Maximizing the Manufacturing Power of Your EOS M 400-4 with the Grenzebach Dual Setup Station - EOS Edition

December 02, 2024 | Reading time: 5 min

Today more than ever, the manufacturing industry is under constant pressure to innovate to remain competitive. Traditional processes like casting and forging, the early enablers of mass production, now face increasing pressure. With growing demand for faster, more cost-effective, and sustainable manufacturing, companies are turning also to additive manufacturing (AM) technologies to bridge the gap.

In many industries, AM has enabled companies to improve applications through freedom of design and supply chain optimization. With the Grenzebach Dual Setup Station - EOS Edition, these companies can now achieve better utilization of the machine. Let’s explore how this innovative technology can help maximize the potential of your AM operations.

Challenges in Today’s Manufacturing Landscape

In traditional manufacturing, inefficiencies are abundant. Processes such as forging and casting come with drawbacks like long lead times, high material costs, and excessive energy consumption. For instance, a report from AM Forward highlights how AM has the potential to reduce lead times by as much as 90%, material costs by 90%, and energy usage by 50%. This represents a massive shift in how production can be managed across industries.

But that’s not all. Traditional supply chains also carry hidden inventory and transportation costs, which can drag down profitability. Studies show that by decentralizing supply chains with AM, transportation costs can be reduced from 57% to 44%, improving overall supply chain efficiency and agility.

A key challenge in manufacturing is unproductive time. Traditional systems suffer from extensive periods of non-productive time, often caused by waiting time or the unavailability of operators. Even with AM systems like the standard EOS M 400-4, non-productive time can account for some 30% of total production time, reducing throughput and impacting costs.

This is why we have brought Grenzebach on board as a strong automation partner to increase the productivity of our AM systems. Our strong partnership brings you the Grenzebach Dual Setup Station - EOS Edition, a testament to years of shared experience.

How the Grenzebach Dual Setup Station Addresses Industry Challenges

The Grenzebach Dual Setup Station for the EOS M 400-4 offers a game-changing solution. By enabling two build jobs to be run in succession, it drastically cuts non-productive time. 

• While a first job is cooling, being unpacked and set up, the system automatically starts a second job, reducing change-over time to less than 30 minutes. 
• Productive time can increase from 60% to up to 90%, boosting overall manufacturing throughput.
• Jobs can be scheduled to start and run unattended outside normal shift hours or even 24/7.
• Ergonomic unpacking and setting up of the job that has already cooled down.

These changes allow even smaller manufacturers to use their resources more efficiently and stay competitive. For industries under pressure for high utilization, this single change is invaluable. By eliminating the bottlenecks associated with cooling, unpacking and setup, the Dual Setup Station allows manufacturers to focus on what matters most — producing high-quality parts, faster and more efficiently.

Financial and Operational Benefits

In industries like aerospace, AM has the potential to cut production costs by up to 50%, making it a competitive option for industries where precision and cost control are paramount. One of the most significant advantages of the Grenzebach Dual Setup Station - EOS Edition is the direct impact on cost savings. With the reduction in non-productive time, manufacturers can expect substantial reductions in overall production costs.

While decentralizing supply chains may seem like an operational shift, it can significantly reduce hidden inventory and transportation costs. With AM and the Dual Setup Station, more time can be spent on productive tasks, optimizing the entire supply chain and accelerating returns on investment.

By maximizing the utilization of your equipment with the Grenzebach Dual Setup Station - EOS Edition, manufacturers can reduce their carbon footprint and align themselves with global sustainability initiatives.

Industry Applications and Case Studies

Clients using the Grenzebach Dual Setup Station - EOS Edition report faster turnaround times, higher throughput, and greater operational efficiency. These early adopters are setting themselves apart by embracing automation and looking toward the future, where AM will play an even larger role in the global manufacturing ecosystem.

"By employing the Dual SES, we significantly reduced system idle time outside of shift hours. The Dual SES greatly increases system utilization and drastically reduces unproductive set up time. The automatic job start eliminates the need to set up the building plate, and operator intervention is no longer necessary. Additionally, the powder extraction system is very ergonomic despite operation through a glovebox"

Marco Linhardt, Production Manager Additive Manufacturing at KSB SE & Co. KGaA

Closing Thoughts

The Grenzebach Dual Setup Station for the EOS M 400-4 offers a strategic advantage for manufacturers looking to stay ahead in today’s competitive landscape. With increased productivity, reduced unproductive time, and significant cost savings, this technology addresses the major challenge of traditional and even modern AM systems.

As industries across the board continue to adopt AM, the Dual Setup Station stands out as a viable solution for manufacturers ready to optimize their operations. Explore how this powerful tool can help you reduce costs, increase productivity, and position your business for long-term success in a rapidly evolving manufacturing world.