The Integration of AM & Traditional Manufacturing

October 15, 2024 | Reading time: 5 min

In the season nine premiere of the Additive Snack Podcast, host Fabian Alefeld sits down with Jake Jones, Project Manager for Tooling and Additive Manufacturing at Penn United. This discussion unveils the intricate journey of Penn United into the additive manufacturing (AM) space and provides invaluable insights for industries looking to navigate the complexities of AM integration.

Penn United: an ingenious blend of tradition and innovation

Jake kicks off the episode with a brief history of Penn United, tracing back to its foundation in 1971 on his grandfather's farm in Cabot, Pennsylvania. What began as a tool and die manufacturing business quickly evolved into a diversified manufacturing powerhouse through several strategic acquisitions, including a carbide material manufacturing business, a grinding OEM, a powdered metal compaction tooling company, and a plastic injection molding production house. These acquisitions have enabled Penn United to build a robust portfolio, which it has meticulously integrated with AM technology.

Embracing additive manufacturing: from skepticism to serial production

Penn United's foray into AM started in 2018 when a customer's interest prompted the acquisition of its first EOS M 290 machine. Jake details how this marked the beginning of their additive journey and highlights the subsequent growth to operating three EOS M 290’s and an EOS M 400, focusing on a wide range of materials including 15 different alloys.

Jake emphasizes the significance of this growth, detailing the company’s entry into the energy sector and continuous exploration of binder jetting technology (which is arguably still a side project). The integration and expansion of AM technologies at Penn United underscore its commitment to staying ahead of technological advancements while addressing the evolving needs of their customers.

Bridging the gap: traditional manufacturing and additive technology

One of the standout aspects of Penn United's strategy is its seamless integration of traditional and additive manufacturing. Jake explains that AM sits within the company’s tooling group, and is viewed as an additional tool in its extensive toolbox. This holistic approach allows them to leverage extensive knowledge in precision manufacturing for post-processing additive components, ensuring high-quality output.

Navigating the challenges of innovative technology

The podcast sheds light on the challenges of adopting AM, especially in a production environment. Jake talks about the importance of precise build times, managing machine uptime, and the innovative practice of cross-training employees to handle both additive and subtractive technologies. This cross-training not only maximizes operational efficiency but also ensures that employees are equipped with a broad skill set to adapt to various manufacturing needs.

Material development: a competitive edge

Jake delves into Penn United's approach to process parameter development, highlighting a comprehensive methodology that includes extensive research and rapid development cycles. This rigorous process allows it to develop and qualify new materials swiftly, often in as little as three builds, which positions the business as a competitive leader in the AM industry.

Penn United's extensive engagement in diverse markets, including defense, aerospace, medical devices, automotive, and oil and gas, reflects their versatile capabilities. For AM, it sees significant potential in specialized components like heat exchangers with intricate lattice structures and improvements in medical devices. Such applications showcase the immense value additive manufacturing brings to enhancing performance and innovation.

Building talent from within

One of the key takeaways from Jake's discussion is Penn United’s approach to talent development. The organization emphasizes internal training and cross-training, bringing employees from different departments, such as machining and tooling, into the additive domain. This strategy has cultivated a workforce proficient in both traditional and cutting-edge technologies.

Jake exudes optimism about the future of AM at Penn United, highlighting the rapid advances in technology and the increasing demand for high-precision components. He looks forward to further educating customers on the benefits of AM, integrating new materials, and expanding their operational capabilities.

Conclusion

This episode of Additive Snack Podcast provides a thorough look at Penn United's journey through the lens of Jake Jones. It’s a testament to how traditional manufacturing companies can effectively incorporate AM to meet modern demands. By blending precision heritage with innovative technology, Penn United exemplifies a path forward for others in the industry.

Stay tuned for more episodes of the Additive Snack Podcast as we continue exploring the transformative potential of additive manufacturing across various sectors.

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Listen to the Additive Snack Podcast Now

Catch the full episode on your favorite podcast platform to dive deeper into the insights shared by Jake Jones and explore the dynamic world of precision and additive manufacturing. Stay updated with the latest episodes featuring industry experts and cutting-edge discussions on additive manufacturing. Follow Jake Jones on LinkedIn to stay connected and gain further insights into his professional journey and expertise.