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

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

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Authors

Luca Beltrametti

Angelo Gasparre

RICHARD HAGUE RICHARD.HAGUE@NOTTINGHAM.AC.UK
Professor of Additive Manufacturing



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

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