3D Printing for Ergonomic Design in Manufacturing Facilities

Workplace ergonomics are extremely important, especially for workers in manufacturing facilities. The repetitive motions these workplaces may require can easily lead to stress, strain, and musculoskeletal disorders that may require weeks of rest for a full recovery.

With 3D printing, it may be possible to custom-create ergonomic equipment and tools that make working in manufacturing facilities much more comfortable and less risky.

The New Focus on Ergonomics in Equipment Design

Without the right tools, workers may be required to move in a way that is awkward, painful, or puts significant strain on muscles, tendons, and joints.

Cumulative strain can lead to repetitive stress injuries over time, but even a single bad motion can cause serious injury. Awkward and difficult motions may also put workers at greater risk of a slip, fall, or struck-by incident, amplifying the dangers that already exist in most manufacturing facilities.

Musculoskeletal (MSK) injuries are expensive to both employers and employees – and the price of treating MSKs has steadily risen over the past few decades.

Workers often need more than a week off work to recover from an MSK, and MSKs like carpal tunnel syndrome may require as many as 25 days on average for recovery. Long-term damage may remain after this recovery as well, potentially making workers more prone to future injuries.

Preventing MSKs With Ergonomic Working Practices and Equipment

The right tool can make daily work both more efficient and more comfortable. Many facilities that need workers to move barrels without a forklift, for example, will rely on something like a lifting drum transporter that workers can use to lift and wheel barrels around the facility.

Using one of these tools will likely be much safer than manually lifting or rolling a barrel to its destination.

Other ergonomic manufacturing tools include lift aids, transportation devices, and adjustable-height platforms. These tools make moving goods easier and can reduce the amount of stooping, stretching, and bending that workers will need to perform on a daily basis.

Using 3D Printing to Create Ergonomic Equipment

Sourcing the right equipment can be both expensive and time-consuming, however. The purchase of a tool that will be used infrequently may also be hard to justify.

3D printing may help. With a 3D printer, it’s possible to economically custom-manufacture ergonomic tools and manufacturing equipment that workers can use to make their movements less painful or repetitive.

Additive manufacturing techniques, like 3D printing, are often much more cost-effective than conventional, subtractive manufacturing techniques when manufacturing volume is low – for example, when a business is prototyping a new product or manufacturing just a few items.

The low cost of 3D printing makes the technology useful when businesses need unusual, personalized, or custom designs – like ergonomic tool grips that can modify existing equipment or be used in future tools.

If a business needs to print just a few copies of a single tool or component, conventional manufacturing methods may be cost-prohibitive. The same job may be practical with 3D printing, however.

Businesses can use 3D printing to create ergonomic lift aids and transportation devices as needed, providing workers with supportive equipment without having to pay as much as these aids would traditionally require.

The same businesses can also use 3D printers to create replacement parts or components, potentially making those ergonomic tools easier to repair or maintain.

Custom orders are also much more practical with 3D printing, meaning businesses may be able to tweak designs and adjust the functionality of ergonomic equipment as needed for their particular needs.

3D printing can also help reduce a company’s carbon footprint. Shipping can generate significant emissions, but 3D printing allows a company to manufacture components or tools closer to where they are needed – helping to minimize shipping emissions and the overall carbon cost of a new tool.

How 3D Printing Can Help Make Manufacturing Jobs More Ergonomic

With ergonomic equipment, businesses can help reduce the risk of injuries due to strain or repetitive motion. Manufacturing ergonomic equipment can be uneconomical, however. 3D printing may be one solution. With a 3D printer, businesses can create ergonomic tools or components that may make work much safer.