Transforming End-of-Line Automation with 3D Printing at TMG Impianti: Case Study

The Customer

TMG Impianti, based in Veneto, Italy, has been providing customized end-of-line automation solutions for over 45 years. Their machines improve the process of placing finished products onto pallets or in boxes, enhancing efficiency in warehouses. By automating this task, TMG speeds up product handling and packaging. Their adaptable machines cater to various product features, backed by a strong understanding of industry needs from years of experience across different sectors.

The Challenge

TMG is seeking new solutions to meet the growing variety of products and shorter delivery times for its customers.

"We produce on demand and have adapted our design process to meet customer needs. As a supply partner for multinational companies, we faced requests that traditional techniques couldn't fulfill due to the required flexibility and speed."

“We have 45 years of history and 1000 plant installations. Ours is a durable asset with an average lifespan of 20-25 years. We design and program and all of that is handled in-house.”

“Being able to offer customized machinery components in the shortest possible time to cope with the great variability of objects to be handled has become a must,” says Andrea Dolzan, COO and Director of Operations for TMG Impianti. For TMG, it was therefore necessary to reduce both the prototyping time and the actual production time of the end-use part.

“Then, during the Covid period, another particularly important demand was for spare parts for the machinery, given the unpredictable timing of the supply chain. 

TMG also needed to:

• Be able to design and manufacture very complex geometries.
• Simplify elements composed of several parts.
• Reduce the weights of moving parts to improve automation performance.

The increasing variability of manipulated products has created new fundamental needs for TMG to better satisfy its customers. These needs include:

• Reducing prototyping, verification, and testing time; minimizing production time; and shortening the delivery time for spare parts.
• Facilitating the creation of very complex geometries and offering maximum freedom in part design.
• Simplifying elements composed of multiple parts and reducing the weight of moving parts to enhance automation performance.

The Solution

To meet these requirements, TMG began considering the integration of 3D printing with traditional manufacturing methods. In 2019, the company embarked on its journey into Additive Manufacturing by investigating new manufacturing technologies.

In early 2020, TMG partnered with 3DZ to manufacture and test its first 3D-printed prototypes. By the second half of the year, TMG began installing these 3D-printed parts as end-use components in its automation plants. 

In 2021, TMG decided to bring 3D printing in-house. With the support of 3DZ, they selected Markforged’s X7 printer, which utilizes CFR filament printing technology. 3DZ handled the installation of the machine and provided training for the staff.

The Markforged X7 printer is known for its capability to print components reinforced with continuous carbon fiber, Kevlar, glass fiber, and high-temperature glass fiber. This use of advanced materials allows for the creation of parts that are as strong as aluminum but significantly lighter. 

In 2023, TMG expanded its Additive Manufacturing capabilities by establishing a dedicated in-house 3D printing area and introducing the FX20 printer from Markforged, one of the first of its kind in Italy. The FX20, known for its power and speed using CFR filament technology, produces large, durable parts. This advancement allows TMG to quickly transition from prototypes to end-use components and replace metal or aluminum parts with lighter plastic alternatives. 

The acquisition of this new printer is a key component of a broader initiative aimed at significantly enhancing the production of end components. The printers are intended to operate continuously, 24 hours a day. With the capability to produce larger parts, TMG plans to undertake a comprehensive redesign of multiple elements of its machinery, rather than focusing solely on a single component.

With some customers printing their own replacement parts, BMF can respond more quickly to 3D printing and CNC machining jobs. Mueller adds that the team can also print parts for new Twister builds without delays in production scheduling.

“We believe that 3D printing has great potential and that Additive Manufacturing will largely replace traditional manufacturing methods in the future. Sustainability is also important to us, as Additive Manufacturing uses less energy and generates minimal waste”

– Andrea Dolzan, COO TMG Impianti

The Conclusion

In conclusion, TMG Impianti's adoption of Markforged 3D printing has transformed its end-of-line automation. This technology has increased productivity, reduced lead times, and enabled efficient manufacturing of lightweight, complex components in-house, enhancing sustainability and lowering energy consumption.