SmileDirectClub had a clear aligner production method in place since its inception in 2014, but due to their growing customer base, the company needed a manufacturing technology that would allow them to meet the increasing demand. Their previous technology produced delicate, fragile 3D-printed parts at slow speeds and high costs.
High-volume mass customized parts enabled by 3D printing
Summary
Challenge
Solution
The company adopted HP’s 3D printing technology with PA12 S material enabled by Arkema, which offered enhanced aesthetics and transparency. This material also supported faster production times and more cost-effective manufacturing.
Value
The adoption of PA12S provided smoother surface finishes, resulting in clearer and more visually appealing aligners. It also reduced production costs by up to 25%, making the process more efficient without compromising on quality.
Products & Services
- HP MJF Technology
- HP 3D HR PA 12S Material
- In-house design and integration
- Post-processing: Ceramic blasting
AM I Navigator Maturity Model
0
1
2
3
4
5
Strategy
S0
S1
S2
S3
S4
AM is fully integrated into the strategy, driving innovation in various sectors.
S5
Product Design
PD0
PD1
PD2
PD3
PD4
AM is heavily utilized in mold design, optimizing functionality and cost, but lacks full integration with product lifecycle management tools.
Could further specify the role of DfAM in optimizing the design process.
PD5
Material
M0
M1
M2
M3
M4
Material selection is based on functional needs, with a focus on performance and durability for molds.
M5
Process Engineering
PE0
PE1
PE2
PE3
AM has optimized mold design and production, but further process simulations are needed for performance improvements.
PE4
PE5
Production Setup
PS0
PS1
PS2
PS3
PS4
AM streamlines mold production, reducing setup time, but manual intervention still exists in the process.
PS5
Manufacturing Execution
ME0
ME1
ME2
Manual process.
ME3
ME4
ME5
Quality
Q0
Q1
Q2
Q3
Product and Process quality planned and inspected for manufacturing process compliant with industry standards.
Q4
Q5
Maintenance & Service
MS0
MS1
MS2
MS3
Regular printer maintenance.
MS4
MS5
Environmental Sustainability
ES0
ES1
ES2
ES3
ES4
AM reduces material waste and energy consumption, improving sustainability in mold production.
ES5
People & Organization
PO0
PO1
PO2
PO3
Developing additional AM offering to existing machine business.
PO4
PO5
Evaluate your additive manufacturing capabilities across 10 different dimensions.
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