With 3D printing and topology optimisation, Baader has made a critical component three times lighter—while also creating a globally standardised solution that is more robust, cheaper, and easier to produce.
The challenge: A design that was too heavy and fragmented component variation
Baader is a global leader in machinery for food processing. However, their previous component design created several challenges:- A single plastic component weighed as much as 1,198 grams and overloaded the shaft joints.
- Frequent breakdowns and wear.
- Different versions of the same part were used across the machine fleet—depending on supplier and location.
- Production depended on local CNC suppliers in Denmark, making it difficult to scale efficiently.
The solution: Lightweight optimisation and a digital standard
By switching to 3D printing in PA12 (food-safe) and implementing topology optimisation, Baader succeeded in:- Reducing the weight by 63 %
- Extending the service life of the machine’s moving parts.
- Creating one standardised design that can be produced anywhere in the world.
- Reducing lead time from 15 to 10 days.
- Achieving greater design freedom and removing unnecessary complexity in the production stage.
Business value: Faster, lighter, and globally scalable
Compared with traditional CNC milling, Baader achieves with 3D printing:- A more robust supply setup with access to global SLS suppliers.
- An overall resilience score of 4.3 out of 5, compared with 2.3 previously.
- A component optimised for functionality rather than machinability.
- Savings on spare-parts inventory, because the same part can now be used across the entire portfolio.
The climate perspective: Less weight, less transport, and lower CO₂e
Weight reduction and local production play a central role in reducing Baader’s carbon footprint:- Less material and waste during manufacturing.
- Localised production enables shorter transport distances.
- Digital production removes the need for large inventories and physical distribution.
- In previous analyses, such redesigns have been shown to reduce CO₂e by up to 60 %.
The future: Standardisation and digital inventory
With the component now digitised and globally available as a 3D print file, this opens up:- Digital inventory and on-demand production at multiple locations.
- Future use of lightweighting and generative design.
- Shorter time-to-market and faster service for customers globally.
