Introduction
After the first three industrial revolutions, the 21st century ushered the next industrial revolution. Industry 4.0 introduces what has been called the 'smart manufacturing' process, in which cyber-physical systems monitor the physical processes of a factory and make decentralized decisions. The physical systems become Internet of Things (IoT), communicating and coordinating both with each other and with humans in real time via the wireless web.
It is said that Industry 4.0 is more than changes in the business process; it is a disruptive technology that will radically change the way businesses / manufacturing is conducted. It will give machines that little bit of intuition – with the help of artificial intelligence, augmented reality and virtual reality - that will help them do mindless and repetitive jobs without human intervention, allowing humans to focus more on their core competencies.
At the heart of Industry 4.0 is digital transformation. At the end of this transformation process, successful industrial companies will become true digital enterprises with physical products at the core, augmented by digital interfaces and data-based, innovative services. These digital enterprises will work together with customers and suppliers in industrial digital ecosystems.
The essential components or framework of Industry 4.0 comprise: Big data, Model Simulation, Cloud Technology, Augmented Reality, 3D Printers / Additive Manufacturing, Industrial Internet of Things (IIoT), Artificial Intelligence, Autonomous Robots and Cyber security.
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Industry 4.0 and 3D Printers
3D printers are a vital part of Industry 4.0. While 3D printers hit the market way back in the 80s, commercially viable 3D printing has been possible only in the last decade or so, thanks to pioneering efforts by companies like Stratasys and others. 3D printing technology today is at a stage where companies are starting to realize significant, tangible new value for themselves and their customers using them. Leading corporates and consultants across the world are making significant investments in 3D printing knowledge and capabilities so that they can advise and join their clients in the Industry 4.0 wave and revolutionize supply chains, product portfolios, and business models in the process. This augurs well for the 3D printing industry and leading manufacturers (like Stratasys).
The parameters that have significantly altered and tipped the scale in favour of 3D printers are following:
Printing speed: 3D printers are great for mass customization, but the earlier printers were a bit too slow for real-life printing needs. To digitally transform the manufacturing industry, parts need to be printed in minutes, not hours. As 3D printing technology improves, the speed of the printers has improved too.
Quality: the earlier 3D printers were not extremely accurate, especially when it came to printing complex designs. However, improvement is 3D software and technology has removed this hindrance.
Safety: Most of the earlier 3D printers used technology that required them to operate at high temperatures. The printers were bulky as well. However, the latest 3D printers from leading manufacturers like Stratasys have bought about significant changes in the way printers work.
Environmental impact: Traditional manufacturing wastes a lot of material. In most cases, it increases the carbon footprint. 3D printing reduces waste, and environmentally conscious manufacturers can use earth friendly, biodegradable material. In addition, the newest 3D printers can also make a single copy if need be. This reduces unsold inventory. As a result, discontinued or unsold products do not end up piling up in landfills.
Choice of Printing Material: This is one of the biggest game changers that work in favour of 3D printers. Today's 3D printers can print almost everything - from metal to food. As the choice of material increases further, industries will find it easier (read: affordable) to manufacture almost anything the customers desire. What is more, manufacturing quantity will not be a deterrent either - 3D printers will be able to print even a single, custom made cake or a single microchip.
Software and 3D printing: One of the key components of Industry 4.0 is big data. As new software becomes available that is capable of processing this big data (e.g. ThingWorx and Vuforia from PTC), it will only increase the importance of 3D printers in the future, as this data can be directly fed to them while prototyping.
Price: Ultimately, manufacturing industry will embrace digital transformation only if the price is right. Apart from speed concerns, one of the biggest obstacles for mass scale digitalization was the high cost of 3D printers. As the competition hots up and more and more small players enter the fray, the cost of 3D printers will keep on dropping. As the prices drop, more and more consumers will start buying 3D printers, benefitting everyone in the process.
3D Printing in Industry 4.0 - who Benefits the Most?
By and large, most manufacturing industries are set to benefit from adopting 3D printing technology at the earliest. However, most tangible benefits will be reaped by automotive and large manufacturing companies, due to the significant cost savings associated with digitalizing their inventory. Other companies that are likely to benefit earlier include consumer manufacturing, defence equipment manufacturers and healthcare companies, especially those in dental healthcare and prosthetics.
To summarize, we are on the threshold of another industrial revolution called Industry 4.0. As the speed, reliability, safety and quality of 3D printers improves, and the cost reduces, 3D printers are set to play an important role in this digital transformation of industry. As the performance of 3D printers improves rapidly and the cost decreases, new opportunities will arise that will take 3D printing ever closer to mass production. As 3D printing develops, the range of products that can be manufactured is also set to grow. Rate of development of specialized printing materials, integration of digital security to protect IP and certification of 3D products by regulatory agencies will boost adoption of 3D printers in Industry 4.0 But of course it is the willingness of innovative manufacturers who choose to embrace the tenets of Industry 4.0 and digitalize their businesses fast who will benefit the most.