As 3D printing becomes more and more popular, big companies are trying to find ways to test the technologies. However, investing in machines can be expensive, especially when your workforce is not trained in additive manufacturing. Luckily, there are other solutions, like our 3D printing startup of the month for July, Replique. The 3D printing platform is designed for end-to-end industrial 3D printing and hopes to make 3D printing more accessible to businesses around the world. And the demand is clear, as the company has worked with large OEMs such as Miele and Siena Garden, among others. To learn more about how the platform works, we sat down with Henrike Wonneberger, one of the founders and COO of Replique.
3DN: Could you introduce yourself and reply?
Of course. My name is Henrike Wonneberger and I am one of the founders and COO of Replique, the end-to-end 3D printing platform that offers OEMs a safe and efficient way to provide parts anytime, anywhere. My academic and professional background is focused on chemistry and business administration, and I previously worked in different positions at BASF, from R&D to start-ups and innovation of digital business models. In fact, my connection and fascination with 3D printing came from the idea of being able to move spare parts from a physical inventory to a digital one and to be able to rethink the supply chain of these parts. 3D printing with the freedom to build all kinds of geometry in different materials purely from data is very powerful!
Henrike Wonnberger, one of the co-founders of Replique and its COO
Replique was founded during my time in BASF’s digitization department. We saw the need for a new solution in the aftermarket business that addresses typical problems such as long lead times, high minimum order quantities, and supply chain disruptions. Our idea was to digitize and produce spare parts on demand so that they are available anytime, anywhere. To make this vision a reality, Replique began its journey at Chemovator GmbH, BASF’s in-house venture maker, in early 2020. Replica helps OEMs shift parts from physical to digital inventory, thereby building a flexible and robust supply chain for those parts. As a comprehensive solution, we support our customers throughout the entire value chain, including design, technology and material selection, digital storage and secure decentralized manufacturing.
3DN: Replica provides what you believe to be the first fully encrypted 3D printed platform. Could you tell us how it works?
From our interviews with OEMs and customers, we know that data security and quality control are two main areas for anyone looking to produce with external partners. That is why the encryption of all data on our platform is a key feature of our business model. For us, the process begins with the qualification of 3D printable parts, as this is the first requirement for high-quality prints. This includes the selection of materials and technologies, as well as the determination of production parameters according to the requirements of the part. We then store qualified part designs with secure production parameters in our digital inventory.
This is where our encryption comes into play: once a customer requests a part, the locked production information, including the requested order amount, is sent to the correct print farm partner on our global network. In this way, parts are only printed in the quantity and quality required. As part of our quality assurance, we also include an automated quality documentation process, where final production information, including a Certificate of Analysis, is linked to the part produced and stored on the Replique platform.
3DN: What is the importance of having this type of end-to-end solution in industrial 3D printing?
To ensure the high quality of 3D printed parts, companies working with service bureaus need to know the best partners at each manufacturing location and for each combination of material and technology. If you think about all the different options in 3D printing, it becomes obvious that this becomes an almost impossible task. Just think of this equation: the number of different AM options = the number of printer manufacturers x technologies x materials x locations. The options seem endless.
Replique is an easy-to-use 3D printing platform for companies like Miele
As a platform, we know more about different materials, printers, partners, and use cases than just one. We know who the best suppliers and specialists are and we can provide our customers with quick access to all common additive manufacturing technologies and materials through our global network. Our qualification services ensure that designs are turned into high-quality printed pieces. Here, we benefit from our experience at BASF in manufacturing and supplying OEMs in various businesses. Additionally, we recently launched our network of trusted materials partners to further accelerate industrial 3D printing with world-class, custom material solutions. Our digital inventory can be seen as the interface between production partners and customers. Especially when connected to business processes like ERP and webshops, it enables a more convenient ordering process.
3DN: You are especially focused on the creation of spare parts, why? How is 3D printing useful for creating spare parts?
All parts managers know the challenge. With each new product line, the number of different spare parts increases over the years, especially in sectors where the machines are used for more than 15 years, for example machinery, transportation, agriculture and construction. Ensuring the availability of spare parts becomes complex. Stocking all the parts creates huge inventory costs as well as the risk of obsolescence. However, if a part is not available, this leads to high acquisition costs due to factors such as high minimum order quantities and rush shipments. For critical spare parts, even worse: lead times can be huge.
Decentralized 3D printing combined with digital inventory can solve those challenges. Spare parts are available at any time and can be produced on demand, wherever they are needed. This reduces costs, while increasing customer satisfaction, a win-win situation for both OEMs and end customers.
Replique takes care of the process, including printing, to manufacture high-quality, optimized parts for its customers.
3DN: Are there other applications you are targeting? Which?
Not only can existing parts be produced with 3D printing, the technologies also enable further innovation in the industry. Right now, we see a growing interest in the industrial production of new parts using 3D printing, for example for the launch of new accessories. In traditional manufacturing, small series production is associated with high costs and risks, for example due to the need for expensive tools and moulds. With 3D printing, we enable OEMs to cost-effectively produce parts from a batch size of just one, with close to zero fixed costs, as no tools or minimum order quantities are required.
One of our clients, the German appliance manufacturer Miele, is a good example from the consumer goods sector. The company uses our platform to quickly and cost-effectively provide new accessories to customers. The full integration of our platform into their online store made the switch to distributed manufacturing possible.
3DN: Any last words for our readers?
Don’t be overwhelmed by the number of different service bureaus and combinations of technology and materials in the 3D printing market. Start small and then scale up fast. Do you have a part where you think 3D printing could be a solution? Come to us and we can help you transform your idea into reality. Once the first step is done, you get a feel for the technology and many more parts can follow. You have started your journey towards a fully digitized supply chain using 3D printing. You can learn more in the video below or on our website HERE.
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*All photo credits: Replica
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