In the near future, an increasing number of die manufacturers in India are expected to realise the immense potential of this technology in addressing productivity and quality challenges in end part production, ” says Vishwas Puttige, Business Head, amace solutions Pvt. Ltd.
By Nishant Kashyap
How would you describe the recent advancements in 3D printing technology and their potential impact on various industries?
In recent times, there have been remarkable advancements in 3D printing technology, particularly in the field of metal printing. These advancements have primarily focused on three key areas: the development of new materials, the enhancement of process quality, and the improvement of productivity. We are pleased to report that the industry has made significant progress in all three aspects. As a result, there has been a notable increase in the adoption of this technology, leading to a growing number of emerging applications.
The continuous development of new materials has played a vital role in the advancement of 3D printing. These materials are specifically designed to cater to various applications and are compatible with highly productive printing machines. As a result, manufacturers are increasingly choosing 3D printing as their preferred manufacturing method.
In your opinion, what are the key factors driving the growth of the 3D printing industry in India?
In recent years, India has undergone a significant paradigm shift, with a strong emphasis on developing indigenous capabilities in various sectors such as aerospace, defence, electronics, and more. One technology that has shown immense potential in aiding new product development and R&D efforts, particularly from a manufacturing standpoint, is 3D printing. This technology has played a pivotal role in driving the growth of 3D printing in the country.
How do you see the adoption of 3D printing technology evolving in India in the next few years?
India has positioned itself as a prominent global manufacturing hub, attracting numerous foreign investments and nurturing the development of homegrown entities. As the country’s needs continue to expand, it becomes increasingly vital for industries to embrace advanced manufacturing technologies like 3D printing. The rise of key sectors such as defence, space, and aviation has further amplified the demand for 3D printing, and this demand is expected to grow exponentially. With increased adoption, the overall cost of manufacturing also drops thereby fuelling further growth.
How do you envision 3D printing technology transforming the die & mould making industry in India?
The die and mould industry has been an early adopter of 3D printing, recognising its clear use case in the form of conformal cooled dies and inserts for plastic injection moulding and die casting applications. This particular strength of 3D printing has the potential to make a significant impact by reducing cycle time and minimising rejection rates of end parts. In the near future, an increasing number of die manufacturers in India are expected to realise the immense potential of this technology in addressing productivity and quality challenges in end part production. Previously, the lack of awareness within the Indian die & mould fraternity about 3D printing hindered its adoption. However, in recent years, this scenario has changed as more and more die and mould makers, ranging from corporate to MSME segments, are opting to explore the benefits of conformally cooled inserts for their applications.
What are the main advantages that 3D printing offers die and mould makers in terms of efficiency, cost savings, and design possibilities?
In the majority of plastic injection moulding cases, we have observed a remarkable increase in productivity of the injection moulding process, ranging from 30% to 60%, as a direct result of minimising cooling time. From a cost perspective, customers benefit from longer-lasting dies, reduced costs associated with poor quality, and quicker availability of dies. The utilisation of 3D printing enables the design of complex geometries with relative ease, facilitating the creation of intricate conformally cooled channels. Additionally, the technology allows for the validation of different designs before proceeding with mass production.
What points should die and mould makers keep in mind when incorporating 3D printing into their manufacturing processes?
Similar to any other industry, it is crucial for manufacturers in the die and mould sector to comprehend the value addition that 3D printing can bring to their dies or inserts. Nowadays, with the advancements in simulation software, customers who opt for conformally cooled dies or inserts have the opportunity to simulate the benefits in a virtual environment. This enables them to make informed decisions regarding the necessity of implementing 3D printing technology.
Moreover, die and mould makers should be well-informed about certain limitations associated with 3D printing. These limitations include considerations such as the size of the parts, availability of suitable materials, dimensional tolerances of the printed part, surface finish, and the requirement for post-processing. Additionally, the design of conformal cooling channels plays a crucial role in determining the level of productivity improvement that can be achieved.
Are there any specific materials or technologies that are particularly suitable for die and mould production using 3D printing?
Maraging steel (18Ni300) has emerged as the most popular 3D printed material for the die and mould industry, showcasing remarkable performance and superior durability compared to conventional tool steels. In addition to Maraging steel, we have also introduced H13 as an alternative option for our die and mould customers, providing them with a wider range of material choices to suit their specific requirements.
In terms of technology, Laser Powder Bed Fusion (LPBF) stands as the preferred choice for the die and mould sector. LPBF offers several advantages, including high density, exceptional strength, intricate detailing capabilities, and minimal shrinkage. The dimensional accuracy achieved through LPBF surpasses that of other metal 3D printing technologies, making it highly favoured among manufacturers in the die and mould industry.
How important is training and skill development in order to fully leverage the benefits of 3D printing in die and mould making?
Inspite of significant improvements in the adoption of 3D printing in the country, we are still at a relatively early stage when we look at its implementation. To propel this technology to the next level, training and skill development will undoubtedly play a crucial role. All stakeholders in the 3D printing field are actively contributing to the training and development of a skilled workforce. However, it is important to acknowledge that this endeavour cannot be achieved in isolation. Industry bodies such as TAGMA must collaborate closely with the additive manufacturing community to bring this technology to a wider audience.
Creating awareness about 3D printing needs to start from the top management level within organisations. Building this awareness is vital to foster a long- term vision for the technology and to harness its sustained benefits. It requires a collective effort from industry leaders, professionals, and organisations to promote the understanding and utilisation of 3D printing across various sectors.
This interview was first published on TAGMA Times Newsletter
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