solution to get the machines going 24/7. That’s really the goal of manufacturing, and it’s starting to happen, which is great.

However, some companies take on a small project to incorporate AM. They may not have the capacity or have the need to have their own machine in-house. There are many great service providers that these companies can connect with and identify a solution to the challenge that job shops face when investing in expensive capital equipment.

For those shops that have a certain amount of need for AM, it may be best to bring it in-house rather than use a service provider. Those machine shops tend to be larger in size. Investing $500,000 to $1 million in an additive machine doesn’t necessarily guarantee a quick return on investment. Companies need to realize that it may take upwards of six months before they even start running a part. There can be a steep learning curve. SMEs need to have a good business case going in.

I suggest starting with a service provider and take those steps to make it a process. It’s not an overnight; you can’t just jump in and expect to be making parts tomorrow. You know, it’s often what I tell a company. I don’t want to see a machine sitting idle and start collecting dust. You’ve heard of those stories. It’s not good for anyone. It’s important that companies know whether they have a good business case because it’s a significant investment.

CM: What should Canadian companies do if they are looking to invest in AM

Frank Defalco, former senior program manager of Canada Makes.

Defalco: Certainly, a big barrier to adoption is skilled operators. AM and 3D printing require specialized skills, especially when it comes to design for AM. I hear of many companies that want to get into it, they have the capital to buy the machine, but they just cannot find anyone to run it. It’s not an easy thing to do. In Canada we have a network of schools that are helping deal with this challenge. Canada Makes engages with these institutions to help build the skills for industrial members.

The federal government has also developed a supercluster focused on advanced manufacturing, including AM and Industry 4.0., to help manufacturers break into this segment. I think it is important for the additive sector that the Canadian government, through the supercluster, identified advanced manufacturing as important. One of the things I always say about additive, especially when I talk to companies, is that you can’t expect it to replace traditional manufacturing. That’s not the perceivable future. However, additive is a new and very powerful tool that can be a big advantage and competitive edge if it’s adopted in the correct manner.

Canada Makes, www.canadamakes.ca