Assemblies get complicated fast. What starts as a clean design can balloon into 10, 12, even 20 components — each with its own cost, lead time, tolerance stack, and failure risk.
But what if your 14-part assembly could be just 4 parts?
That’s not hypothetical — it’s exactly what we did for a recent customer.
Additive manufacturing (AM), when applied strategically, lets you consolidate multiple components into fewer, smarter parts — simplifying everything from sourcing to assembly to long-term performance.
What’s Wrong With Complex Assemblies?
More parts means:
- More touchpoints
- More fasteners, welds, and alignments
- More variation
- More chances for something to go wrong
It also means:
- Higher cost
- More labor
- Slower builds
- Harder troubleshooting
- Delays when even one piece is backordered
You’re not just managing parts — you’re managing risk.
Where Additive Makes the Difference
Additive manufacturing changes the rules of what’s possible in part design. You’re no longer limited by:
- Tool access
- Mold complexity
- Multi-axis machining
- Separate operations for internal features
That means you can combine multiple parts into one printed component — often eliminating:
- Fasteners
- Brackets
- Precision alignment steps
- Redundant hardware
Real Example: From 14 Parts to 4
A rail OEM came to 3DEO with a 14-part subassembly that required manual alignment and hand assembly by a technician — a slow, error-prone process.
We reviewed the system and delivered a simplified version:
- 2 printed components (with internal geometry CNC couldn’t produce)
- 2 off-the-shelf parts
- All aligned and optimized for performance and speed
They cut build time, reduced cost, and hit their production goals faster — without sacrificing function.
Expert Tip:
Additive isn’t about printing every part.
It’s about printing the right parts — the ones that unlock real simplification.
When Should You Simplify?
You’re likely ready to consolidate if:
- You’re using 3+ fasteners to hold something together
- Multiple components could share the same geometry
- Your assembly requires manual fitting or custom tooling
- You’re troubleshooting recurring failures at connection points
The Bottom Line
Additive lets you think beyond how parts are made — and start thinking in terms of how systems should work.
At 3DEO, we don’t just print parts. We help you:
- Identify smart consolidation opportunities
- Combine AM with off-the-shelf components
- Deliver simpler, stronger, faster-to-build assemblies
Start a design review — let’s see how much we can simplify.
