Interview: All about 3D Print Manufacturing

Join Midlands 3D founder, Paul Moloney as he talk with his brother Andrew about the evolution of 3D Printing technology, the opportunities it presents and examples of how customers are using it for batch manufacturing today.

Chapters:
00:00 Introduction
01:01 Midlands 3D History
03:10 Growing Demand
05:23 FDM Explained
07:51 Transition to Production
13:06 Supply Chain Benefits
21:51 Digital Warehousing
24:13 Multi jet Fusion (MJF)
34:40 Future of 3D Printing
49:35 Contact Info

Summary:

Introduction and Personal Background
- Andrew Visits Paul: Andrew Moloney visits his brother Paul in Staffordshire to learn about 3D printing and Midlands 3D. They haven't seen each other in three years, providing an opportunity for Andrew to ask "dumb questions" on behalf of those new to the topic.
- 3D Printing Initiation: Paul shares his initial foray into 3D printing in 2017 with a hobbyist wooden-framed 3D printer, sparking interest from a local manufacturer who needed custom brackets, leading to the creation of Midlands 3D.

Earl Growth and Business Foundation
- Initial Orders and Scaling: After Paul's first commercial order of 300 brackets, he quickly scaled operations from a single wooden printer to 15 machines in his garage within 12-18 months, showcasing growing demand.
- Transition to Full-Time Business: Paul balanced the growing side hustle with his full-time job until it necessitated a larger operation, moving to a dedicated unit on the Whitebridge estate, hiring additional staff, and officially establishing Midlands 3D.

Technology and Evolution
- What is FDM?: Introduction to Fused Deposition Modelling (FDM), a common 3D printing technology that draws parts layer by layer using melted filament. It’s cost-effective for low-volume, functional applications where form is less critical.
- Limitations and Evolution: While FDM technology is useful for prototyping and hobbyist applications, the evolution towards more industrial applications led to adopting advanced technologies like HP Multi Jet Fusion (MJF).

Adapting to Market Needs and Customisation
- From Prototyping to Production: Early on, Midlands 3D transitioned from producing prototypes to larger orders as clients needed volumes they couldn’t produce in-house, like batches of 500 parts.
- Customisation and Flexibility: 3D printing’s ability to produce customised and iterative designs on demand, without the need for costly injection moulding tools, is highlighted as a key advantage for small organisations to minimise cash flow issues.

Technology Overview and Capabilities
- Explaining MJF: Multi Jet Fusion uses a powder-based approach enabling high-volume, high-quality, strong parts without the need for support materials. This method contrasts with FDM's filament-based process.
- Efficient Production: Paul's explanation includes how MJF allows efficient production by filling a print volume with various parts, supporting parallel production of different orders.

Impact on Supply Chain and Manufacturing
- Near-Sourcing Benefits: Producing parts closer to customers cuts down on transport costs and supply chain fragility, emphasising digital warehousing and on-demand production.
- Economic Impact: Highlighting cases like Synetica, where on-demand part production avoids large inventories and adapts quickly to changing electronic components, reducing waste and increasing agility.

Future Trends and Industry Direction
- Sustainability and Efficiency: Midlands 3D incorporates recycled materials and aims to reduce waste. The interview discusses the future of 3D printing in sustainability, where on-demand and digital warehousing play significant roles.
- Technological Growth: On the larger industry scale, the discussion addresses the anticipated growth of 3D printing technologies as younger generations bring fresh ideas, and companies recognize the efficiency and customization possibilities.

Conclusion and Contact Information
- Getting in Touch: Paul encourages interested parties to contact Midlands 3D for consultations, highlighting the flexibility and personal engagement offered by their service. They can be reached via their website, social media, and direct phone calls.