Embracing industry 4.0
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IN conversation with Deepkamal Kaur, Dr CR Tripathy, Dean, School of Engineering, Design and Automation, GNA University, says that students need to be trained in design and robotic technologies to be industry-ready.
Industry 4.0 represents a paradigm shift in manufacturing and design, where advanced technologies and automation redefine traditional processes. This transformation addresses global challenges such as workforce shortages and skill gaps while fostering innovation and efficiency.
Japan’s ageing society highlights this shift, as companies face increasing staff shortages — 85 per cent to 89 per cent of organisations reported challenges in recent years. Similarly in India, many graduates remain unemployed due to an education system struggling to provide relevant skills for the industry.
Under the umbrella of Industry 4.0, technologies like Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM), Computer-Aided Engineering (CAE) and Product Lifecycle Management (PLM) streamline operations from conceptualisation to production.
Innovations like Augmented Reality, Virtual Reality and Industrial Internet of Things enhance product visualisation, process optimisation and connectivity. Fused Deposition Modelling and robotics are central to automation, enabling precise, faster production with fewer errors, better quality control and improved synchronisation of processes.
According to the International Federation of Robotics, China has surpassed the US in manufacturing robot density, marking a significant milestone in industrial automation.
Automation shifts manual tasks to mechanised processes involving mechanical, electronic and computer technologies. This is critical for faster production rollout, meeting high accuracy demands and minimising errors. Robots are increasingly utilised across sectors like production, military, security, commerce and transportation. These advancements also extend to household tasks, emphasising the ubiquity of robotics in the future.
Rapid prototyping, a vital aspect of Industry 4.0, facilitates part-building processes with minimal human intervention. Technologies like additive manufacturing, particularly FDM, simplify prototype creation by converting CAD files to STL formats for 3D printing. This integration reduces material waste, enhances customisation and accelerates production cycles.
In comparison, CNC machining requires extensive manual input, specialised tools, and time-consuming secondary operations. Additive manufacturing provides a seamless approach to creating intricate designs while minimising risks associated with prototype development.
The design cycle evolves significantly in Industry 4.0. Traditional processes involve distinct stages, from concept design to production, with higher costs incurred in later stages. Industry 4.0 emphasises early prototyping to reduce these costs. Studies suggest that a product’s delayed market entry by six months can result in the loss of 66 per cent of gross profit margins. Furthermore, by the detailed design stage, 80 per cent of the product cost is already finalised, underscoring the importance of early-stage efficiencies.
Additive manufacturing has broad applications across industries such as aerospace, automotive, defence and medical fields. It supports customisation, reduces energy consumption and adapts quickly to new product designs. The FDM is particularly prominent, offering solutions for design verification, functional testing, marketing models and tooling.
The potential of Industry 4.0 extends to education and research, promoting STEM through accessible 3D printing technology. This fosters hands-on learning experiences and prepares future generations for a digitally-driven industry landscape. Innovations like biocompatible tissue scaffolds in biomedical applications showcase how additive manufacturing can meet complex demands while advancing sustainability and efficiency.
Industry 4.0 is further exemplified by initiatives like the European 4.0 Transformation Centre at Aachen University, Germany, which demonstrates the rapid development of complex projects such as the e.GO Life electric car. Developed in under three years with only €30 million invested, this project epitomizes the resourcefulness and adaptability of Industry 4.0 technologies.
As industries adopt these advancements, the convergence of digitalisation, automation and innovation continues to reshape the global manufacturing and design landscape.
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