Ways in which 3D printing is revolutionizing the manufacturing industry.
3D printing is a method to make three-dimensional objects. It works differently from conventional manufacturing, which is subtractive, removing parts of a material to create the required shape. 3D printing adds layer upon layer till the part is created. That's why it is also called additive manufacturing.
How does 3D printing work?
The method consists of three steps, as briefly explained below:
1. Modeling
Manufacturers create 3D models of the object using software or what is known as computer-aided design (CAD). The model is saved in a printing file format, either stereolithography (STL) or an additive manufacturing (AMF) file. The files are reviewed for errors to prevent defects in the printed object.
2. Printing
The file is uploaded to the 3D printer, which deposits the material per the instructions. The bottom layer is first created and more layers stacked on to form the printed object.
3. Finishing
The printed object undergoes final touches. This could be the addition of a solvent to smooth out imperfections or create a glossy surface.
What are the benefits of 3D printing?
3D printing has become widespread due to its design and cost benefits. It offers the following key benefits:
More design freedom: Because 3D printing is additive, you can create more complex designs and customized products. In this sense, it is free from the restrictions of traditional manufacturing.
Faster prototyping: Once your CAD model is ready, printing can start immediately, and your model can be ready within the day. A huge advantage is that you can verify and develop design ideas rapidly.
Excellent to build lightweight parts: 3D printing can make strong yet lightweight parts that increase vehicle and aircraft efficiency. It can also use different materials to ensure higher strength, heat, water, and chemical resistance.
Cost-effective: Unlike injection molding, 3D printing does not become cost-effective as parts' volume increases. But as it requires little human oversight, labor cost is low. And as you can eliminate prototype errors sooner, you also avoid costly errors during production.
No waste/Environment-friendly: Additive manufacturing prevents the material wastage common in subtractive manufacturing. It also reduces material costs in parallel. Less waste of materials and the use of recyclable plastics reduce environmental impact.
Industries using 3D printing
Additive manufacturing technologies have the potential to transform several industries. They're particularly advantageous in the following sectors, where their uptake has predictably been high:
Industrial goods
Manufacturers of machinery components, tooling and equipment used to make other goods are leveraging 3D printing to reduce costs, innovate and respond to changes brought about by digitalization in the industry.
Use cases
Tooling
Spare parts
End use parts
Benefits
Shorter lead times
Ability to create complex designs
On-demand production
Automotive
Fully functional car parts can be 3D printed. Generative design using 3D printing and artificial intelligence creates high-performance design iterations in arenas of motorsports and performance racing.
Use cases
Tooling
3D-printed exteriors and interiors
Spare and replacement parts
End-use part
Benefits
Greater design flexibility
Faster production
More customization
Aerospace
Aircraft parts are complex and must be structurally sound to assure safety. In this high-consequence industry, additive manufacturing enables the production of complex parts efficiently. Some aerospace companies, including Boeing, GE, Airbus, and Safran, began using additive manufacturing as early as the 80s.
Use cases
Tooling
Prototypes
Lightweight components
Structural components for defense systems
Spare parts for engine components
Benefits
Reduced mass
Increased design flexibility
Reduced material cost
Low-volume production
Medicine
The traditional method of taking physical impressions and sending them to the laboratory is laborious and time-consuming. 3D printing allows custom implants, splints and surgical guides to be produced efficiently.
Use cases
Custom prosthetics and implants
Clear aligners
Anatomical models
Complex micro gadgets for health monitoring and drug delivery
Benefits
Patient-specific devices
New and innovative medical devices
Electronics
Additive manufacturing is disrupting the electronics industry. It represents the evolution of 2D printing for circuit boards using processes like inkjet and aerosol jetting. And it can be more powerful when paired with disruptive technologies like the Internet of Things (IoT).
Use cases
Electronics components such as resistors, antennas, capacitors, sensors, and thin film transistors
Sensor and network enclosures
Prototypes for complex electronics
OLED displays
Satellites
Benefits
Greater customization
Improved efficiency
Faster time to market
How long has 3D printing been around?
Since the 80s, although back then it was envisioned as a way to accelerate prototyping in industrial production. A number of inventors were working on their version of a rapid prototyping machine. The earliest 3D printer was created in 1981 by Dr. Hideo Kodama, who described his invention as a rapid prototyping machine. But the patent failed. In 1986, Chuck Hull filed the first patent for stereolithogaraphy, more commonly referred to as SLA 3D printing.
Around this time, multiple patents for 3D printing were filed, including Selective Laser Sintering (SLS) by Carl Deckard in 1987 and Fused Deposition Modeling (FDM) by S. Scott Crump in 1989. The 3D printing industry grew steadily through the 90s, and in 2006, the first SLS machine became commercially available.
A year prior marked a milestone for 3D printing technology, with the launch of the low-cost self-replicating 3D printer RepRap. Anyone with RepRap could print another 3D printer, and other parts and designs. More commercial 3D printers followed, including the MakerBot in 2009, an open-source DIY kit for buyers to build their own 3D printers.
In 2011, Utrecht-based Prototype FabLabs built a 3D printer inspired by the RepRap project, as a way to create accurate parts cost-effectively. But the time and upkeep it required to function properly drove the makers to brainstorm improvements, culminating into an ecosystem of software, hardware, and materials for industrial use.
In the last decade, 3D printing has taken off. A number of industries, from manufacturing, healthcare and aerospace, to automotive, architecture and construction use 3D printing to rapidly build models, prototypes and final products. The technology is revolutionizing parts and tools manufacturing at factories, generating spare parts on demand and allowing the personalization of tools.
The list of 3D printing materials has grown. Plastic and its various blends and types are the most widely used, and come in filament, resin, granule, and powder forms. 3D printing can create parts made of metal, glass fiber, and carbon fiber. Some 3D printing innovations are mind-boggling. Take bioprinting, which uses cells and biomaterials to create functional tissues, or 3D printed modular homes that combine 3D printing, robotics, and automation.
3D Printing Materials
As already mentioned, thermoplastics are the most commonly used 3D printing material. Other materials that can be 3D printed include metals, ceramics, and composites.
Materials are chosen based on their properties, such as heat resistance, flexibility, durability, UV resistance, and others. For example, dental applications use acrylic (PMMA) plastic, which is rigid, flexible, cost-effective, and low-density. Nylon and ABS are well-suited to 3D printing IoT enclosures. Gears and tools use nylon, a synthetic polymer with good heat and abrasion resistance and a low friction coefficient for smoother functioning. For prototyping, PLA, an inexpensive, easy-to-use and versatile plastic, is preferred. It is commonly used for 3D printing wear and tear decorative items.
3D Printing Technologies
There are seven types of 3D printing, each with its benefits and limitations. Here's a brief look at each:
Polymer 3D printing
Stereolithography (SLA)
This method uses ultraviolet laser beams to selectively cure thin layers of polymer resin. It is ideal for parts that need a high level of detail, tight tolerances and smooth surface finishes. But SLA prints are brittle, making them ill-suited for functional prototypes.
Selective laser sintering (SLS)
This process melts nylon-based powders into solid plastic. It creates stronger parts compared to SLA, but with rougher finishes. It is well-suited to functional prototyping, end-use parts and custom manufacturing.
This is a widely used desktop 3D printing technology for plastic parts. It involves extruding a plastic filament layer by layer until the part is complete. It creates parts that have low strengths and rough finishes, and is therefore mainly used for low-cost prototyping of simple parts.
Polyjet
It is used to fabricate strong, stiff parts that have a high heat resistance. An interesting aspect of this method is that it can create prototypes with multiple colors and materials.
Digital Light Processing (DLP)
Similar to SLA but using a digital light projector screen, DLP is used for rapid protoyping. As the size of the object depends on the projector and resolution of the image, this method is not suitable for very large models.
This method uses nylon powder and an inkjet array to build accurate and finely detailed functional prototypes and end-use parts.
Metal 3D printing
In this method, layers of metallic powder are melted and fused using a computer-controlled, high-power laser beam. Materials used include stainless steel, aluminium, and titanium. It creates parts with excellent surface quality and mechanical properties.
Electron Beam Melting (EBM)
In this method, metal powder is melted and fused layer by layer using a high electron beam. It is used to fabricate aerospace, automotive and medical parts and components.
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