3D Printing: Rapidly Turning Concepts into 3D Models One Layer at a Time
3D printing, better known as additive manufacturing, is the development of a three-dimensional object from a CAD or digital 3D concept. The term 3D printing refers to various processes that include deposition, combining, or hardening of material under digital control to produce a 3D object with the layer by layer addition of the materials. Industrial 3D printing is at the cusp of progress and is about to be the next big disruptor technology. 3D printing covers a broad spectrum of processes and techniques that confer extensive capabilities for producing components and items using different materials.
New 3D printing applications are arising every day. As the penetration of technology perpetuates across various industrial verticals, the scope of 3D printing is poised to snowball. In the last decade, 3D printing has exceeded its primary prototyping and manufacturing applications as the technology is now easily accessible to everyone, from individuals to small companies, opening up a broader audience on all fronts. 3D printing is an emerging technology that augments and propels innovation with extraordinary freedom for designing while simultaneously existing as an equipment-less technique that effectively reduces costs and saves time. According to Emergen Research, the global 3D Printing Market is poised to attain a market valuation of USD 28.23 Billion by 2027, expanding at a CAGR of 13.7%.
3D Printing ‒ The Historical Layer
The foremost 3D printing technology first came to surface in the late 1980s when the procedure was called Rapid Prototyping (RP) technology. The technique was so-called because the procedures were primarily thought of as a rapid and cost-effective method to produce prototypes for product development in industrial verticals. One of the first patent applications for rapid prototyping was registered by a Japanese Dr Kodama, in May 1980. However, the first patent for the technology issued to Charles Hull for his invention of stereolithography apparatus (SLA) machine in 1983. Charles Hull then co-founded 3D Systems Corporation, which is one of the pioneering and enormous conglomerates in the 3D printing market today.
Over the years after that, several patent applications for 3D printing processes and techniques were filed. The early 90s witnessed a surge in the emerging companies in the industry with only three of the original companies standing still today, namely ‒ 3D Systems, Stratasys, and EOS. Through the 90s and early 2000s saw the emergence of a broad spectrum of technologies, focuses on industrial applications while simultaneously extensive R&D was carried out for specific tooling, casting, and manufacturing applications.
The 2010s became the first decade where metal end-use materials such as engine brackets and large nuts were developed using additive manufacturing. 3D printing or additive manufacturing started making significant inroads over the years with the market witnessing substantial growth. Additive manufacturing was extensively applied in the aviation industry. With the number of air travelers crossing 3.8 million in 2016, the demand for fuel-efficient and efficiently designed jet engines was like never before. Large original equipment manufacturers (OEMs) such as General Electric and Pratt and Whitney turned towards additive manufacturing to reduce manufacturing costs, develop lightweight engines to increase fuel efficiency, and minimize the number of non-conforming parts. GE’s LEAP engine, which was delivered to Airbus, is one of the prime examples of 3D printing. The engine is equipped with 3D printed fuel nozzles that confer reduction of parts from 20 to 1 and 25% reduction in weight and decreased assembly times.
As the technology continued to develop, manufacturers and companies started focusing on 3D printing with some people speculating its more prominent role in the sustainable development of the ever-developing world.
3D Printing: The Technology Layer
Similar to traditional printers, 3D printing is done through a variety of technologies. The predominantly used technique is fused deposition modeling (FDM), otherwise called fused filament fabrication (FFF). This technology incorporates a filament, primarily composed of acrylonitrile butadiene styrene (ABS) or some other thermoplastic, and is deposited in layers via a heated nozzle after the material has melted. One of the first 3D printers of the sector, developed by Stratasys, implemented FDM technology.
Another technology is stereolithography, wherein UV laser is used for ultraviolet-sensitive photopolymer, tracing the desired object on its surface. The polymer typically solidifies where the beams touch while the beam prints the selected object in layers according to the CAD or CAM file.
On the other hand, a digital light projector (DLP) 3D printing subjects a liquefied polymer to light through a digital light processing projector. This method solidifies the polymer layer-by-layer till the item is developed, and the excess liquid polymer is removed by draining. Other techniques include multi-jet modeling and selective laser sintering (SLS).
Depending on the procedure, 3D printers utilize numerous materials, including but not limited to plastics, metals, polymers, ceramics, glass, plaster, and even food items like icing, cheese, and chocolate.
3D Printing Market: The Developmental Layer
Additive manufacturing is currently making inroads to pave the way for a digital reinvention in the manufacturing industry, both technology and economy-wise. For nations to comprehend the economic and environmental benefits of additive manufacturing in the rapidly digitizing world, extensive awareness campaigns and government initiatives are necessary.
3D printing is revolutionizing every industry vertical from aviation to healthcare. For instance, surgeons from the Israeli Galilee Medical Center (GMC) have introduced an innovative technology with the combination of 3D printing and Augmented Reality (AR) to treat eye socket fractures. The technique is believed to be a first-of-its-kind in the world, and the surgeons developed a metal implant for the patient and using Microsoft HoloLens glasses accurately placed the implant in the skull. The procedure was both rapid and precise, opening up new opportunities for improving patient outcomes and diminishing the need for follow-up surgeries.
Each generation of Mars rover sent by NASA’s Jet Propulsion Laboratory is extensively sophisticated than the previous one, which is why the next rover to land on Mars will include 11 metal parts manufactured by 3D printing. NASA’s car-sized Perseverance rover, which is programmed for a February 18, 2021, Mars landing, will have 11 3D printed parts within its two instruments ‒ PIXL and MOXIE. However, these structures will be secondary structures and will not interfere with the mission if they fail to work. PIXL will have five 3D printed parts: a fixture frame, a titanium shell of two pieces, and two supporting structures. MOXIE will have six 3D printed nickel allow heat exchangers to protect MOXIE’s sensitive parts from higher temperatures. In the longer-term, NASA and other private organizations are actively pursuing 3D printing construction systems for future missions on the Moon and Mars.
On January 5, 2021, Atomstack, a technology firm bringing about a revolution in the 3D printing market, made news for the launch of the world’s first thermoplastic rubber filament 3D printer, called “Cambrian”. The new and powerful 3D desktop printer utilizes the FDM technique and can virtually create any rubber end product while managing traditional 3D printing tasks simultaneously.
On January 6, 2021, Stratasys Ltd., a leading maker of 3D printers and 3D production systems, acquired 3D printing startup Origin Inc. Under the agreement, Origin’s software-centric 3D printing technology which is based on digital light processing (DLP) will be added to the portfolio of Stratasys.
In September 2020, Boston Micro Fabrication launched a micro-precision 3D printer, called the microArch S240, which can print microstructures nearly 100 times smaller than a human hair. The technology is apt for the manufacturing of medical devices, microfluidics, and others.
3D Printing: Benefits and Future Outlook Layer
3D printing is emerging as one of the highly energy-efficient technologies that can augment the environmental efficiencies, with regards to both the manufacturing process ‒ by using 90% standard materials and reducing material wastage ‒ and through 3D printed product’s lifespan ‒ by creating a lighter and resilient design that reduces carbon footprint.
Moreover, 3D printing is exhibiting lucrative potential in terms of manufacturing models, wherein the products are created at the place where they are in demand, thereby eliminating the need for huge inventories and unsustainable logistics. While 3D printing may not have a massive impact on the consumer’s everyday life, it definitely has the potential to revolutionize the global manufacturing industry, over the next few years.
