Page 25 - 3D Metal Printing Winter 2018

“To be quite honest, I am disappoint- ed in the level of adoption of metal AM for toolmaking,” Staub says. “I'm not saying that metal AM is the best for every situation, but there are many cases where it should be used. Often it's just viewed as a future technology.”
High-level closed-mindedness com- monly reveals itself in three ways. First, expecting metal AM to be a single-step process in spite of the fact that milling, casting and forming usually are multi- step, multi-machine processes. Second, requiring metal AM to meet the highest output standards of current processes. Third, seeking only benefits in time or cost, especially with parts designed for the current process.
In a sense, it is a case of familiarity. Metal AM is unfamiliar, so its advantages may not be fully understood, and its lim- itations may fuel a perception of risk. On the other hand, traditional methods are so ingrained that the processes and out- comes are just accepted.
“All kinds of errors coming out of tool shops result in tools being welded or fixed con- stantly, and people think nothing of it because they've been doing it that way for years,” says Staub. “Yet, if metal AM can’t promise a tight tol- erance without a finish- ing pass on a CNC mill, these people may reject the solution.”
BasTech turns to these metal-AM machines for parts and tools as a complement to the company’s machining cen- ters.
Decisions based on price and time also fall into this familiarity conundrum that stymies open-mindedness. Rou- tinely, Staub encounters those that balk at a higher price for a metal-AM part, often designed to cater to the capabili- ties of the traditional process they hope to replace.
“They may be shocked by the price and that’s the end of the conversation,” he says. “But they don’t take the time to
understand or appreciate why and when metal AM makes sense.” 3DMP
Look for Part 2 in the next issue of 3D Metal Printing, where Staub offers real- life examples where metal AM makes sense for toolmaking, and Grimm pro- vides insightful commentary. Have a dif- ference of opinion or insights that you would like to share? Contact Brad Kuvin (bkuvin@pma.org), editor, to schedule an interview.
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