FUJIFILM Biotechnologies: Reduced lead time and greater agility in production with 3D printing

A springboard for scaling additive solutions more broadly across the organisation

FUJIFILM Biotechnologies reduces lead time and increases production agility with 3D printing. By rethinking a key component as an additive solution, they achieve significantly faster delivery, less complexity, and lower inventory tied up in stock-while also taking the first step towards a more scalable and flexible production model.

The case: Overview and context

FUJIFILM Biotechnologies is an international CDMO player, where high-speed production and frequent changeovers are a natural part of the business. With capacity expansions and new facilities, efficiency and flexible solutions are crucial to keeping processes scalable. Therefore, technologies that can reduce bottlenecks and strengthen equipment robustness are particularly relevant to them.

They were familiar with 3D printing, but primarily for small, non-critical prototype applications, and were looking for a way to work more systematically with additive solutions using already approved materials. The ambition was to test whether 3D printing could create operational agility and reduce time, complexity, and tied-up inventory.

The development process was designed for rapid iterations and to identify the most valuable place to start, so that FUJIFILM could obtain a reliable proof of concept without committing additional resources or time.

As part of the programme, key employees were trained, enabling them to translate the technological possibilities-such as metal and (plastic) powder technologies-into a significantly greater potential than previously.

Results and potential

The results clearly demonstrate the potential: the 3D-printed gripper can be delivered in one-sixth of the time, at no higher cost, and enables a significant reduction in tied-up inventory and air freight. AM enables local production close to the site, avoiding air freight when time is critical-or having too many parts produced and sitting in stock. Increased digitalisation with print-optimised parts enables much faster changes and optimisation of sub-components, making it realistic to expand the share of 3D-printed parts without major investments in in-house design capabilities.

This provides a springboard for scaling additive solutions more broadly across the organisation, also across sites and national borders-from fast internal parts to more flexible process equipment, as capabilities and practices mature.

Results from programmes with Dansk AM Hub

Up to 6x shorter delivery time for components
Significantly reduced tied-up inventory and less need for air freight
Consolidation of approx. 20 parts into one single component
Increased flexibility and faster adaptation of production equipment

Value and impact for the company

Through the AM Sustain programme we worked in collaboration with the Danish Technological Institute to convert a classic (milled metal) vacuum gripper into an additively optimised solution: significantly lower weight, improved vacuum distribution, and design consolidation from around 20 parts to a single integrated component. As the component must operate in pharmaceutical production, the design was based on already approved material, with a focus on ease of cleaning and surfaces that meet FUJIFILM’s requirements.

About the company