System Planning

Thorough planning is essential for the successful installation of any additive manufacturing (AM) system, whether polymer or metal. Accurate, proactive preparation minimises costly delays, rework, and compliance risks while ensuring a smooth and efficient transition from delivery to production. A structured installation plan allows for controlled timelines, manages critical milestones, and ensures that all infrastructure, equipment, and utilities are in place and aligned with the machine supplier’s technical requirements and the operating organisation’s needs.
Central to this process is the layout and design of the operational area. Spatial planning must prioritise safety, ergonomic efficiency, and workflow optimisation to minimise unnecessary movement, reduce material handling, and maximise operator productivity. Just as important is validating OEM specifications against local codes, environmental standards, and site-specific constraints, ensuring full regulatory compliance and future scalability.
Installation planning can be particularly challenging for new entrants to AM, as OEM-provided documentation often assumes prior knowledge and may vary significantly depending on optional components, system configurations and externally supplied 3rd party ancillary equipment. With direct experience supporting over 200 installations across metal and polymer platforms, we understand the common pitfalls and critical success factors. Our involvement starts at the point of system consideration, helping clients interpret OEM requirements, evaluate facility readiness, and anticipate hidden complexities.
Most installation guides are geared toward facility managers with an assumed baseline of system knowledge. We bridge that gap, translating technical requirements into actionable steps for stakeholders across procurement, operations, and engineering. Our hands-on experience enables us to quickly identify and resolve issues before they impact timelines or budgets, keeping projects on track and within controlled, predictable costs.
By aligning infrastructure with system specifications and ensuring readiness for OEM commissioning and training, our planning support accelerates the path to full operational capability. The result is a smoother startup, faster ROI, and a solid foundation for efficient, sustainable, and scalable additive manufacturing operations.
System Type
Successful implementation of an additive manufacturing (AM) setup begins with a strategic assessment of whether AM is the right solution for your application. This involves evaluating part complexity, customization needs, production volumes, and total cost of ownership. It is essential to account for not only the core system cost, but also all peripheral requirements, such as: post-processing equipment, material handling, consumables storage, facility upgrades, and the costs of service contracts, software, and training.
Once AM is confirmed as the appropriate technology, selecting a system that aligns with your production goals becomes critical. Considerations should include build volume, layer resolution, throughput requirements, material compatibility, and the system’s ability to scale with future product needs. A platform that supports both current and projected demands will deliver a stronger return on investment and enable seamless integration into your production environment.
Beyond equipment selection, effective installation planning is vital to operational success. This includes aligning infrastructure with OEM specifications, ensuring regulatory compliance, and optimizing facility layout for workflow and ergonomics. With our vast experience in AM installations, we help clients navigate OEM documentation, interpret technical requirements, and anticipate potential challenges. This comprehensive, front-loaded approach minimises delays, controls costs, and accelerates time to full production, laying the foundation for long-term performance and growth.
Installation and Planning
Additive manufacturing (AM) systems are highly sensitive to environmental and operational conditions, making meticulous installation planning essential for long-term success. Proper preparation ensures that all infrastructure and support systems, such as power, ventilation, and temperature control, meet the OEM’s specifications, significantly reducing the risk of build failures, material contamination, or unplanned downtime. A structured plan also manages delivery schedules, site readiness, and time-critical dependencies to ensure a seamless setup and commissioning process.
Beyond the core AM system, the integration of third-party equipment and peripheral technologies (e.g., post-processing units, material storage, sieving stations) have significant impacts on spatial layout and infrastructure requirements. Consideration must be given to health and safety regulations such as COSHH (Control of Substances Hazardous to Health), particularly where fine powders or volatile materials are involved. Adequate ventilation, extraction systems, fire safety measures, and secure chemical handling protocols are vital for compliance and operational safety.
Equally important is designing the workspace with the needs of personnel in mind. Efficient layout planning should support ergonomic workflows, minimise unnecessary movement, and provide sufficient space for maintenance, inspection, and material handling. Creating a safe, functional, and compliant working environment not only enhances productivity but also supports staff well-being and retention. Comprehensive, people-centred installation planning is a cornerstone of reliable, scalable additive manufacturing operations.
Optimising Layout and Workflow
While an efficient and future-ready layout is essential for additive manufacturing (AM) systems, a forward-thinking design also plays a critical role in supporting safe, ergonomic workflows across key operational tasks, including material loading and unloading, part handling, and post-processing. Strategically planned workspaces that incorporate clearly defined zones for clean and used media, logical material flow, and effective dust and vapor control significantly reduce the risk of contamination, improve operator safety, and maintain consistent part quality.
Beyond enhancing daily operational efficiency, a well-optimisedlayout contributes to lower operating costs by streamlining movement, reducing material loss, and minimising rework. Planning with future flexibility in mind enables the seamless integration of new equipment and facilitates the scaling of operations without major disruptions. Thoughtful consideration of the positioning and interaction of adjacent systems, such as de-powdering stations, automated material handling, or finishing equipment, ensures process compatibility, eliminates workflow bottlenecks, and supports a cohesive, high-performance production environment. Ultimately, a thoroughly designed facility layout not only protects personnel and product quality but also strengthens operational resilience and long-term return on investment.
Compliance
Additive manufacturing systems must comply with a range of stringent safety, handling, and environmental regulations to ensure safe, efficient, and legally compliant operations. This includes full alignment with machine supplier specifications and all applicable local and national standards. Key regulatory requirements include ATEX directives for explosive atmospheres, particularly relevant when processing fine polymer or metal powders, as well as adherence to fire codes, dust control measures, and COSHH (Control of Substances Hazardous to Health) for the proper handling, storage, and disposal of hazardous materials.
Operational safety is further supported by PUWER (Provision and Use of Work Equipment Regulations) and LOLER (Lifting Operations and Lifting Equipment Regulations), which ensure that all equipment is appropriate, well-maintained, and safely used during installation and material handling. RAMS (Risk Assessments and Method Statements) are also critical for identifying potential hazards and implementing safe working procedures throughout the system lifecycle.
Early planning should address all critical infrastructure requirements, including utility loads, ventilation and exhaust systems, temperature and humidity control, and certification needs. This proactive approach prevents compliance issues, costly delays, and operational inefficiencies. Comprehensive risk assessments, COSHH procedures, and alignment with relevant ISO standards further support structured workflows, safe operations, and long-term regulatory compliance tailored to the specific demands of powder-based additive manufacturing.
System Type
Successful implementation of an additive manufacturing (AM) setup begins with a strategic assessment of whether AM is the right solution for your application. This involves evaluating part complexity, customization needs, production volumes, and total cost of ownership. It is essential to account for not only the core system cost, but also all peripheral requirements, such as: post-processing equipment, material handling, consumables storage, facility upgrades, and the costs of service contracts, software, and training.
Once AM is confirmed as the appropriate technology, selecting a system that aligns with your production goals becomes critical. Considerations should include build volume, layer resolution, throughput requirements, material compatibility, and the system’s ability to scale with future product needs. A platform that supports both current and projected demands will deliver a stronger return on investment and enable seamless integration into your production environment.
Beyond equipment selection, effective installation planning is vital to operational success. This includes aligning infrastructure with OEM specifications, ensuring regulatory compliance, and optimizing facility layout for workflow and ergonomics. With our vast experience in AM installations, we help clients navigate OEM documentation, interpret technical requirements, and anticipate potential challenges. This comprehensive, front-loaded approach minimises delays, controls costs, and accelerates time to full production, laying the foundation for long-term performance and growth.
Installation and Planning
Additive manufacturing (AM) systems are highly sensitive to environmental and operational conditions, making meticulous installation planning essential for long-term success. Proper preparation ensures that all infrastructure and support systems, such as power, ventilation, and temperature control, meet the OEM’s specifications, significantly reducing the risk of build failures, material contamination, or unplanned downtime. A structured plan also manages delivery schedules, site readiness, and time-critical dependencies to ensure a seamless setup and commissioning process.
Beyond the core AM system, the integration of third-party equipment and peripheral technologies (e.g., post-processing units, material storage, sieving stations) have significant impacts on spatial layout and infrastructure requirements. Consideration must be given to health and safety regulations such as COSHH (Control of Substances Hazardous to Health), particularly where fine powders or volatile materials are involved. Adequate ventilation, extraction systems, fire safety measures, and secure chemical handling protocols are vital for compliance and operational safety.
Equally important is designing the workspace with the needs of personnel in mind. Efficient layout planning should support ergonomic workflows, minimise unnecessary movement, and provide sufficient space for maintenance, inspection, and material handling. Creating a safe, functional, and compliant working environment not only enhances productivity but also supports staff well-being and retention. Comprehensive, people-centred installation planning is a cornerstone of reliable, scalable additive manufacturing operations.
Optimising Layout and Workflow
While an efficient and future-ready layout is essential for additive manufacturing (AM) systems, a forward-thinking design also plays a critical role in supporting safe, ergonomic workflows across key operational tasks, including material loading and unloading, part handling, and post-processing. Strategically planned workspaces that incorporate clearly defined zones for clean and used media, logical material flow, and effective dust and vapor control significantly reduce the risk of contamination, improve operator safety, and maintain consistent part quality.
Beyond enhancing daily operational efficiency, a well-optimisedlayout contributes to lower operating costs by streamlining movement, reducing material loss, and minimising rework. Planning with future flexibility in mind enables the seamless integration of new equipment and facilitates the scaling of operations without major disruptions. Thoughtful consideration of the positioning and interaction of adjacent systems, such as de-powdering stations, automated material handling, or finishing equipment, ensures process compatibility, eliminates workflow bottlenecks, and supports a cohesive, high-performance production environment. Ultimately, a thoroughly designed facility layout not only protects personnel and product quality but also strengthens operational resilience and long-term return on investment.
Compliance
Additive manufacturing systems must comply with a range of stringent safety, handling, and environmental regulations to ensure safe, efficient, and legally compliant operations. This includes full alignment with machine supplier specifications and all applicable local and national standards. Key regulatory requirements include ATEX directives for explosive atmospheres, particularly relevant when processing fine polymer or metal powders, as well as adherence to fire codes, dust control measures, and COSHH (Control of Substances Hazardous to Health) for the proper handling, storage, and disposal of hazardous materials.
Operational safety is further supported by PUWER (Provision and Use of Work Equipment Regulations) and LOLER (Lifting Operations and Lifting Equipment Regulations), which ensure that all equipment is appropriate, well-maintained, and safely used during installation and material handling. RAMS (Risk Assessments and Method Statements) are also critical for identifying potential hazards and implementing safe working procedures throughout the system lifecycle.
Early planning should address all critical infrastructure requirements, including utility loads, ventilation and exhaust systems, temperature and humidity control, and certification needs. This proactive approach prevents compliance issues, costly delays, and operational inefficiencies. Comprehensive risk assessments, COSHH procedures, and alignment with relevant ISO standards further support structured workflows, safe operations, and long-term regulatory compliance tailored to the specific demands of powder-based additive manufacturing.
Quality Planning Prepared for Operational Success
Successful additive manufacturing (AM) implementation begins with thorough installation planning. Aligning facility infrastructure, environmental controls, safety compliance, and workflow layout with OEM specifications ensures efficient, safe, and scalable operations. Considerations include utilities, ventilation, powder handling, ergonomic design, and regulatory requirements such as COSHH, ATEX, PUWER, and LOLER. Integrating peripheral systems and futureproofing for expansion further supports long-term productivity. With experience in over 200 installations, our team helps mitigate risks, reduce downtime, and accelerate time to value, ensuring your AM system performs reliably from day one.

