Industry 4.0 & additive manufacturing: the fourth industrial revolution aims to deliver efficiency and sustainability in production

Industry 4.0 is driving a revolution in manufacturing, powered by the adoption of digital, robotic and automated technologies. Within this transformation, Caracol stands out as a leading player in the large-format additive manufacturing (LFAM) sector. Additive manufacturing & industry 4.0 technologies are reshaping the industrial landscape and optimizing processes according to new standards of efficiency and sustainability.

Industry 4.0 marks the beginning of a new era in industrial production. Characterized by the concept of the smart factory where the key isn’t volumes and growth at all costs, but a more efficient and sustainable evolution. This concept is structured around three main dimensions:

• Smart production: the introduction of advanced technologies that facilitate collaboration between operators, machines and tools, optimizing the entire production process.
• Smart service: the set of IT and technical infrastructures that enable system integration, fostering cooperation between companies and external structures.
• Smart energy: a particular focus on sustainability, designing high-energy-efficiency systems to reduce waste and improve performance in line with sustainable energy principles.

This approach aims to maximize efficiency, reduce costs and promote the sustainability of industrial operations by innovating every aspect of the production cycle.

LFAM fits perfectly within the new context of additive manufacturing industry 4.0 enabling a smarter, connected and more sustainable production model. In contrast to many traditional methods, often described as the “opposite of additive manufacturing” for their subtractive nature (where material is removed from a raw block), additive and LFAM create objects layer by layer, minimizing waste, increasing efficiency, accuracy and flexibility of the entire production process.

The benefits of industry 4.0’s additive manufacturing
Additive manufacturing is a production process that perfectly meets the industry 4.0’s concepts around automation, machine learning, robotics and more, but also due to its numerous advantages in terms of production efficiency and sustainability:

• Production efficiency: 3D printing cuts lead times by reducing the need for specific tools or molds. This is particularly useful for creating prototypes or small batches of components, where flexibility is crucial. Additionally, the ability to print complex geometries in a single step eliminates secondary production processes, accelerating time-to-market.
• Localized and customized production: additive manufacturing enables production to be close to part point of use, reducing logistics steps connected costs. Furthermore, 3D printing is ideal for creating tailored products, meeting the specific needs of each customer.
• Environmental benefits: LFAM technologies are inherently more sustainable than traditional methods. The reduction of material waste, achieved by using only the material necessary to build the part, and the possibility of using recycled or bio-based materials minimize overall environmental impact. Additionally, on-demand and localized production reduces CO2 emissions associated with logistics and storage.
• Cost reduction: due to possibility of avoiding tooling or production supports, lower material use, faster lead times, as well as reduced assemblies of components and often of manual labor required, LFAM technologies can reduce the cost of production, transportation and of the overall manufacturing process.

The importance of technology integration within industry 4.0’s additive manufacturing
To maximize the benefits of additive manufacturing and industry 4.0, it is essential to control the full process of production. Coming from a background in industrial production, Caracol, as LFAM leader, developed a multiplatform integrated robotic turnkey set up that combines hardware, software and automation: Heron AM for 3D printing of thermoplastic and composite parts and Vipra AM for additive manufacturing of metal alloys.

Within the realm of industry 4.0’s additive manufacturing paradigms, Heron AM and Vipra AM provide a solution to many manufacturing problems due to the true integration between hardware and software components. This approach simplifies the implementation of new technologies, reduces setup time or maintenance times, and provides greater operational efficiency. The advantage of having a complete solution allows companies to focus on production, while the technology provider takes care of ensuring interoperability between different technology components, analyzing production data, identifying possible inconveniences and solving them before they occur.

Eidos IoT: the digital core of Caracol technologies
A key element of Caracol’s integrated LFAM technologies is Eidos IoT, the proprietary software designed for real-time monitoring and optimization of production processes. Eidos IoT aligns seamlessly with Industry 4.0’s focus on data and analytics to extend the value that additive manufacturing can deliver, by enabling optimization at every step of the process. The software developed and integrated in Caracol’s robots tracks machine parameters, enables fleet management, reduces errors and non-conformities on parts, saving resources, time and costs. Key features of Eidos IoT include:

• Platform monitoring: during printing, Eidos IoT collects real data related to the platform (e.g. temperature, printing speed, etc…) by checking for any anomalies against the parameters set by the operator. This data can be easily visualized in real time or archived with data logging for later analysis.
• Remote supervision and support: Eidos IoT enables monitoring of a single platform or an entire fleet of platforms either directly at the machine or remotely. The cloud-based nature of Eidos IoT allows operators’ remote access in real time, providing timely support in the event of detected problems during a print.
• Event log and reporting: the software tracks all warnings and errors detected during printing, facilitating rapid operator intervention and reducing risks of downtimes.
• Measuring efficiency and productivity: Eidos IoT monitors energy consumption, processing time and the number of successfully completed prints, providing detailed statistics on operational efficiency.
• Predictive platform maintenance: through continuous dialogue with all hardware components, Eidos IoT monitors the status of the platform and alerts the operator when a replacement or maintenance is needed.

Many new features enabled by data collection and machine learning will lead to further advancements in the platforms’ functionalities and continue extending productivity, reliability and automation of the whole process. With Eidos IoT, Caracol’s solutions offer a unique level of control and precision in the LFAM landscape, positioning Heron and Vipra as an extremely reliable industrialized robotic 3D printing platform.

Caracol: leading the way of industry 4.0 and additive manufacturing innovations
In a world where efficiency and sustainability are increasingly crucial, Caracol’s integrated approach is the key to unlocking the full potential of additive manufacturing and industry 4.0.

Thanks to its robotic 3D printing technologies, Heron AM and Vipra AM, and cutting-edge software solutions like Eidos IoT, Caracol continues to redefine industry standards, providing customers with tools to meet the production challenges of the future.

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