Small series production
3D printing: an innovative solution for small batch production
Innovative solutions for small series production From the idea to the product:
The possibilities of small-batch metal production with 3D printing Small-batch production is a manufacturing process in which products are produced in small quantities. This can be useful for prototypes, custom-made products or spare parts, for example. Small series production differs from mass production primarily in terms of the flexibility and individuality of the products, but also in terms of the higher costs and the greater time required per unit. In this article, we will introduce you to the possibilities and methods of small-batch metal production and show you a practical example from Rosswag Engineering.
What is small series production?
Small series production is a type of production in which products are manufactured in small quantities. Small batch production is a form of series production that differs from mass production in terms of the flexibility and individuality of the products. It is particularly suitable for prototypes, custom-made products or spare parts. There are various manufacturing processes for small series production with metal, such as CNC milling, laser cutting or turning. A particularly innovative process is 3D printing with metal, in which the material is applied and fused layer by layer. 3D printing offers many advantages for small series production, such as a high degree of design freedom, low material waste and rapid adaptation to customer requirements. Small-batch production offers many advantages for the manufacture of high-quality, customized metal products.
What distinguishes small series production from mass production?
Small batch production and mass production are two different types of production that differ in several aspects. Small batch production is characterized by a small number of products, usually less than 20 units per month. Mass production, on the other hand, produces large quantities of products, often reaching over 1000 units per month. Small batch production requires more flexibility and adaptability of manufacturing processes and machines, such as CNC milling, laser cutting or 3D printing with metal. Mass production, on the other hand, uses standardized and automated processes and machines that guarantee high efficiency and quality. Small series production is suitable for prototypes, custom-made products or spare parts made of metal, while mass production is suitable for products with high demand and low variation.
Methods of small series production: advantages and disadvantages
Small series production includes various methods for manufacturing products in small quantities. Common methods include CNC milling, laser cutting and turning. These methods use computer-controlled machines that can process the metal precisely. One advantage of these methods is the high quality and accuracy of the products. A disadvantage is the high effort and costs involved in retooling the machines for different products. 3D printing with metal is an innovative method. One advantage of this method is the high flexibility and individuality of the products. A disadvantage is the lower strength and durability of the material compared to other methods.
Special features of small series production with metal
Small series production with metal has some special features that distinguish it from other types of production. One special feature is the high demands on the quality and precision of the metal products, which are often intended for special applications or industries. Another special feature is the high flexibility and adaptability of the manufacturing processes and machines, which make it possible to produce different products in small quantities. A third special feature is the use of innovative technologies such as 3D printing with metal, which opens up new possibilities for the design and function of products.
3D printing in small-batch metal production
Metal 3D printing is an innovative method for the small-batch production of metal products. Metal 3D printing makes it possible to create complex and customized shapes that are difficult or impossible to achieve with other manufacturing processes. Metal 3D printing can also save time and money, as less material is wasted and no expensive tools are required. There are different processes for metal 3D printing, each of which has its own advantages and disadvantages in terms of quality, speed and cost of production.
Advantages / disadvantages : SLM / FDM / DED
SLM (Selective Laser Melting), FDM ( Fused Deposition Modeling) and DED ( Direct Energy Deposition) are three different processes for 3D printing with metal. Each process has its own advantages and disadvantages for the small series production of metal products. SLM offers high precision and product quality, but also high costs and long printing times. FDM is simple and cost-effective, but also less durable and accurate than SLM. DED is fast and flexible, but also less precise and clean than SLM or FDM.
Make it yourself or have it made?
If you want to produce small series from metal, you have two options: Manufacture them yourself or have them manufactured. Self-manufacturing means that you use your own machines and processes for metalworking, such as CNC milling, laser cutting or turning. However, this requires a high level of investment, expertise and space. Manufacturing to order means that you commission a service provider to produce your products according to your specifications. One such service provider is Rosswag Engineering, which specializes in metal 3D printing. Metal 3D printing is an innovative manufacturing process that enables complex and individual geometries to be created from various metals. Rosswag Engineering offers you a globally unique variety of materials and high quality for your small series. The advantages of metal 3D printing include high flexibility, short delivery times and low material waste.
Materials in metal 3D printing small series production
Choosing the right material is an important factor for the quality and cost-effectiveness of small metal series. The most important materials for metal 3D printing are stainless steels, aluminum alloys, titanium alloys and tool steels. These materials offer various advantages for the additive manufacturing of metal parts, such as high strength, corrosion resistance, lightweight construction or wear resistance:
- Stainless steel is a commonly used material for metal 3D printing. It offers high strength, ductility and corrosion resistance. It is suitable for the production of tools, jewelry or medical devices.
- Aluminum is a lightweight, durable and strong material with good thermal and electrical properties. It is ideal for the production of lightweight structures, heat sinks or electronic components.
- Titanium is a lightweight and high-strength material with excellent biocompatibility. It is perfect for the production of implants, prostheses or aerospace parts.
- Tool steel is a hard and wear-resistant steel with high heat-treatability. It is used for the production of cutting tools, dies or molds.
Practical example from Rosswag
Rosswag Engineering, a leading service provider for metal 3D printing, is a practical example of the possibilities and methods of small-batch metal production. Rosswag Engineering offers a holistic and in-house process chain that ranges from design and 3D printing to CNC machining and material analysis. This enables Rosswag Engineering to produce functionally optimized metal components from many different alloys that are suitable for both prototypes and small series. Metal 3D printing allows you to realize complex geometries that would not be possible with conventional manufacturing processes such as milling or turning. Rosswag Engineering can also reduce material waste and increase product quality. One example of such a product is a turbine blade holder made from a high-strength nickel-based alloy, which has improved cooling and a longer service life thanks to metal 3D printing.
Conclusion: Trends in manufacturing
Small series production in metal offers many advantages for the manufacture of individual and high-quality products. By using modern manufacturing processes such as 3D printing, complex and functionally optimized geometries can be realized that would not be possible with conventional methods such as milling or turning. Small series production in metal is therefore an important trend in the manufacturing industry that is adapting to the increasing demands of customers and the market. If you would like to find out more about the possibilities and methods of small-batch metal production or have a specific project, then contact Rosswag Engineering, your expert partner for metal 3D printing. Rosswag Engineering has a globally unique variety of materials and an integrated process chain that offers you an efficient and economical solution for your requirements!