Charles R. Goulding and Preeti Sulibhavi explain how six industrial leaders are using 3D printing to build smarter, greener, and more automated U.S. manufacturing facilities.
The resurgence of U.S. onshore manufacturing is a multifaceted endeavor, hinging on advancements in construction, energy, and automation. A pivotal technology that is driving progress across these sectors is 3D printing. This article delves into how leading companies—CRH, Eaton, GE Vernova, Rockwell Automation, Ametek, and Schneider Electric—are integrating 3D printing to revolutionize their operations and contribute to the onshoring movement.
Barron’s March 24th issue broke down this national initiative into three critical categories, highlighting companies that are powering the future of American manufacturing:
- Powering New Plant Construction
- Powering New Plant Energy
- Powering New Plant Automation
Each of these areas is essential for ensuring that new U.S. manufacturing facilities can be built, powered, and operated efficiently—especially amid a national labor shortage. Below, we explore five companies that Barron’s identified as leaders in this push and how they’re leveraging 3D printing to enhance capabilities within each category.
1. Powering New Plant Construction: CRH
CRH, a global leader in building materials, plays a crucial role in new plant construction. While specific instances of CRH’s adoption of 3D printing are not widely publicized, the construction industry is increasingly exploring additive manufacturing for its potential to enhance efficiency and reduce waste. Companies in this sector are investigating the use of 3D printing for creating complex concrete structures and components, which can expedite construction timelines and offer greater design flexibility.
2. Powering New Plant Energy: Eaton and GE Vernova
Eaton
Eaton, a diversified power management company, has been integrating 3D printing into its manufacturing processes to improve product performance and reduce development cycles. By utilizing additive manufacturing, Eaton can produce complex components with enhanced functionality, leading to more efficient energy management solutions. This approach not only streamlines production but also supports the development of innovative products tailored to modern energy demands.
GE Vernova
GE Vernova, through its subsidiary GE Renewable Energy, has been at the forefront of incorporating 3D printing into energy solutions. In April 2022, GE Renewable Energy inaugurated a research and development facility in Bergen, New York, dedicated to exploring 3D printing for wind turbine towers. This facility features a 3D printer the size of a three-story building, capable of printing tower sections up to 20 meters high. The initiative aims to enable on-site printing of wind turbine tower bases, reducing transportation costs and promoting sustainability. This research is supported by a grant from the U.S. Department of Energy, highlighting its significance in advancing renewable energy infrastructure.
Further solidifying its commitment, GE Renewable Energy announced a minority investment in COBOD International in May 2022. COBOD is known for providing large-scale 3D concrete printers, and this partnership is set to enhance GE’s capabilities in manufacturing wind turbine components. The collaboration underscores the potential of 3D printing in creating more efficient and sustainable energy solutions.
3. Powering New Plant Automation: Rockwell Automation and Ametek
Rockwell Automation
Rockwell Automation, a leader in industrial automation, has been leveraging 3D printing to enhance its product development and manufacturing processes. By adopting additive manufacturing, Rockwell can rapidly prototype components, allowing for quicker iterations and more efficient designs. This capability is particularly beneficial in developing customized automation solutions tailored to specific manufacturing needs, thereby improving overall plant efficiency.
Ametek
Ametek, a global manufacturer of electronic instruments and electromechanical devices, has incorporated 3D printing into its operations to produce complex parts with high precision. This technology enables Ametek to create components that would be challenging or impossible to manufacture using traditional methods. The result is a reduction in production time and costs, as well as the ability to produce more intricate and efficient designs for their automation products.
Addressing Labor Shortages Through Automation
The U.S. manufacturing sector is currently grappling with labor shortages, making automation a critical component of new plant operations. By integrating advanced technologies such as 3D printing into their automation strategies, companies can maintain high levels of productivity with a reduced workforce. This approach not only mitigates the impact of labor shortages but also enhances the precision and efficiency of manufacturing processes.
Schneider Electric: A Strong Player in Energy and Automation
Schneider Electric has emerged as a significant contributor to the energy and automation sectors, particularly through its adoption of 3D printing technologies. In September 2022, Schneider Electric collaborated with HP to utilize the Metal Jet S100 Solution, a cutting-edge metal 3D printing technology. This partnership led to the development of new applications, including a filter used in Schneider’s NSX breaker. The 3D printed filter features complex shapes that enhance performance by reducing gas, pressure, and heat impact within a limited space. This innovation not only improves product functionality but also demonstrates the potential of 3D printing in creating more resilient and efficient supply chains.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
The integration of 3D printing across construction, energy, and automation is playing a pivotal role in revitalizing U.S. onshore manufacturing. Companies like CRH, Eaton, GE Vernova, Rockwell Automation, Ametek, and Schneider Electric are at the forefront of this transformation, leveraging additive manufacturing to enhance efficiency, reduce costs, and drive innovation. As these technologies continue to evolve, they promise to further strengthen the competitiveness and sustainability of domestic manufacturing operations.
