Additive manufacturing as a cost-effective way to produce metal parts

Recent developments in additive manufacturing technologies for the production of metal parts make this processes very attractive to high technology industries. Especially the geometrical freedom allow to produce components optimized for their functionality, disregarding limitations imposed by the manufacturing process. However, production costs should be evaluated to assess the convenience of additive manufacturing (AM) with respect to traditional technologies. Thus in this paper a break-even analysis is described, comparing the Selective Laser Melting (SLM) additive process with High Pressure Die Casting (HPDC) and 5-axis machining. Costs models are discussed for each process and benefits of applying redesign for additive manufacturing are illustrated. An aeronautical component is selected as case study to estimate the production volume for which additive manufacturing is cost-effective. The study proves the economical convenience of additive manufacturing with respect to traditional technologies from prototypes to small batch production. © 2014 Taylor & Francis Group.