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Additive manufacturing (AM) opens new possibilities for how to make things. What was once considered unmanufacturable geometry can now be created. The things you're already producing can be made faster, lighter, more reliable, better performing, and more sustainable.
And that's not all: AM can also protect your supply chain by enabling more flexibility in the manufacturing process, even enabling true just-in-time manufacturing by producing parts - even tooling for your own operations - on demand.
Fundamentally, additive manufacturing starts with a digital model of your part, dividing it into layers and then an additive manufacturing machine, often referred to as a 3D printer, is used to build that part, one layer at a time, by depositing, joining or solidifying materials.
At Eaton, our approach includes an Additive Manufacturing Center of Excellence that delivers enterprise-wide capabilities across our businesses. We leverage our deep knowledge in manufacturing, material science and digital design to drive value for our customers and as well as efficiencies for our operations. This yields important advantages and enables new possibilities.
EV manufacturers face new safety considerations in response to increasing vehicle system voltage levels. As a result, automakers are rapidly seeking new technologies to solve these problems. A major automaker sought to make a prototype for a new battery disconnect unit (BDU) that would provide switching and protection for its next generation vehicles' electrical systems. Importantly, the automaker had a a challenging fixed delivery date for the proof-of-concept prototype to go into their battery packs.
The timeline was difficult becasue of the part's original design, which included overmolding that typically requires prototype injection mold tooling. Creating the prototype using traditional manufacturing methods would take at least six months under the best of circumstances, yet the customer needed the parts in just three months.
To solve this problem, we developed a novel AM approach, breaking up a single large plastic component into four pieces that could be assembled around copper busbars to form the prototype in record time - two months faster than any other competitor. We won the bid for the prototype because of our speed, and went on to win the production contract. Our approach enabled our customer to meet their tight timeline while improving safety of the EV system with our technology.
Massive landing-gear assemblies for heavy-lift orbital launch vehicles are hard to make with traditional machining processes, especially given the challenging weight and size constraints. We used AM to develop a unique design for the hydraulic manifold assemblies that operate the landing gear.
Using electron beam powder bed fusion technology, we were able to design and produce components that resulted in
when compared to conventional manufacturing of this component.
Without using AM, these results would be impossible to achieve. Our improved, AM-manufactured product is now supporting a new chapter of space flight.
We're using AM to reduce lead times on tooling used in our operations, rapidly iterate on manufacturing aids, and minimize downtime on production lines by quickly responding to demands for replacement spares and repairs. AM gives our manufacturing engineers tools to experiment and continuously improve our operations, helping us maintain world-class manufacturing facilities.
When drawings or models are not available, we leverage 3D scanning to quickly reverse engineer models and use AM to then replicate parts, keeping our factories humming. AM enables our factories to be nimble and agile so we can keep our production lines moving and provide our customers with the solutions they need, when they need them.
The results are impressive:
For decades, aerospace customers have relied on us for ground fueling technology essential to around-the-clock operations. In 2022, our ability to meet customer demand was tested when we encountered significant supply chain delays for coupler handle castings, an essential device in pit valve assemblies that are used to refuel aircraft.
Airport operators around the world were expecting deliveries of Eaton products to enable refueling of aircraft. Leveraging our strength in AM, we developed a protype aluminum coupler handle in less than two weeks and used AM to manufacture 120 production coupler handles in less than six weeks - less than half the time it would have taken for the delayed couplers to arrive.
By quickly pivoting to a successful AM solution, we were able to provide uninterrupted deliveries to our customers and further increase the value of Eaton ground fueling products in the market. Our AM capabilities also offer our customers an additional assurance that Eaton can deliver high quality products on time despite supply chain bottlenecks that might otherwise impact delivery schedules.
We're leveraging our AM expertise to develop a transformative design method that has the potential to replace vast industrial LED lighting inventory with customized designs that can be made closer to the projects where they're needed.
Under a U.S. Department of Energy grant, we're aiming to develop this automated approach to mass-produce customized industrial lighting that significantly reduces energy consumption, cost, lead time and supply chain complexity. While the results are too early to share, we're targeting reducing materials usage by 50%, process steps by 30%, and cost by 30%.
Additive manufacturing capabilities deliver powerful advantages
Our AM capabilities are an accelerator for innovation, allowing us to overcome the common challenges facing industrials, enabling us to go fast without paying a premium. Staying agile as supply chains become more complex. Achieving new levels of performance with solutions that would be otherwise unmanufacturable. Reducing environmental impact by enabling products that weigh less, require fewer materials and can be made locally. And reducing cost through technologies that require less infrastructure, parts and materials.
AM is a critical enabler and differentiator, and an integral part of the Industry 4.0 initiatives that are transforming how, what, when and where we make things. As a result, we're switching on AM projects to win big for our customers across our business.
By leveraging the benefits of AM, we are making what matters work - better, faster, and more sustainably.
