FESTO Relies on Markforged 3D Printers for Electronics Component Manufacturing
With over 20,000 employees in more than 60 countries, FESTO is a leading global supplier of automation technology. The company is known for its innovative products, excellent quality, and solutions for complex automation technology and technical education. The Scharnhausen Technology Plant is FESTO’s primary facility for producing valves, valve terminals, and electronic components.
High Demand for Individual Operating Equipment
Since 2014, the FESTO Technology Factory in Scharnhausen, located south of Stuttgart, Germany, has been a leading plant for producing valves, valve terminals, and electronic components. The facility is notable for its extensive production equipment and highly optimized automation processes.
To minimize unplanned downtime and maintain production efficiency, the use of high-tech machines and systems requires a wide range of individual operating resources, such as spare parts, individual parts, and fixtures. Using high-quality spare parts and fixtures ensures high production quality and customer satisfaction.
ESD Requirements Posed a Challenge
Stefan Fent, Head of Operating Equipment Design, and his team sought a solution beyond basic 3D printing to reduce the high costs and workload associated with operating diverse equipment. They needed a real manufacturing system capable of producing mechanically resilient components in a process-safe and repeatable manner. The focus was on substituting plastic and aluminum components, which previously had to be machined or manufactured externally, leading to long lead times. Additionally, the system had to reliably produce ESD-compliant components to meet strict requirements for manufacturing electronics.
FESTO had previously attempted to integrate 3D printing into their workflow but faced challenges due to ESD requirements. However, Markforged's technology met these standards effortlessly.
Industrial 3D Printing from a Single Source
At a regional trade show, the team discovered Markforged’s additive manufacturing machines. Using Markforged's continuous fiber reinforcement technology, the issue of mechanical strength was quickly resolved. Continuous carbon fiber allows for greater strength than aluminum. Markforged designs their software, hardware, and materials to work seamlessly together, offering maximum reliability and process safety. The Markforged Onyx ESD material is static-dissipative and meets the EMS industry's antistatic property requirements.
In spring 2022, Stefan Fent integrated two manufacturing machines from Markforged into the production equipment: the Markforged Onyx Pro and the Markforged X7. The Onyx Pro is a desktop machine for producing continuous fiberglass-reinforced components, while the X7 produces mechanically strong components by incorporating continuous carbon fiber, fiberglass, and Kevlar. The X7 can also print electronics production components using Onyx ESD material.
"Markforged is a real manufacturing system. The quality and strength of the components, as well as the reliability, have convinced us over other competitors."
– Johannes Hablizel, Design Engineer for Production Equipment
The Transition to Thinking Additively
It took about 2-3 months for designers to start integrating 3D printing into equipment manufacturing. Today, nine months later, the printers are already scheduled weeks in advance, with the team's learning curve growing exponentially.
Several employees operate the manufacturing machines, producing additively manufactured components found throughout production, including sensor holders, housings, handles, clamping and holding devices, tools, templates, and spare parts. FESTO has already produced over 200 different components that would otherwise need to be milled or ordered at high costs. A shared database provides an overview of upcoming print jobs, costs, and savings, ensuring efficient job processing.
Over 80,000 EUR Saved in Nine Months
Analysis of the order database showed significant savings from printed components. Due to high demand from various departments, the equipment design team saved around 80,000 euros in nine months.
Practical Example: Handheld ESD Scanner Holder
A simple three-piece holder for a handheld scanner illustrates the cost reduction. The planned mechanical production cost for 10 pieces was estimated at about 4,000 euros. Using 3D printing, the cost of the holder made of Onyx ESD material was only 385.88 euros, plus 200 euros in labor costs, resulting in a total saving of 3,414.12 euros compared to mechanical production.
The Digital Forge
Printed components at FESTO often have serial numbers or component identifiers, allowing damaged or worn parts to be reprinted. Markforged’s Eiger dynamic additive manufacturing software enables on-demand manufacturing at any production site globally. Selected employees can access and manage the data.
Future Plans
FESTO plans to maintain the current capacity utilization of their 3D printers. If demand continues to grow, an expansion of the portfolio will be considered. The potential of the new Markforged FX20 industrial 3D printer is currently being evaluated for use in production. With increased capacity and the ability to produce larger components, the FX20 could be another success story for FESTO.
