Use Case Can 3D printers replace entire CNC machining centers?

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For Walter Reckmeyer Werkzeug und Maschinenbau, CNC milling machines have long been the measure of all things. However, in some cases they are lagging behind the rapidly changing challenges. But initial attempts to get started with 3D printing failed. What to do?

The company Walter Reckmeyer has specialized as a toolmaker for injection molded parts in the automotive industry. For this area of activity, CNC milling of aluminum components has been the perfect process in the past. However, the requirements are gradually changing. A high variety of variants, small batch sizes, and intense competition from the Far East are becoming more and more challenges that the responsible parties have to overcome. For example, the demanded small quantities with lot sizes of one to two for cable overmolding have proved to be very cost-intensive.

Additive manufacturing promises light at the end of the tunnel. However, initial attempts with 3D printing and providers from the hobby sector failed due to the quality, accuracy and mechanical properties of the components.

Mechanically resilient components using 3D printing?

Since Jan Reckmeyer, second-generation managing director of the company, believes in the potential of AM, he does not just dismiss the subject but continues to explore. In his search, he comes across Markforged 3D printers and is impressed by the parts they produce. Particularly, the prospect of being able to produce plastic parts with strengths comparable to those of aluminum appeals to him. The reduced weight of the parts and lower production costs further convince him, leading Reckmeyer to ultimately order two industrial Markforged 3D printers. The devices include an Onyx One and a Mark Two, which is used for high-strength components. The latter allows for reinforcing the parts with continuous fiber made of carbon, Kevlar, or fiberglass.

Greater flexibility and efficiency

The printers are now scoring points in practical use due to time and cost savings. According to the company, both values have decreased by a factor of ten. Reckmeyer's customers also seem to accept the new manufacturing process, with requirements already geared towards additive manufacturing. For example, many customers expect the "Poka Yoke" principle of zero defects, which is then directly integrated, as stated by the company.

We save one CNC machining center including operator per 3D printer. Some of the new parts can no longer be produced conventionally from aluminum. The geometries are too complicated. The effort involved would be many times greater.

Jan Reckmeyer, Managing Director, Walter Reckmeyer Werkzeug- und Maschinenbau

Jan Reckmeyer is now certain that he will continue to use additive manufacturing to produce resilient components for the automotive industry in the future. The process is not intended to replace conventional machining, but to complement it.