Informing additive manufacturing technology adoption: total cost and the impact of capacity utilisation

Baumers, Martin; Beltrametti, Luca; Gasparre, Angelo; Hague, Richard

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.

Citation

Baumers, M., Beltrametti, L., Gasparre, A., & Hague, R. (in press). Informing additive manufacturing technology adoption: total cost and the impact of capacity utilisation. International Journal of Production Research, 55(23), https://doi.org/10.1080/00207543.2017.1334978

• Journal Article Type: Article
• Acceptance Date: May 12, 2017
• Online Publication Date: Jun 6, 2017
• Deposit Date: Jun 7, 2017
• Publicly Available Date: Jun 7, 2017
• Journal: International Journal of Production Research
• Print ISSN: 0020-7543
• Electronic ISSN: 1366-588X
• Publisher: Taylor and Francis
• Peer Reviewed: Peer Reviewed
• Volume: 55
• Issue: 23
• DOI: https://doi.org/10.1080/00207543.2017.1334978
• Keywords: rapid manufacturing, cost estimating, operational research, additive manufacturing, build volume packing, technology selection
• Public URL: https://nottingham-repository.worktribe.com/output/864743
• Publisher URL: http://www.tandfonline.com/doi/full/10.1080/00207543.2017.1334978
• Additional Information: This is an Accepted Manuscript of an article published by Taylor & Francis in International Journal of Production Research on 6 June 2017, available online: http://www.tandfonline.com/10.1080/00207543.2017.1334978
• Contract Date: Jun 7, 2017