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A global sustainability perspective on 3d printing technologies
A global sustainability perspective on 3D printing technologies (2014) | Malte Gebler
Journal Article•DOI•
Additive manufacturing of metals
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Dirk Herzog1, Vanessa Seyda, Eric Wycisk, Claus Emmelmann1•Institutions (1)
Hamburg University of Technology1
15 Sep 2016-Acta Materialia
TL;DR: In this paper, the authors describe the complex relationship between additive manufacturing processes, microstructure and resulting properties for metals, and typical microstructures for additively manufactured steel, aluminium and titanium are presented.
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Abstract: Additive Manufacturing (AM), the layer-by layer build-up of parts, has lately become an option for serial production. Today, several metallic materials including the important engineering materials steel, aluminium and titanium may be processed to full dense parts with outstanding properties. In this context, the present overview article describes the complex relationship between AM processes, microstructure and resulting properties for metals. It explains the fundamentals of Laser Beam Melting, Electron Beam Melting and Laser Metal Deposition, and introduces the commercially available materials for the different processes. Thereafter, typical microstructures for additively manufactured steel, aluminium and titanium are presented. Special attention is paid to AM specific grain structures, resulting from the complex thermal cycle and high cooling rates. The properties evolving as a consequence of the microstructure are elaborated under static and dynamic loading. According to these properties, typical applications are presented for the materials and methods for conclusion.
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1,782 citations
Cites background from "A global sustainability perspective..."
Journal Article•DOI•
3D printing with polymers: Challenges among expanding options and opportunities.
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Jeffrey W. Stansbury1, Jeffrey W. Stansbury2, Mike J. Idacavage•Institutions (2)
Anschutz Medical Campus1, University of Colorado Boulder2
01 Jan 2016-Dental Materials
TL;DR: The goal of this review is to connect the various additive manufacturing techniques with the monomeric and polymeric materials they use while highlighting emerging material-based developments.
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Abstract: Objectives Additive manufacturing, which is more colloquially referred to as 3D printing, is quickly approaching mainstream adoption as a highly flexible processing technique that can be applied to plastic, metal, ceramic, concrete and other building materials. However, taking advantage of the tremendous versatility associated with in situ photopolymerization as well as the ability to select from a variety of preformed processible polymers, 3D printing predominantly targets the production of polymeric parts and models.
The goal of this review is to connect the various additive manufacturing techniques with the monomeric and polymeric materials they use while highlighting emerging material-based developments. Methods Modern additive manufacturing technology was introduced approximately three decades ago but this review compiles recent peer-reviewed literature reports to demonstrate the evolution underway with respect to the various building techniques that differ significantly in approach as well as the new variations in polymer-based materials being employed. Results Recent growth of 3D printing has been dramatic and the ability of the various platform technologies to expand from rapid production prototypic models to the greater volume of readily customizable production of working parts is critical for continued high growth rates. This transition to working part production is highly dependent on adapting materials that deliver not only the requisite design accuracy but also the physical and mechanical properties necessary for the application.
Significance With the weighty distinction of being called the next industrial revolution, 3D printing technologies is already altering many industrial and academic operations including changing models for future healthcare delivery in medicine and dentistry.
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790 citations
Journal Article•DOI•
Additive manufacturing and sustainability: an exploratory study of the advantages and challenges
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Simon Ford1, Mélanie Despeisse1•Institutions (1)
University of Cambridge1
20 Nov 2016-Journal of Cleaner Production
TL;DR: In this paper, the role of additive manufacturing process technology on industrial sustainability is investigated and the consequences of adopting this novel production technology are not well understood and an exploratory study draws on publically available data to provide insights into the impacts of additive additive manufacturing on sustainability.
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Abstract: The emergence of advanced manufacturing technologies, coupled with consumer demands for more customised products and services, are causing shifts in the scale and distribution of manufacturing In this paper, consideration is given to the role of one such advanced manufacturing process technology: additive manufacturing The consequences of adopting this novel production technology on industrial sustainability are not well understood and this exploratory study draws on publically available data to provide insights into the impacts of additive manufacturing on sustainability Benefits are found to exist across the product and material life cycles through product and process redesign, improvements to material input processing, make-to-order component and product manufacturing, and closing the loop As an immature technology, there are substantial challenges to these benefits being realised at each stage of the life cycle This paper summarises these advantages and challenges, and discusses the implications of additive manufacturing on sustainability in terms of the sources of innovation, business models, and the configuration of value chains
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709 citations
Cites background from "A global sustainability perspective..."
...Lightweight components will reduce energy consumption and could deliver savings of $56e219 billion by 2025 (Gebler et al., 2014)....
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...Savings are estimated at $113e370 billion by 2025, with these arising from reductions in material inputs and handling, along with shorter supply chains (Gebler et al., 2014)....
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...The adoption of additive manufacturing (AM) and other advanced manufacturing technologies appears to herald a future in which value chains are shorter, smaller, more localised, more collaborative, and offer significant sustainability benefits (Gebler et al., 2014)....
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...To date, investigations by researchers into the sustainability implications of AM have either been done at a broad level (Gebler et al., 2014; Kohtala, 2015) or been highly focused on the issue of material and energy consumption (Baumers et al.
, 2011; Faludi et al., 2015)....[...]
...To date, investigations by researchers into the sustainability implications of AM have either been done at a broad level (Gebler et al., 2014; Kohtala, 2015) or been highly focused on the issue of material and energy consumption (Baumers et al....
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Journal Article•DOI•
Additive manufacturing: scientific and technological challenges, market uptake and opportunities
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Syed A. M. Tofail1, Elias P. Koumoulos2, Amit Bandyopadhyay3, Susmita Bose3, Lisa O'Donoghue1, Costas A. Charitidis2 - Show less +2 more•Institutions (3)
University of Limerick1, National Technical University of Athens2, Washington State University3
01 Jul 2017-Materials Today
TL;DR: Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the bottom-up manufacturing where a structure can be built into its designed shape using a "layer-by-layer" approach rather than casting or forming by technologies such as forging or machining as discussed by the authors.
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Abstract: Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the ‘bottom up’ manufacturing where a structure can be built into its designed shape using a ‘layer-by-layer’ approach rather than casting or forming by technologies such as forging or machining. AM is versatile, flexible, highly customizable and, as such, can suite most sectors of industrial production. Materials to make these parts/objects can be of a widely varying type. These include metallic, ceramic and polymeric materials along with combinations in the form of composites, hybrid, or functionally graded materials (FGMs). The challenge remains, however, to transfer this ‘making’ shapes and structures into obtaining objects that are functional. A great deal of work is needed in AM in addressing the challenges related to its two key enabling technologies namely ‘materials’ and ‘metrology’ to achieve this functionality in a predictive and reproductive ways.
The good news is that there is a significant interest in industry for taking up AM as one of the main production engineering route. Additive Manufacturing, in our opinion, is definitely at the cross-road from where this new, much-hyped but somewhat unproven manufacturing process must move towards a technology that can demonstrate the ability to produce real, innovative, complex and robust products.
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631 citations
Journal Article•DOI•
The evolution of production systems from Industry 2.0 through Industry 4.0
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Yong Yin1, Kathryn E. Stecke2, Dongni Li3•Institutions (3)
Doshisha University1, University of Texas at Dallas2, Beijing Institute of Technology3
17 Jan 2018-International Journal of Production Research
TL;DR: Potential applications of lean and seru principles for Industry 4.0 are presented and comparisons between seru with TPS and cell are given.
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Abstract: This paper discusses production systems with a focus on the relationships between product supply and customer demand in the context of Industry 2.0–4.0. One driver of production evolution is change...
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269 citations
Cites background from "A global sustainability perspective..."
A global sustainability perspective on 3D printing technologies
3D Printing in Architecture: One Step Closer to a Sustainable Built Environment
- Figen Beyhan, Semra Arslan Selçuk
Computer Science
- 2017
Results indicate that the special features of the 3D printing process, such as faster and precise construction, reduced labour costs and construction waste etc, offer a revolutionary approach in terms of sustainability.
3D Concrete Printing Sustainability: A Comparative Life Cycle Assessment of Four Construction Method Scenarios
- Malek Mohammad, E.
Masad, Sami G. Al‐Ghamdi Engineering
Buildings
- 2020
Three-dimensional concrete printing (3DCP) has become recognized as a possible alternative to conventional concrete construction, mainly due to its potential to increase productivity and reduce the…
3D printing trends and discussing societal, environmental and ethical implications
- J. Marić, Florence Rodhain, Yves Barlette
Materials Science
- 2016
In this paper, we present a study on a growing technological sector – additive manufacturing. Additive manufacturing, also known as three-dimensional (3D) printing, presents a novel manufacturing…
A holistic decision framework for 3D printing investments in global supply chains
- C. Feldmann, Andreas Pumpe
Business
- 2017
3D printing towards implementing Industry 4.0: sustainability aspects, barriers and challenges
- Abrar Malik, M. Haq, Ankush Raina, K.
Gupta Materials Science, Business
Industrial Robot: the international journal of robotics research and application
- 2022
Purpose Environmental degradation has emerged as one of the major limitations of industrial revolution and has led to an increased focus towards developing sustainable strategies and techniques.…
Sustainable 3D Printing: Design Opportunities and Research Perspectives
- E. Rossi, Massimo Di Nicolantonio, P. Barcarolo, Jessica Lagatta
Business
AHFE
- 2019
This paper investigates the new concept of Sustainable 3D Printing using recent Design for Sustainability’s research theories and design approaches, in order to evaluate, and later describes, promising design opportunities and research perspectives that can be used and taken into account, simultaneously, by designers, researchers, entrepreneurs and policymakers to support the societal transition toward sustainable ways of design, production and consumption.
3D printing technology and its impact on Chinese manufacturing
- Yunguang Long, Jieyi Pan, Qinghui Zhang, Yingjie Hao
Business
Int. J. Prod. Res.
- 2017
The definition, characteristics and mainstream technologies of 3DP are explored, the current 3DP promotion and industrialisation situation in China as well as the issues with promoting 3DP in CM are introduced and the potential impact of3DP on the development of CM is analyzed.
Biomaterials Printing for Sustainability
- Guravtar Singh, R. Dondapati, L. Singh
Business
- 2022
3D printing (3DP) is one of the emerging technology in 21th century and popular in academics and industries. Wide range of materials printed by 3DP and it should be noted that the flexibility of 3DP…
3D Printing Services: A Supply Chain Configurations Framework
- H. Rogers, Norbert Baricz, K. Pawar
Business
- 2017
This study examines in more detail 105 of the 558 originally identified 3D printing service providers in Germany, Austria, Switzerland and the Benelux countries, with the goal of further clarifying the main drivers, linkages, buildings blocks and modules that shape these three individual branches of services.
Colombian Sustainability Perspective on Fused Deposition Modeling Technology: Opportunity to Develop Recycled and Biobased 3D Printing Filaments
- M. Morales, A. Maranon, Camilo Hernandez, V. Michaud, A. Porras
Materials Science
Polymers
- 2023
In the context of the preservation of natural resources, researchers show a growing interest in developing eco—friendly materials based on recycled polymers and natural fiber biocomposites to…
top three industry trends for 2022 from HP
1. Impact of sustainable development principles
Businesses and consumers are increasingly choosing greener products and packaging, which has an impact on supply chains. At the end of 2020, HP conducted a survey among digital manufacturing and 3D printing decision makers. The vast majority of respondents (89%) said they are already changing their business models with an eye on the environment, and 9out of 10 respondents are looking for new solutions to ensure the sustainability of the supply chain.
3D printing is enabling businesses to adopt more sustainable manufacturing practices, from a design process that minimizes final product weight and minimizes industrial waste, to a carbon-neutral manufacturing process.
Decathlon case
French company Decathlon is taking advantage of HP's 3D printing technologies in its additive manufacturing lab, ADDLAB. This division is responsible for the production of spare parts for Decathlon products, the development of prototypes and design approvals, as well as the manufacture of small tooling. The installation of two HP Multi Jet Fusion printers at ADDLAB in 2016 enabled the sporting goods brand to produce functional parts with complex features, as well as improve production efficiency and streamline workflows. In doing so, the company has reduced its carbon footprint with HP's unique 3D material reuse capability.
L'Oréal Case
Partnering with HP enables L'Oréal, the world's largest cosmetics company, to increase production flexibility and create innovative packaging.
L'Oréal plans to leverage HP's digital manufacturing network across its global supply chain to achieve sustainability goals by producing parts more efficiently, where and when they are needed.
2. Personalization era
Digital manufacturing is about to change a number of major industries; it will drive innovation and generate new value for business and consumers. The healthcare industry will undergo significant changes.
The area of highly personalized healthcare is the area with the greatest growth potential. There is nothing more unique in the world than the human body. Patients seek such medical care that would take into account their individual needs. For example, orthotics and prosthetics offer new opportunities for additive manufacturing and personalization.
In addition, there are prospects for using additive technologies for mass production of metal parts, as the fastest growing segment of the traditional 3D printing market.
HP's Metal Jet technology enables the individual production of unique and high-value parts, replacing mass production. Automotive companies such as Volkswagen and sporting goods manufacturers such as the Cobra Golf are increasingly using 3D printing techniques such as metal powder inkjet printing and metal binder jetting to produce structural components and unique , individual details.
Arize case
A new comprehensive digital solution in the field of orthopedics Arize allows you to automatically determine the anatomical features of the patient's foot on a special scanner, and then quickly and at affordable prices print orthopedic insoles for shoes according to individual parameters. Such individualization is not available with the traditional method of manufacturing insoles.
Volkswagen case
Volkswagen uses HP Metal Jet printer parts for the A-pillar of the T-Roc convertible. These parts have been certified and crash tested while weighing almost half as much as traditionally made components.
In collaboration with customers including Volkswagen, HP Inc. continues to explore the possibilities of this technology for mass production. This trend is pushing the brand to expand the commercial availability of the Metal Jet in 2022.
LMI case
Laser Modeling Israel (LMI) is a pioneer in the rapid prototyping industry, using HP Multi Jet Fusion technology to create complex and realistic 3D printable models that help surgeons and doctors perform complex operations.
The benefits of HP Multi Jet Fusion printers are extremely important to LMI when it comes to prototyping. Firstly, printed parts are economically available, they can be produced quickly, in large batches. Another advantage is the material of the final product, which can not only be dyed to match the skin color, but also sterilized. Thus, the resulting products are safe when placed in operating rooms. The accuracy of the resulting layouts is also important - the printer's print quality check technology helps to minimize errors and allows you to easily and accurately track the progress of the job.
On top of all this, HP 3D printing technology allows you to produce a model in one assembly, which means that there is no need to print many separate parts and then put them together.
3. 3D printing as one of the factors transforming traditional supply chains
In light of the ongoing pandemic, companies are starting to develop new strategies for organizing supply chains to protect them from possible logistical disruptions. Advanced 3D printing solutions can help them accelerate this transformation. Industries are expected to use 3D printing technologies as a tool to completely move away from traditional supply chain approaches and make them more efficient and flexible. It is likely that such a transformation even contributes to the emergence of new alliances and ecosystems that will increase the value of the product for end users. This trend is already being seen in industries such as automotive, consumer goods, healthcare and industrial manufacturing.
Nissan case
Nissan uses HP's 3D printing technology to extend the life of older vehicles. The automaker produces spare parts for older Nissan models using 3D printing on demand, thus solving the problem of a large inventory of spare parts that cannot be maintained under traditional manufacturing processes for a long period of time.
L'Oréal case
In addition to achieving sustainability goals, L'Oréal uses HP Multi Jet Fusion to quickly respond to changes in its manufacturing processes and production lines. As a result of cooperation, the companies quickly developed and launched mass production of universal conveyor equipment - product holders, which allowed L'Oréal to more flexibly move products along the conveyor, perform packaging and labeling of products, and, ultimately, achieve a cost reduction of 33% and save time by 66%.
Source
3D printing technology, HP company, additive manufacturing laboratory ADDLAB, HP Multi Jet Fusion 3d printers
4 3D printing trends in 2023
Analytics and business
Experts recommend
Author: Viktor Naumov
Victor Naumov Year after year, the adoption of additive manufacturing reaches new heights. What can we expect from 2023? Materialize, a leader in the global 3D printing market, offered its forecast based on four key trends that will drive the industry over the next twelve months:
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the rise of smart, distributed manufacturing;
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focus on cost reduction;
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transition from automation of individual processes to complex automation of the workflow;
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data security and integrity becomes a priority.
By addressing these issues, companies will be able to bring 3D printing to the level of mass production and accelerate the adoption of additive technologies.
Over the past three decades, 3D printing has established itself as a versatile and flexible tool in the manufacturing arsenal. Being a relatively new technology, it has spent most of this time somewhat isolated from the traditional manufacturing process. But in recent years, the wall between classic manufacturing and 3D printing has begun to disappear. We are starting to see these two separate worlds coming together, and the implications are enormous.
In 2023, the above trends will be the key to overcome the barriers that are still associated with the introduction of technology into industrial production. Addressing these issues will help companies scale up 3D printing to mass production and accelerate the adoption of 3D printing.
Fried Vankran, CEO of Materialize
© Materialize
1. The rise of smart, distributed manufacturing
Traditionally, production has always been concentrated in one place - usually a factory in another country. This system worked well until it stopped working. Over the past few years, we have seen how the COVID-19 crisis has paralyzed production and disrupted supply chains. We have witnessed an increase in geopolitical tensions and environmental concerns. All this taken together forced manufacturing companies to reconsider their model of centralized production. And with the help of smart digital technologies like 3D printing, manufacturers can move to multiple, smaller sites closer to customers.
Find the right 3D printer for you
However, many of the recent implementations owe their success to quick decision making in the face of scarce funds, such as reaching out to local 3D printing service providers to produce essential medical devices during the coronavirus pandemic. It can be said that 3D printing has been used as a temporary replacement. But, fortunately, such decisions have sparked new conversations about the future of production.
Now we see that many companies are ready to take a more strategic approach. These companies need to carefully consider which applications will deliver the most value in terms of supply chain efficiency or environmental sustainability. And this requires a change in thinking, moving from short-term solutions to the use of additive technologies as a stable method for the production of certified final parts.
A good example is CNH, an agricultural machinery company. During the pandemic, CNH was 3D-printing a vital part that could not be obtained due to COVID-related logistical constraints. The experience has proved useful, and the company is now looking at 3D printing as part of its strategy to manage supply chains in a more cost-effective way.
3D printing at CNH © cnhindustrial.com
Thus, the potential is real even in such a highly regulated field as medicine. We are seeing hospitals increasingly turning to 3D printing to create medical models and personalized implants in situ, close to patients.
We can say that this is the medical equivalent of a decentralized model of industrial production. Ultimately, we have smart, distributed manufacturing enabled by 3D printing that, when approached strategically, can be a recipe for success rather than an ad hoc response to problems.
Hanne Gielis, Innovation Manager, Mindware
2.
The history of 3D printing is a history of added value. Additive manufacturing allows for design optimization, delivering performance, weight savings, time savings and supply chain savings that traditional manufacturing methods cannot achieve. In many cases, these benefits create opportunities for cost savings that affect overall manufacturing costs, from design to delivery.
Manufacturers planning to scale additive manufacturing to thousands or even millions of parts must ensure that the 3D printing process is efficient, reliable, and repeatable across multiple manufacturing sites.
Peter Lace, Executive Chairman, Materialize
A recent survey showed that the ability to reduce overall manufacturing costs is cited as the most important benefit of 3D printing. But this does not necessarily mean that the additive process itself is cost effective. Rising material and energy prices have only further increased costs.
The cost of 3D printed parts is determined by several factors, including the materials needed, the lead time per part, and the type of printer. There are two really important ways to reduce these costs. The first is more efficient work to increase production capacity. Software plays a big role in this, allowing you to optimize your designs. We can also customize the printing process to make it more efficient and repeatable. The second way is to use tools and improve quality. And you have to pay for quality.
© Materialize
If we take a certified production in the medical or aviation industry, we will see that up to 70 percent of the cost of production is accounted for by quality control. 3D printing continues to transform factory floors as companies increasingly turn to the technology for large-scale production. But to accelerate this adoption, our industry will have to work harder to bring down the cost of 3D printing.
Brian Crutchfield, Vice President and General Manager, North America
3.
3D printing is a digital manufacturing technology, but it still requires a lot of human intervention. And such skilled workers are becoming increasingly difficult to find. According to a recent study by Materialize, finding the right people with the right knowledge and experience is a major challenge for companies that already use or are considering using 3D printers.
At the same time, scaling industrial additive manufacturing to thousands or millions requires repeatability and stability of the printing process. These two issues have increased the need for automation in recent years. The software allowed us to automate various steps in the 3D printing process, from preparing and editing files to creating supports, optimizing object placement in the build chamber, and even post-processing.
But these are all separate processes. In 3D printing, they follow each other, merging into a complex digital manufacturing process. The promise of large-scale industrial 3D printing requires us to automate not only each individual process, but also the workflows between them. And this is what we call end-to-end workflow automation.
© Materialize
We see the same thing in the medical industry, where complex process automation is needed to cope with the surge in custom 3D solutions. The good news is that opportunities to meet this need are growing with the creation of software platforms that allow manufacturers to customize their own unique 3D printing process.
Isabelle Rombaugh, Director of Global Sales and Business Development Medical
4. Data security and integrity becomes a priority
We have already talked about such an important trend as distributed production. Smart digital technologies, including 3D printing, are making it possible to move production to several smaller sites closer to customers. This is a clear sign that the factory of the future will not have a single, central location. This new digital distributed manufacturing environment revolves around one key asset - data, and this data must be protected so that an unscrupulous supplier cannot steal the design and print the product on their own 3D printer.
Of course, data security is important in any kind of manufacturing, be it traditional or smart. In both cases, companies share their unique designs with contractors and suppliers, and they want to know that their design data will remain secure. But in the case of 3D printing, that's not all. Manufacturers planning to scale additive manufacturing to thousands or even millions of parts must optimize and fine-tune their unique printing process to ensure it is efficient, reliable and repeatable across multiple manufacturing sites.
A well-thought-out manufacturing process guarantees the same quality of all 3D printed components, regardless of where they are produced. Creating such a process is a complex and time-consuming task, but it allows companies to stay ahead of the competition.
