INDUSTRIAL CHALLENGES AND AGILE SOLUTIONS THROUGH ADDITIVE TECHNOLOGIES
In the era of global challenges and growing market demands, modern industry faces the need for more flexible and efficient production processes. Our company offers a comprehensive solution that combines reverse engineering with cutting-edge additive technologies, transforming the way industries approach the production of spare parts and tools.
-
UNPREDICTABLE SUPPLY CHAINS AND HIGH COSTS OF UNPLANNED DOWNTIME
According to a 2022 Siemens report , manufacturing companies lose an average of $129 million per year and 25 hours per month per plant due to unplanned downtime, with critical sectors such as the automotive industry losing up to $2 million per hour .
One of the most common causes of unplanned downtime is equipment failure (mechanical damage, component failure, failure of critical machinery) and long delivery times for spare parts.
Inefficiency in the procurement of spare parts is a critical problem for industrial systems, with over half of orders being delayed by more than 30% compared to the planned delivery time , directly threatening the continuity of production. The scale of this challenge is illustrated by research from 2022 , which reveals that as many as 78% of manufacturers have experienced a partial or complete stoppage of production lines due to the unavailability of necessary components .
-
THE PROBLEM OF PROCUREMENT OF OBSOLETE COMPONENTS
Obsolescence of components is an operational risk that can lead to unplanned machine downtime and loss of productivity. This is particularly pronounced in industries with long life spans cycles equipment (e.g. aviation industry, shipbuilding), where companies often encounter the situation that original components are no longer available and traditional procurement methods become unfeasible. [ 1 ]
By combining reverse engineering methods with modern additive manufacturing technologies , companies can quickly and at minimal cost produce the necessary parts, thereby reducing downtime and ensuring efficient machine operation over a longer period of time. The effectiveness of this approach is particularly significant in the case of critical components, where availability has a direct impact on the safety of operations (hydraulic systems, drive unit components). [ 2 ]
Key advantages :
-
Reconstruction of parts from the only remaining copy (original or damaged),
-
The possibility of optimizing the original design (e.g. weight reduction, improvement of resistance and strength of the part, integration of several functional components into one, more efficient component),
-
Eliminating the need for expensive tools in small batch production,
-
The possibility of creating a digital archive of spare parts and on-demand production,
-
The possibility of localized production, without additional logistics costs and long lead-time,
and all without capital investment!
APPLICATION PROCESS
-
WORK IDENTIFICATION
By getting to know the operations in your production process and analyzing the technical - logistical challenges you encounter in that process, we help you find space for a specific customized solution.
-
REVERSE ENGINEERING
Using a technical drawing or an original part, we offer the possibility of creating a 3D CAD model with high-precision 3D scanning and/or modeling in CAD software, as well as the preparation of accompanying technical documentation.
-
DESIGN OPTIMIZATION
In order to improve manufacturability, functionality and reliability, we offer the possibility of optimizing the part depending on its specific application and choice of manufacturing technology.
-
3D PRINTING
Using a farm of 3D printers of different technologies and a wide selection of engineering materials, we provide the possibility of rapid individual/serial production and subsequent processing of parts in our production sector and then deliver to your address.
Use case 1 : The process of obtaining a new, functional impeller from a damaged original part using reverse engineering methods and metal 3D printing - top-left to right: damaged impeller, preparing the part for 3D scanning, finishing the model in CAD software; bottom-left to right: prepared technical documentation of the part, a new part made with SLM 3D printing technology and finally - a functional part in the production environment.
Use case 2 : Stoppage of the production line due to the delay in the delivery of spare parts: k from a client whose factory runs non-stop, the shutdown of a critical part of the automatic line due to the failure of a small component was resolved in record time: in less than 48 hours, the part was scanned, produced using reverse engineering and 3D printing and then returned to the client, enabling the restart of the production line.
HOW TO CONTACT US?
Do you need urgent production of a critical component in your production process?
Do you want to materialize your idea and do you need help in creating a prototype?
Do you want to integrate 3D printing into your production processes, but you don't know how?
Not sure what is the right choice of 3D printing technology and material for making your piece?
Your production problem is our challenge!
You can contact us by e-mail at beograd@3drepublika.com and we will respond to your inquiry within 48 hours.
For print service requests, send us your 3D model in .STEP, .STL, .3MF or .OBJ format.
If you are not sure which is the right choice of 3D printing technology and material for making your part, describe to us its functionality and application, and we will provide you with the desired performance.
We can work with you on individual projects or continuously, and we provide our support during all phases of the service!
YOUR COMPANY NEEDS A FREE SAMPLE?
Send us your 3D model and we will send you a free sample worth up to 100 EUR, or give you a discount of 100 EUR, if the sample is more expensive.