The need for cost-effective, sustainable manufacturing has never been more pressing. Selective Absorption Fusion (SAF) technology presents a compelling solution to the waste and inefficiencies found in traditional manufacturing. From material and energy waste to costly setup requirements and overproduction, traditional methods like CNC machining, injection molding, and casting often drive-up operational expenses and environmental costs. Here’s how SAF technology tackles these challenges, offering an efficient, lower-cost alternative.
In traditional manufacturing, material waste is virtually unavoidable. CNC machining, for example, often requires starting with a block of material, much of which is removed and discarded as shavings. Injection molding has similar issues, with excess plastic scraps and mold flashes. While some of this waste can be recycled, it’s often a costly process both in terms of finances and energy.
With SAF technology, waste is minimized by optimizing material use. During the printing process, excess powder from SAF builds can often be reused in subsequent cycles, significantly reducing raw material requirements. Though there is some inevitable loss (approximately 0.5g per 1g of part material due to powder adhesion and temperature degradation), SAF still results in far less waste than most traditional methods, translating directly into material cost savings.
Traditional manufacturing processes require substantial energy to operate heavy machinery, especially in high-volume production environments. Casting equipment and injection molding machines consume massive amounts of power, especially when factoring in extended idle periods and the energy required to recycle scrap material.
SAF, however, operates with efficiency at its core. Machines like the Stratasys H350 SAF printer consume around 3.25kW during active use, with a peak at 5kW and a low idle power draw of 0.15kW. In comparison, traditional manufacturing setups often require multiple machines or high-power settings, leading to much higher overall energy consumption. The power consumption of electric injection molding machines for example, ranges from 3.8kWh to 17.9kWh.
One of the most resource-intensive aspects of traditional manufacturing is the tooling required to shape and create parts. Injection molding and metal stamping, for instance, require specialized tools that need frequent setup and maintenance. Producing custom tooling for different parts is both time-consuming and costly, especially when production needs change frequently.
SAF technology eliminates the need for dedicated tooling by enabling on-demand part production without extensive reconfiguration. Multiple part designs can be printed simultaneously, eliminating setup times between runs. This capability not only saves time but also reduces costs associated with tool creation, maintenance, and staffing requirements.
Ready to simplify your production process and cut costs? Let’s talk about how SAF technology can take your on-demand part production to the next level.
Overproduction is a common challenge in traditional manufacturing, where high minimum production volumes are required to achieve economies of scale. However, this can lead to surplus inventory and, ultimately, wasted products when demand shifts or products go unsold.
SAF technology supports just-in-time manufacturing, allowing companies to produce only what they need, reducing the risk of overproduction. This means manufacturers can adapt to real-time demand without incurring the costs of excess inventory, storage, and potential disposal of unsold goods. In this way, SAF technology aligns production volume with demand, significantly cutting costs and material waste associated with traditional manufacturing.
See how leading industries are putting SAF technology to work. Dive into real-world applications and success stories that prove on-demand manufacturing delivers.
Reduced Packaging and Logistics Costs
Traditional manufacturing often requires complex supply chains with parts produced in different locations and then shipped to a central assembly facility. This process involves excessive packaging materials and increased waste, driving up both costs and environmental impacts.
With SAF technology, manufacturers have the option of more localized production, reducing the need for packaging materials and lengthy transportation. By consolidating production steps and minimizing the logistical footprint, SAF reduces expenses associated with packaging and fuel, delivering cost savings and a more sustainable manufacturing process.
Less shipping, more saving. See how SAF technology is helping manufacturers bring production closer to home with smarter, more sustainable 3D printing.
Managing SAF-Specific Waste Effectively
Although SAF is efficient in many respects, it does produce some unique waste types, primarily unused powder, support materials, and fluid waste. Unlike other 3D printing technologies, SAF allows the reuse of support materials and does not require disposable supports, reducing overall waste. Fluid waste in SAF is minimal, with one cartridge typically lasting through numerous builds, which can help keep disposal costs down. Proper handling and disposal of SAF powder are crucial to ensuring safety and minimizing environmental risks, but these challenges are minor compared to the waste burden from traditional manufacturing processes.
Don’t let waste slow you down. Learn how SAF technology and the Stratasys H350 can help you cut down on waste and boost efficiency—watch the webinar now.
SAF technology provides an innovative and cost-effective alternative to traditional manufacturing. By reducing material, energy, and tooling waste, and by allowing for flexible, on-demand production, SAF significantly lowers operating costs and environmental impacts. For companies looking to cut costs while staying agile and sustainable, SAF technology offers a robust solution that not only enhances production efficiency but also aligns with modern sustainability goals.
Embracing SAF technology is an investment in the future of efficient manufacturing, setting a new standard for waste reduction and cost savings across industries.