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International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P) Volume-8, Issue-8, August 2018
3 www.erpublication.org
Abstract — Industry 4.0 is the recent move into intelligent
technology automation. In this new era the use of modern skills
of Additive Manufacturing within the context of information
technology integration plays an important role in industrial
economic competitiveness. This short review provides a basic
understanding of the role of 3DP technology in the Industry 4.0.
As can be seen, there’s no doubt that 3DP technologies are
leading to the next major industrial revolution. Due its
versatility the Additive Manufacturing plays a key-role in the
Industry 4.0, saving time and costs, being decisive for process
efficiency and reducing its complexity, allowing for rapid
prototyping and highly decentralized production processes.
Currently, more and more industrial segments are adopting
AM. The smart factories of the future have all processes
interconnected by the Internet of Things, incorporating greater
flexibility and individualization of manufacturing processes.
Index Terms — 3D Printing, Industry 4.0, Production
Process, Smart factory
I. INTRODUCTION
A production chain is the process of turning raw materials
into commodities. However, many steps are required to
convert the available resources into products, such as design,
planning, manufacturing and sales. Recently, the production
chain procedure seems to have changed, since additive
manufacturing (AM) technology or 3D printing (3DP) has
transformed its steps. Custom products with difficult
geometries can be designed and printed with the help of
additive technology. Thus, markets can be supplied without
requiring companies to store or produce commodities at great
expense [1].
While there are still some doubts about its applicability in
mass production, the use of AM in industry 4.0 is on the rise
due to new advances. Being a technology in development to
create precise objects with high speed of production, this one
can offer a way to replace the conventional manufacturing
techniques in the near future. Thanks to increased product
quality, AM is currently being used in a number of industries,
including aerospace, biomedical, and food [2].
Digitization and intelligentization of manufacturing
process is the need for today’s industry. The manufacturing
industries are currently changing from mass production to
customized production. The rapid advancements in
manufacturing technologies and applications in the industries
help in increasing productivity [3].
Diogo José Horst, Department of Exact and Earth Sciences, Federal
University of São Paulo, Brazil, 09913-030, Phone: +55(11)4044-0500.
Charles Adriano Duvoisin, Department of Exact and Earth Sciences,
Federal University of São Paulo, Brazil, 09913-030.
Rogério de Almeida Vieira, Department of Exact and Earth Sciences,
Federal University of São Paulo, Brazil, 09913-030.
The term Industry 4.0 stands for the fourth industrial
revolution which is defined as a new level of organization and
control over the entire value chain of the life cycle of
products; it is geared towards increasingly individualized
customer requirements. Industry 4.0 is still visionary but a
realistic concept including: Internet of Things (IOT),
Industrial Internet (II), Smart Manufacturing (SM) and
Cloud-based Manufacturing (CBM). Industry 4.0 concerns
the strict integration of human in the manufacturing process
so as to have continuous improvement and focus on value
adding activities and avoiding wastes [4]. The physical part of
intelligent factories is limited by the capacity of existing
manufacturing systems. This way, due to the need for mass
customization in the 4.0 industry new non-traditional
manufacturing methods are constantly developed. Thus AM
has become a key technology for manufacturing custom
products because of its ability to create sophisticated objects
with advanced attributes [5]. The Figure 1 presents a
comparison between the conventional industry process and
3DP process:
Fig. 1 Classical procedure (a) and the 3DP procedure (b) [1].
Compared to traditional manufacturing, the general
advantages of additive manufacturing are the capabilities in
design and development of products. Despite certain
limitations, companies are using AM increasingly to use the
many possible benefits like complexity-for-free
manufacturing. In traditional manufacturing there exists a
direct connection between complexity and manufacturing
costs [6].
Designs intended for traditional manufacturing are often
heavily limited by high costs in construction and tool-making.
The greater freedom of design via AM makes it possible to
combine an assembly of parts into one part and, therefore, to
reduce the required assembly work and costs. In addition, no
compromises regarding the assembly capabilities are
necessary [7]. 3DP is emerging as an enabling technology for
a wide range of new applications. From the point of view of
the fundamentals, the available materials, speed of
manufacture and resolution of the 3DP processes should be
considered for each specific application [8]. Currently there
are machines that allow the printing of 3D shapes by various
techniques: extruder (fused filament), chemical agent (binder)
Additive Manufacturing at Industry 4.0: a Review
Dr. Diogo José Horst, Dr. Charles Adriano Duvoisin, Dr. Rogério de Almeida Vieira
Additive Manufacturing at Industry 4.0: a Review
4 www.erpublication.org
or laser (sintering / fusion), this process being technically
known as additive manufacture (MA), which has several
advantages [9].
Industry 4.0 is the recent move into intelligent technology
automation. In this new era the use of modern skills of AM
within the context of information technology integration plays
an important role in industrial economic competitiveness.
Within this context, this short review provides a basic
understanding of the fundamentals of 3DP technology into the
Industry 4.0.
II. LITERATURE REVIEW
A. 3DP Materials
Freedom of design, mass customization, waste
minimization and the ability to fabricate complex structures
are the main benefits of additive manufacturing. The current
state of 3DP material development includes the use of metal
alloys, polymer composites, ceramics, wood, fibers, and
composites, concrete among numerous others [10]. The 3DP
technology covers a wide range of materials used in a variety
of industries (including aerospace, automotive, dental,
jewelry, oil and gas, orthopedics printed electronics, and
tooling [11].
The Figure 2 presents an overview of the main materials
most used in AM:
Fig. 2 General overview of current research materials for AM
in the forthcoming era [12].
The components considered for driving the additive
manufacturing cost are material cost, labor cost, machine
cost, and energy consumption. Material cost constitutes major
proportion of additive manufacturing cost for laser sintering
process. Labor cost would be 2- 3% and energy consumption
is less than 1% [13].
Metal AM started to gain attention in aerospace, oil and
gas, marine, automobile, manufacturing tools and medical
applications because of the advantages offered by this
process. Every part manufactured by AM can be unique and
produced in very short time which enables mass
customization. AM also reduces assembly requirements by
integrating number of parts required in assembly into a single
part. It reduces overall weight, decreases manufacturing time,
reduces number of manufacturing processes required, reduces
cost and material requirements and optimizes required
mechanical properties [14].
Recently, one of the actively researched areas lies in the
additive manufacturing of smart materials and structures.
Smart materials are those materials that have the ability to
change their shape or properties under the influence of
external stimuli. With the introduction of smart materials, the
AM-fabricated components are able to alter their shape or
properties over time (the 4th dimension) as a response to the
applied external stimuli. Hence, this gives rise to a new term
called 4D-printing (4DP) including structural reconfiguration
over time [15].
B. 3DP Processes Technology
Recently, three-dimensional printing has been highlighted
as it shows a great promise to perform almost all structural
parts from computer aided drawing (CAD). Several different
processes are available for 3D printing, which includes fused
deposition modeling (FDM), selective laser sintering (SLS),
stereolithography (SL), photopolymerization (PPT) among
others [16].
The Figure 3 shows the processes currently most used in
AM:
Fig. 3 Categorization of AM processes in the current
state-of-the-art [12].
The basic principle of SL process is the
photopolymerization, which is the process where a liquid
monomer or a polymer converts into a solidified polymer by
applying ultraviolet light which acts as a catalyst for the
reactions; this process is also called ultraviolet curing. It is
also possible to have powders suspended in the liquid like
ceramics [17].
Prometal is a 3DP process to build injection tools and dies.
This is a powder-based process in which stainless steel is
used. The printing process occurs when a liquid binder is
spurt out in jets to steel powder [18].
Already SLS is a 3DP process in which a powder is sintered
or fused by the application of a carbon dioxide laser beam
[19-20].
FDM is an 3DP process in which a thin filament of plastic
feeds a machine where a print head melts it and extrude it in a
thickness typically of 0.25 mm. Materials used in this process
are polycarbonate (PC), acrylonitrile butadiene styrene
(ABS), polyphenylsulfone (PPSF), PC-ABS blends, and
PC-ISO, which is a medical grade PC. The main advantages
of this process are that no chemical post-processing required,
no resins to cure, less expensive machine, and materials
resulting in a more cost effective process [21-22]. The
disadvantages are that the resolution on the z axis is low
compared to other additive manufacturing process (0.25 mm),
so if a smooth surface is needed a finishing process is required
and it is a slow process sometimes taking days to build large
complex parts [23]. To save time some models permit two
modes; a fully dense mode and a sparse mode that save time
but obviously reducing the mechanical properties [24].
Electron beam melting (EBM) is a process that melts the
powder using an electron laser beam powered by a high
International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P) Volume-8, Issue-8, August 2018
5 www.erpublication.org
voltage, typically 30 to 60 KV. The process takes place in a
high vacuum chamber to avoid oxidation issues because it is
intended for building metal parts. Other than this, the process
is very similar to SLS. EBM also can process a high variety of
pre-alloyed metals. One of the future uses of this process is
the manufacturing in outer space since it is all done in a high
vacuum chamber [25-26].
Polyjet is an AM process that uses inkjet technologies to
manufacture physical models. The inkjet head moves in the x
and y axes depositing a photopolymer which is cured by
ultraviolet lamps after each layer is finished. The layer
thickness achieved in this process is 16 µm, so the produced
parts have a high resolution. However, the parts produced by
this process are weaker than others like stereolithography and
selective laser sintering. A gel-type polymer is used for
supporting the overhang features and after the process is
finished this material is water jetted. With this process, parts
of multiple colors can be built [27-28].
It is noteworthy that multi-material extrusion in 3DP is
gaining attention due to a wide variety of possibilities offered,
especially driven by the commercial availability of a wide
variety of unconventional filament materials. As a result, it is
possible to print models that are not limited to aesthetic
purposes, but now can also provide greater functionality and
therefore with mechanical performance adjusted for its
purpose [29-30].
The use of AM techniques are shown to be advantageous
for parts which have a high buy: fly ratio, have a complex
shape, have a high cost of raw material used for machining
from solid, have slow machining rates and are difficult and
expensive to machine. The specific cost of material deposited
by additive manufacturing systems required to give a 30%
saving over conventional Machine from solid techniques is
estimated for a typical aerospace-Titanium alloy over a range
of buy: fly ratios [31-32].
C. Additive Manufacturing in Industry 4.0
As shown in Figure 4, the Industry 4.0 offers cybernetic
and physical systems to cooperate profitably with the goal of
building intelligent factories, redefining the role of human
beings:
Fig. 4 Schematic of smart factories with general properties
required in Industry 4.0 [12].
The term Industry 4.0 has many meanings. It seeks to
describe the intelligent factory, with all processes
interconnected by the Internet of Things. The first advances in
this field involved the incorporation of greater flexibility and
individualization of manufacturing processes [33].
The paradigm of Industry 4.0 is essentially outlined by three
dimensions: (1) horizontal integration across the entire value
creation network, (2) end-to-end engineering across the entire
product life cycle, as well as (3) vertical integration and
networked manufacturing systems [34].
The Industry 4.0 is encouraging the integration of
intelligent production systems and advanced information
technologies. Additive manufacturing is considered an
essential ingredient in this new movement [12].
In Industry 4.0 the use of the 3DP technology will be
decisive for process efficiency and reducing complexity,
allowing for rapid prototyping and highly decentralized
production processes: the product model could simply be off
to the 'printing' site nearest to the customer, eliminating
intermediate manufacturing steps, transportation and
warehousing [35].
Table 1 provides an overview of the main trends and
expected development for the different value creation factors
in Industry 4.0:
Equipment
The manufacturing equipment will be characterized
by the application of highly automated machine
tools and robots. The equipment will be able to
flexibly adapt to changes in the other value creation
factors, e.g. the robots will be working together
collaboratively with the workers on joint tasks [36].
Human
The current jobs in manufacturing are facing a high
risk for being automated to a large extent. The
numbers of workers will thus decrease. The
remaining manufacturing jobs will contain more
knowledge work as well as more short-term and
hard-to-plan tasks [37]. The workers increasingly
have to monitor the automated equipment, are
being integrated in decentralized decision-making,
and are participating in engineering activities as
part of the end-to-end engineering [34].
Organization
The increasing organizational complexity in the
manufacturing system cannot be managed by a
central instance from a certain point on. Decision
making will thus be shifted away from a central
instance towards decentralized instances. The
decentralized instances will autonomously consider
local information for the decision making. The
decision itself will be taken by the workers or by the
equipment using methods from the field of artificial
intelligence [34].
Process
Additive manufacturing technologies also known
as 3D printing will be increasingly deployed in
value creation processes, since the costs of additive
manufacturing have been rapidly dropping during
the last years by simultaneously increasing in terms
of speed and precision. This allows designing more
complex, stronger, and more lightweight
geometries as well as the application of additive
manufacturing to higher quantities and larger scales
of the product [38].
Product
The products will be manufactured in batch size one
according to the individual requirements of the
customer [34].This mass customization of the
product integrates the customer as early as possible
in the value chain. The physical product will be also
combined with new services offering functionality
and access rather than product ownership to the
customer as part of new business models [38].
D. Industrialization of 3DP Technology
Nowadays, industrial companies face more and more
complex challenges in product development. Customers ask
for innovative, individually tailored products with a high
Additive Manufacturing at Industry 4.0: a Review
6 www.erpublication.org
product quality for a reasonable price. In addition, the
economic lifespan of products decreases which forces the
companies to shorten their time to market and their
development cycles [39].
Through globalization the competition in fertile markets
increases. Imitators from foreign markets make it harder for
the companies to maintain achieved market shares [40]. One
solution to increase innovation and shorten the time to market
is delivered by a new production technology, the AM [6].
At present, AM technology is gradually becoming the core
technology [41] and there is a growing consensus that 3DP
technologies will be one of the next major technological
revolutions [42].
The Figure 5 shows the 3DP procedure future Industry 4.0:
Fig. 5 The 3DP procedure in the future [1].
Some applications of 3DP technology in various industrial
segments are listed below:
Pharmaceutical Industry: 3DP is expected to be a highly
revolutionary technology within the 4.0 pharmaceutical
industry. In particular, 3DP's key benefits lie in the production
of small batches of drugs, each with custom dosages, shapes,
sizes and release characteristics. In this way the manufacture
of personalized medicines becomes a reality. In the short
term, 3DP could be extended throughout the drug
development process, from pre-clinical development and
clinical trials to first-line medical care [43]. The exploration
of the emerging technologies of the pharmaceutical industry
4.0 facilitates the creation of sustainable value, leads to a
more agile, intelligent and personalized pharmaceutical
industry and, in the long run, allows pharmaceutical
companies to obtain competitive advantages. A more
sustainable pharmaceutical supply chain should be
implemented to combine future operations and management
of pharmaceuticals throughout the entire life cycle [44].
Biomedicine: The 3DP of human organs is one of the latest
advances in the medical industry of the world today. With the
help of current bioprinting technology, it is possible to print
human organs directly from cells. In today's world, millions of
dollars have been spent on many research and education
institutes to eliminate the limits of organ imprinting. The goal
of the researchers is to replace a human organ successfully. In
the process of organ printing, various machines and materials
are searched around the world. The most printed organs with
this technology are tissues of the liver, cartilage, skin, heart
and bone, etc. Some of the major challenges in these
technologies rely on the printing of living organs (print organ
life), printing environments and post-processing (such as
autoclaving). Advances in this area clearly show that
researchers are very close to the future, where the replacement
of the human organ by the printed organ is attainable [11]. 3D
printing has already been proved viable in several medical
applications including the manufacture of eyeglasses, custom
prosthetic devices and dental implants [45]. Also, 3DP is
becoming popular due to the ability to directly print porous
scaffolds with designed shape, controlled chemistry and
interconnected porosity. Some of these inorganic scaffolds
are biodegradable and have proven ideal for bone tissue
engineering [46]. 3D printing is emerging as a powerful tool
for tissue engineering by enabling 3D cell culture within
complex 3D biomimetic architectures [47].
Food Industry: In recent years 3DP of food has been widely
investigated in the food industry, due to its many advantages
such as customized food designs, personalized nutrition,
simplified supply chain and expanding food material
available. However, in order to obtain an accurate impression,
three main aspects should be considered: material properties,
process parameters and post-processing methods, with special
attention to rheological properties, bonding mechanisms,
thermodynamic properties, pretreatment methods and
powders -processing. In addition, there are three main
challenges in 3DP of food: 1) accuracy and accuracy of
printing 2) process productivity and 3) production of
multicolored, multi-flavored products [48-49].
Fashion industry: 3DP shows a number of advantages
compared to traditional manufacturing processes, including
an accelerated design process, less-production time, and
lower costs related to inventory, warehousing, packaging, and
transportation. This paper discusses the five types of 3DP
methods that exhibit great potential in an application of
fashion, including stereolithography, selective laser sintering,
fused deposition modelling, PolyJet, and binder jetting [50].
Electrical components: 3D printing is a unique technology
that potentially offers a high degree of freedom for the
customization of practical products that incorporate electrical
components, such as sensors in wearable applications. The
availability of inexpensive, reliable, electrically conductive
material will be indispensable in the fabrication of such
circuits and sensors before the full potential of 3D printing for
customized products incorporating electrical elements can be
realized. To date, 3D printable conductive filaments with
sufficiently high conductivities to fabricate practical circuits
remain lacking for fused deposition modeling [51].
Casting Industry: The application of the technology of 3DP
foundry moulds permits a considerable acceleration of works
at prototype castings, enabling a reduction of foundry-mould
printing costs. In order to reduce printing costs, a shell mould
may be made and then complemented with cheaper molding
material. The technology of foundry mould making in
three-dimensional printing process offers huge manufacturing
potential. That is why; a further research on its application for
various cast elements of non-ferrous alloys is advisable [52].
So, there is a growing consensus that 3D printing
technologies plays a major role in technological industrial
revolution. History has shown that technological revolution
without adequate business model evolution is a pitfall for
many businesses. In the case of 3DP, the matter is further
complicated by the fact that adoption of these technologies
has occurred in four successive phases (rapid prototyping,
rapid tooling, digital manufacturing, and home fabrication)
that correspond to a different level of involvement of 3DP in
the production process [42].
International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P) Volume-8, Issue-8, August 2018
7 www.erpublication.org
III. CONCLUSION
There’s no doubt that 3DP technologies are leading to the
next major industrial revolution. Due its versatility the
Additive Manufacturing plays a key-role in the Industry 4.0,
saving time and costs, being decisive for process efficiency
and reducing its complexity, allowing for rapid prototyping
and highly decentralized production processes. Currently,
more and more industrial segments are taking advantage of
AM. The smart factories of the future have all their processes
interconnected by the Internet of Things, incorporating
greater flexibility and individualization of manufacturing
processes.
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Diogo José Horst PhD in Production Engineering
from Federal Technological University – Paraná
–UTFPR (2017), currently a researcher of the
Department of Earth and Exact Sciences from the
Federal University of São Paulo - UNIFESP, working
in the following areas: Production Engineering,
Bioengineering, Nanotechnology, Ceramic Materials, Polymerics and
Metals, Electro-Mechanics, Renewable Energies, and Innovation,
Technology and Sustainability.
Charles Adriano Duvoisin PhD in Biomedical
Sciences by the Italian Institute of Rosario (2015).
Post-Doctorate in Chemical Engineering by the
Federal University of São Paulo - UNIFESP (2018) and
Post-Doctorate in Life Sciences by the University of
Coimbra (2018).. Currently develops scientific
research in the field of Food Safety,Quantum Physics
and technological applications.
Rogério de Almeida Vieira PhD in Space
Engineering and Technology by the National Institute
of Space Research (2005), post-doctorate by the
National Institute of Space Research (2005),
postdoctoral degree by the Research and Advanced
Studies Center of the National Polytechnic Institute
(2010) He is currently a Reviewer of Matéria
newspaper (UFRJ), reviewer of Materials Research
journal, reviewer of Brazilian Journal of Vacuum Applications and Adjunct
Professor of the Federal University of São Paulo. Has experience in the area
of Materials Engineering and Metallurgy, with emphasis on Transformation
Metallurgy. Acting mainly on the following topics: interface, thin films,
interface dilution, surface modification.
