Festo uses Markforged 3D printers for manufacturing electronic components

Explore how FESTO, a global leader in automation technology, uses Markforged 3D printers to improve their electronic component manufacturing at the Scharnhausen Technology Plant. This case study shows how additive manufacturing has transformed traditional processes. Discover the financial and operational benefits FESTO has gained by using Markforged.

With over 20,000 employees in more than 60 countries, FESTO is a global leader in automation technology. Known for its innovative products and high quality, FESTO provides solutions for complex automation and technical education. The Scharnhausen Technology Plant is FESTO’s main facility for manufacturing valves, valve terminals, and electronics.

High Demand for individual operating equipment

Since 2014, the FESTO Technology Factory in Scharnhausen, south of Stuttgart, Germany, has been a leading facility for producing valves, valve terminals, and electronic components. Upon entering the plant, one is immediately impressed by the vast array of production equipment and the highly optimized automation processes.

The use of advanced machines and systems requires a variety of operating resources, such as spare parts, individual components, and fixtures, to minimize unplanned downtime and maintain production efficiency. By utilizing high-quality spare parts and fixtures, FESTO ensures high production quality and customer satisfaction.

ESD requirements posed a challenge

Stefan Fent, Head of Operating Equipment Design, and his team wanted more than just basic 3D printing. Their goal was to reduce the high costs and workload involved in running a variety of equipment.

They needed a manufacturing system that could produce durable components consistently and safely.

Their main focus was on replacing plastic and aluminum parts, which previously had to be machined or made externally, leading to long wait times.

The system also needed to reliably produce ESD-compliant components to meet the strict requirements for manufacturing electronics.

FESTO had tried to integrate 3D printing into their workflow before but couldn't due to ESD requirements. While many 3D printers exist, only a few meet industry standards reliably. For Markforged, however, this wasn't an issue.

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, they quickly solved the issue of mechanical strength. With constant carbon fiber, it's even possible to achieve greater strength than aluminum.

Markforged designs its software, hardware, and materials to work seamlessly together. This integrated ecosystem ensures maximum reliability and process safety.

The Markforged Onyx ESD material is static-dissipative and meets the EMS industry's antistatic requirements.

In the spring of 2022, Stefan Fent decided to add two Markforged manufacturing machines to their production equipment. Since then, a Markforged Onyx Pro and a Markforged X7 have been manufacturing fixtures and templates around the clock. The Onyx Pro is a versatile desktop machine for producing continuous fiberglass-reinforced components. The Markforged X7 creates strong components by incorporating continuous carbon fiber, fiberglass, and Kevlar. Additionally, the X7 can print components for electronics production 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 the designers to start incorporating 3D printing into their equipment manufacturing.

Now, nine months later, the printers are booked weeks in advance. The team's learning curve is growing rapidly.

Several employees operate the manufacturing machines, and additively manufactured components, both large and small, are used throughout production. These include sensor holders, housings, handles, clamping and holding devices, tools, templates, and spare parts.

FESTO has already 3D printed over 200 different components that would otherwise need to be milled or ordered at a high cost.

A shared database tracks upcoming print jobs, costs, and savings, ensuring efficient job processing.

Additive manufacturing has become a standard technology for the FESTO team in Scharnhausen.

Over 80,000 EUR saved in nine months

Analysis of the order database revealed significant savings from the printed components.

Thanks to the high demand from various departments, the equipment design team managed to save around 80,000 euros in just nine months.

Practical Example: Handheld ESD Scanner Holder

A simple, three-piece holder for a handheld scanner illustrates the cost reduction.

If produced mechanically, the cost for 10 pieces was estimated at about 4,000 euros.

Using 3D printing with Onyx ESD material, the holder cost only 385.88 euros, plus 200 euros in labor costs.

This resulted in a total saving of 3,414.12 euros compared to mechanical production.

When used appropriately, 3D printing offers enormous added value for any company.

The Digital Forge

When you look at the printed components at FESTO, you’ll quickly notice that each one has a serial number or component identifier.

If a component or part of an assembly is damaged or worn, a replacement can be reprinted.

With Markforged’s Eiger dynamic additive manufacturing software, any part can be produced on-demand at any production site worldwide.

Authorized employees have access to the data and can manage it as needed.

Future

Moving forward, FESTO aims to maintain the current utilization of their 3D printers. If demand continues to rise, they will explore expanding their portfolio.

Additionally, they are evaluating the potential of the new Markforged FX20 industrial 3D printer for production use. With its increased capacity and capability to produce larger components, the FX20 holds promise as another success story for FESTO.