Going beyond physical boundaries and embracing 3D modeling

3D modeling and virtualization insights

Embracing 3D modeling in manufacturing enhances decision-making, boosts innovation and reduces risks, offering a competitive edge over traditional methods.

Failing to adopt 3D modeling technology can lead to costly misinterpretations, inefficient operations, and missed opportunities for innovation and optimization.

In the fast-paced world of manufacturing, 3D modeling technology can change operations by offering streamlined operations, sharper decision-making and greater innovation. Understanding its benefits and the risks of not embracing it is crucial.

Traditional 2D diagrams are essential but often insufficient for depicting the details of physical plants and processes. Detail often equates to money, and 3D modeling offers lifelike simulations that validate data integration before real-world deployment. This functionality allows manufacturers to test advanced systems like manufacturing execution systems (MES) without needing physical equipment, providing a chance to “try before you buy.”

These capabilities boost confidence in engineering assumptions and throughput calculations while enhancing facility planning through laser scans, ensuring design accuracy and alignment with physical constraints (see Figure 1).

Figure 1: Spot in action on a case packing line, enhancing automation and operational efficiency. Courtesy: Gray Solutions

3D modeling is a powerful resource for technical evaluators, allowing them to explore design intent visually and identify optimal solutions before project initiation. The seamless integration with computer-aided design (CAD) systems fosters collaboration across diverse technical resources, improving communication and early risk management. This visualization reduces ambiguity and misinterpretation from cryptic 2D drawings, making complex designs conveyable through visual simulations.

Moreover, 3D modeling enables precise scenario testing without hefty investments in physical equipment, encouraging innovative exploration. Research and development (R&D) concepts can be validated through virtual or hybrid systems, expediting proof of concept and minimizing resource allocation. This promotes cross-platform synergy and innovation through seamless integration with databases, AI tools and communication systems (see Figure 2).

Figure 2: A close-up view of the automated case packing process, optimizing packaging operations. Courtesy: Gray Solutions

Business, technical benefits of 3D Modeling

3D modeling enhances comprehension of equipment and costs through immersive simulations, aiding decision-making before capital expenditure. It provides a direct visual representation of design intent, streamlining communication and pre-implementation validation. Tools can ensure connectivity before real-world deployment, reducing risks and potential roadblocks.

For technical buyers, 3D models empower visual exploration of design intent, identifying optimal solutions before investments. The integration with CAD systems fosters interdisciplinary collaboration, while virtual testing validates engineering assumptions related to throughput without physical equipment. This precision in facility planning, combined with proactive risk mitigation, addresses backend scenarios and test scripts early on, reducing later-stage bottlenecks and issues.

Modernization benefits

The benefits of 3D modeling extend to modernization efforts, offering accurate scenario testing without significant upfront investments, which promotes innovative exploration (see Figure 3). Virtual equipment and hybrid systems expedite R&D concept validation, minimizing resource commitment. 3D modeling also provides versatile integration with diverse technology platforms, fostering cross-platform synergy and innovation. These advantages underscore the significant influence of 3D modeling on comprehension, technical accuracy, and innovation.

Figure 3: Precision barrel filling system visualized in Emulate 3D, highlighting high-speed accuracy and control. Courtesy: Gray Solutions

However, the risks of not adopting 3D modeling in manufacturing should not be overlooked. Not utilizing this technology isn’t just a missed opportunity — it’s a potential pitfall.

The downside of not adopting 3D modeling

Skipping 3D modeling technology means missing out on visual clarity and accurate cost estimation, leading to potential business risks. Without these tools, companies may struggle to interpret concepts and proposed costs, akin to shopping in a “no returns” section. This lack of preemptive testing and validation can make integrating new equipment and processes difficult and reduce the engineer’s ability to make informed decisions and proactively identify and correct issues.

For those involved in technical evaluation, skipping 3D process or system simulation can disrupt design concepts, commissioning and training phases. Ignoring emulation can lead to issues during commissioning, particularly with untested code. Tools can help mitigate these risks by testing code and processes early. Resource selection is another critical area, as having skilled simulation and modeling experts is crucial for reliable virtual designs (see Figure 4).

Figure 4: Autonomous mobile robots (AMRs) navigating a production line, improving material handling and logistics. Courtesy: Gray Solutions

For innovation-focused organizations, the absence of 3D modeling hinders scenario testing and exploration. Financial limitations may restrict new ideas, and specific real-world elements, such as varying food products, cannot be simulated. This limits the potential to explore new scenarios, including immersive “what If” testing using virtual reality (VR).

Addressing these challenges demands seasoned professionals, meticulous planning and comprehensive understanding. Mitigating these risks means manufacturers can unlock 3D modeling’s full potential across modern manufacturing.

Simulation and modeling’s future in manufacturing

Looking ahead, simulation and modeling will increasingly integrate with digital twin design, blending seamlessly with traditional engineering. This vision sees operations, strategists and technical resources using these tools for integrated design and innovation. Digital twin technology is set to surpass traditional supervisory control and data acquisition (SCADA) and human-machine interface (HMI) systems, marrying simulation and modeling with real-time plant data, empowering innovation, design and strategies.

As AI and digital twin technologies evolve, the demand for virtualized factory solutions will enhance AI insights and digital twin potential. This convergence of real-time insights, virtualization and intelligent design will reshape manufacturing, establishing new standards for design and operation.

Chad Wedding is a modeling engineer at Gray Solutions.

Original content can be found at Control Engineering.

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