CARRER MEMO

SUBJECT: Requested Research Regarding Additive Manufacturing

In response to your request, I have researched information regarding additive manufacturing (AM) as it pertains to the engineering industry. In my research, I came across a helpful article, “Revolutionary Additive Manufacturing: An Overview”, by R.M. Mahamood. The article addresses several key concepts that could be implemented at Keystone Holdings to ultimately lower the costs of manufacturing standard and customized parts while increasing the efficiency of the overall process. The article also addressed, in detail, the various technologies available to those utilizing additive manufacturing.

Additive Manufacturing Overview

Over the past few decades, the additive manufacturing market has improved its 3D printers from technological and cost standpoints. With affordable, high quality machines on the market, many industries have begun the transition to AM, and I feel that it is time for Keystone Holdings to join this ‘revolution’. Traditional methods, such as subtractive manufacturing (SM) and formative shaping (FS), are known to be more laborious, energy intensive, and wasteful compared to AM methods.

Advantages of Additive Manufacturing Technology

· Reduces design error and production delay

· Reduces cost and lead time

· Reduces impact of manufacturing on environment

· Allows for production of high value products

· Allows for production of light weigh products (eliminating multiple parts and joints)

· Provides flexibility needed in manufacturing customized products

Additive Manufacturing and Product Development

An improved manufacturing process that utilizes AM could decrease the high lead times we are experiencing with the development of new products. AM not only generates detailed prototypes within a few hours, but also physical, end use products directly from CAD files. Ultimately, the process would cut down the time spent to introduce a new product from concept, to prototype, to final introduction into the market. Overall, AM is a lean and agile technology.

Additive Manufacturing and Customized Products

A demand for customized products, like our orthopedic braces, is slowly taking over the medical device industry. Incorporating AM technologies into our manufacturing process will aid us in meeting these recent consumer demands. AM will be able to provide our engineers with a flexible system to generate and produce customized products efficiently. The sooner we embark on this trend, the farther we will stand ahead of our competitors. Utilizing AM in the production of customized parts would set Keystone Holdings apart as the first company in our industry to do so, opening the floor to possible patents on new processes and products.

Concerns

Endless opportunities exist for the world of AM technology. However, being that the concept is relatively new, some areas are still working to be improved. Such areas include

· Dimensional Accuracy

· Surface Finish

· Productivity (for large volume parts)

· Repeatability and Reliability

Though these areas are still being perfected, AM offers unprecedented potential in the areas of product design and customization. The available technology would still help Keystone Holdings improve its existing manufacturing methods and redefine the way it approaches its custom market.

Conclusion

Keystone Holdings is currently experiencing high lead times in product development and facing a costly, wasteful process for producing customized parts and products. I propose that we address this issue by incorporating additive manufacturing technologies into our engineering and manufacturing departments. We must begin by continuing to research the technology that will best suite our needs and investing in AM soon in order to stay ahead of competing industries. I would be glad to further discuss AM and the specifics regarding additional research and investment.

Attached: “Revolutionary Additive Manufacturing: An Overview”