Additive manufacturing (AM), also known as “3D printing,” has transitioned from concepts and prototypes to part-for-part substitution—and now to the creation of part geometries that can only be made using AM. As a wide range of mobility OEMs begin to introduce AM parts into their products, the question between insourcing and outsourcing the manufacturing of AM parts has surfaced. Just like parts made using other technologies, AM parts can require significant post-processing operations. Therefore, as AM supply chains begin to develop, the sourcing of AM part building and their post-processing becomes an unsettled and important issue. Unsettled Aspects of Insourcing and Outsourcing Additive Manufacturing discusses the approaches and trade-offs of the different sourcing options for production hardware for multiple scenarios, including both metallic and polymer technologies and components. Click here to access The Mobility Frontier: Metals, Polymers, or Composites Click here to access the full SAE EDGETM Research Report portfolio. https://doi.org/10.4271/EPR2021023

Additive manufacturing (AM), also known as “3D printing,” now provides the ability to have an almost fully digital chain from part design through manufacture and service. This “digital thread” can bring great benefits in improving designs, processes, materials, operations, and the ability to predict failure in a way that maximizes safety and minimizes cost and downtime. Unsettled Aspects of the Digital Thread in Additive Manufacturing discusses what the interplay between AM and a digital thread in the mobility industry would look like, the potential benefits and costs, the hurdles that need to be overcome for the combination to be useful, and how an organization can answer these questions to scope and benefit from the combination. Click here to access The Mobility Frontier: Metals, Polymers, or Composites Click here to access the full SAE EDGETM Research Report portfolio. https://doi.org/10.4271/EPR2021026

Now that metal additive manufacturing (MAM), also known as “metal 3D printing,” has seen its first successful implementations across the mobility industry, the question is whether it will continue to grow beyond these initial applications or remain a niche manufacturing process. Moving to broader applications will require overcoming several barriers, namely cost and rate, size, and criticality limitations. Recent progress in MAM indicates that these barriers are beginning to come down, pointing to continued growth in applications for MAM through the end of the decade and beyond. Metal Additive Manufacturing in the Mobility Industry: Looking into 2033 discusses the obstacles to future MAM growth, how they can be conquered, and what its role in the mobility industry will look like in 2033. Click here to access The Mobility Frontier: Metals, Polymers, or Composites Click here to access the full SAE EDGETM Research Report portfolio. https://doi.org/10.4271/EPR2023022

In the early days, there were significant limitations to the build size of laser powder bed fusion (L-PBF) additive manufacturing (AM) machines. However, machine builders have addressed that drawback by introducing larger L-PBF machines with expansive build volumes. As these machines grow, their size capability approaches that of directed energy deposition (DED) machines. Concurrently, DED machines have gained additional axes of motion which enable increasingly complex part geometries—resulting in near-overlap in capabilities at the large end of the L-PBF build size. Additionally, competing technologies, such as binder jet AM and metal material extrusion, have also increased in capability, albeit with different starting points. As a result, the lines of demarcation between different processes are becoming blurred. Internal Boundaries of Metal Additive Manufacturing: Future Process Selection examines the overlap between three prominent powder-based technologies and outlines an approach that a product team can follow to determine the most appropriate process for current and future applications. Click here to access The Mobility Frontier: Metals, Polymers, or Composites Click here to access the full SAE EDGETM Research Report portfolio. https://doi.org/10.4271/EPR2022006

As metal additive manufacturing (MAM), also known as "metal 3D printing,” moves from prototype to low-rate and high-rate production for increasingly critical applications for more industries, many product teams are tasked with determining design properties for the first time in many years. Not only is it necessary to determine basic material properties, but it is also necessary to accommodate new geometries and design concepts as well. While some of the methods and approaches are common to other product forms, others are unique to MAM. Determining Design Properties for Metal Additive Manufacturing in the Mobility Industry covers the challenges in determining design properties and provides a comparison with existing technologies, along with an example and recommendations for future work. Click here to access The Mobility Frontier: Metals, Polymers, or Composites Click here to access the full SAE EDGETM Research Report portfolio.. https://doi.org/10.4271/EPR2023004

SAE EDGE Research Reports provide state-of-the-art and state-of-industry examinations of the most significant topics in mobility engineering. SAE EDGE contributors are experts from research, academia, and industry who have come together to explore and define the most critical advancements, challenges, and future direction in areas such as vehicle automation, unmanned aircraft, IoT and connectivity, cybersecurity, advanced propulsion, and advanced manufacturing.

All organizations outsource. They differ only in the scope and extent of what they procure as goods and services from outside entities. These choices drive an organization's financial performance and long-term competitive viability, and establish the tenor of day-to-day operations. Outsourcing can solve many problems, but is also fraught with hidden costs and risks. This monograph examines outsourcing from a lifecycle perspective. This means tracing the full arc from the germination of the idea to outsource, to the assessment of options, to the installation of control mechanisms, to grappling with conflicts that inevitably arise over time, all the way to the sunset of the chosen strategy. The analysis is highly attentive to the details of operational execution, especially regarding how human resources participate in these decision processes and are impacted by the choices made.