Product Innovation Through Lightweighting with Additive Manufacturing

Irish Manufacturing Research (IMR) kicked off the year with a compelling webinar, Product Innovation through Lightweighting with Additive Manufacturing, featuring insights from Anthony O’Riordan of Kaizen PLM, Rodrigo Fraga from Siemens Digital Industries Software, and IMR’s own Jay Rossiter. This webinar highlighted how lightweighting, paired with additive manufacturing, is transforming industries by enabling innovative designs, reducing material usage, and enhancing efficiency.

Why Lightweighting Matters

Lightweighting is the process of reducing the weight of components without compromising strength or durability. Its significance is especially prominent in industries like aerospace, automotive, and manufacturing, where weight reductions lead to improved fuel efficiency, reduced emissions, and cost savings. Using cutting-edge digital engineering workflows, including topology optimisation, engineers can design high-performance parts that are both lighter and more durable.

As demonstrated during the webinar, a redesigned airplane torque link achieved a remarkable 44% weight reduction. While this change may seem minor for a single component, it leads to significant fuel savings and reduced environmental impact when applied across an aircraft’s lifespan.

Additive Manufacturing: Enabling Innovation

Additive manufacturing (AM), often referred to as 3D printing, allows engineers to create intricate, organic shapes that traditional manufacturing methods struggle to produce. From wire arc additive manufacturing for large-scale parts to polymer-based production for lightweight robotics, AM offers flexibility and efficiency across applications.

A standout example was the redesign of a robot gripper by Siemens. By transitioning from aluminium to polymer and leveraging additive manufacturing, the gripper’s weight was reduced from 47 kg to just 2 kg—a 95% reduction—while achieving a 90% cut in production costs and a lead time of just two days. Such advancements not only optimise part performance but also enhance the overall efficiency of production lines.

Applications Across Industries

The webinar showcased diverse use cases, from Bugatti’s topology-optimised rear spoiler to aerospace applications like landing gear components. Each example underscored the transformative potential of lightweighting and additive manufacturing in achieving sustainability goals and operational excellence. Furthermore, these technologies are no longer confined to high-performance sectors; they are now accessible to small and medium enterprises, with software bundles available at significant discounts.

A Holistic Approach to Digital Engineering

Speakers emphasised the importance of a holistic digital manufacturing workflow. Integrating design, simulation, manufacturing, and quality control within a unified system ensures seamless data transfer and minimises errors. This approach enables companies to not only innovate faster but also ensure traceability and certification compliance.

Learn More

For more information on lightweighting, additive manufacturing, or training opportunities, feel free to contact IMR. With these technologies at your disposal, the possibilities for innovation are limitless.

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