INDEX-Werke

The Challenge

INDEX manufactures high precision CNC turning machines used worldwide in industrial production. A key component within these systems is the bar feeder, which transports raw material into the machining area.

The bar feeder relies on two critical parts working together:

• A slider trolley

• A clamping piece

These components were previously produced using conventional manufacturing processes that involved multiple parts, welding, assembly and several suppliers.

This approach created several challenges:

• Complex manufacturing processes

• High assembly effort

• Long lead times for replacement parts

• Increased production costs

• Quality issues caused by weld seams

The company wanted to explore whether metal additive manufacturing could simplify production and improve overall efficiency.

The Solution

INDEX introduced metal 3D printing to manufacture the slider trolley and clamping piece using its in-house One Click Metal MPRINT system.

Using additive manufacturing allowed the team to redesign the parts so they could be produced as single components rather than multiple assembled parts.

This brought several benefits:

• Reduced assembly steps

• Simplified supply chain

• Faster production times

• Improved part consistency

The clamping piece, which previously required several components and multiple assembly steps, can now be printed as a single part with threads already included in the design.

Similarly, the slider trolley design was optimised for additive manufacturing, reducing both material usage and print time.

Results

The adoption of metal 3D printing delivered significant improvements in both cost and production efficiency.

Key results include:

• 62 percent reduction in manufacturing costs

• 80 percent reduction in assembly effort

• 66 percent less storage space required

• 10 percent reduction in scrap

Lead times were also dramatically reduced. Conventional production required up to 42 days, while additive manufacturing enables production and finishing in approximately 10 days.

This allows INDEX to produce spare parts and customised components much faster, improving flexibility across its production operations.

Looking Ahead

The successful integration of metal additive manufacturing has opened new opportunities for INDEX to optimise further components within its machines.

By continuing to redesign parts specifically for additive manufacturing, the company aims to reduce material use, simplify production and respond more quickly to changing customer requirements.

Conclusion

Metal 3D printing has enabled INDEX to transform the production of critical components within its CNC turning machines.

By moving from complex multi-part assemblies to optimised single-piece designs, the company has reduced costs, shortened lead times and improved manufacturing efficiency.

This project demonstrates how metal additive manufacturing can deliver real value for industrial production environments.

Ready to bring your designs to life? Get in touch with our team today to discover how our expertise and cutting-edge technology can help turn your vision into reality. Call the team on: 01782 814551 drop us an email at: info@tritech3d.co.uk