How 3d printing changed the world

• The first category includes printers that create objects by extruding molten semi-liquid material from a print head nozzle. Most often it is thermoplastic that quickly hardens when it leaves the printhead. Other extrusion-based 3D printers produce objects by extruding molten metal or chocolate icing (for printing culinary creations). There are also printers that use concrete, ceramic paste or clay.
• The second category of 3D printers creates layers of objects by selectively solidifying a liquid resin, known as "photopolymer" , which cures when exposed to a laser or other light source. Some of these machines create layers of objects inside a reservoir of liquid. Others release a layer of resin from the print head and use UV light to cure it before applying the next layer. There are devices that mix several different photopolymers in one print job, which allows them to output color objects made from several materials. In particular, one of these printers is J750 by Stratasys - offers a palette of 360 thousand shades and can make objects from a mixture of different materials.
• The third and most common category of equipment is layering by selectively bonding very fine powder granules. This "granular bonding" is achieved by applying adhesive to powder layers or by melting the granules with a laser or other heat source. There are many types of powder adhesion based on various materials. These include nylon, wax, bronze, stainless steel, cobalt chromium and titanium.
• The latest category of 3D printer is built on lamination . Successive layers of cut paper, metal, or plastic are glued together to form a solid object. If sheets of paper are used as a building material, they are cut with a blade or laser, then glued together. They can be sprayed with ink during the printing process to create inexpensive, full-color 3D objects.

Market and application

3D printing is used for prototyping, mold making, digital direct manufacturing and custom manufacturing. Suppliers of 3D printing hardware, software and materials are already serving the needs of various market sectors. And now we will look at these areas of application to understand how 3D printing technology is developing.

Rapid Prototyping

Most often, 3D printers are used for rapid prototyping (RP - Rapid Prototyping). This includes concepts and functional prototypes. Concepts are simple, non-functional "drafts" of product design (such as a bottle without a removable cap) and are intended to allow artists to recreate their ideas in a physical format. Functional prototypes, on the other hand, are more complex and allow you to evaluate the form, fit, and function of each part of a product before putting it into production.

Functional prototypes and concepts were created before the advent of 3D printers using laborious methods and tools. Therefore, their production often takes many days, weeks or even months, and the cost is thousands or tens of thousands of dollars. 3D printers can create concepts and functional prototypes in days or even hours, and at a fraction of the cost of traditional fabrication methods. Examples from this industry include concept cars for Formula 1.

In addition to saving time and money, printing prototypes allows improved products to be brought to market as designs typically go through many iterations. For example, thermos maker Thermos uses Stratasys 3D printers to produce prototypes in hours, not days, at a fifth of the cost of production from an external supplier. Because designers can now “create as many prototypes as needed,” the company has been able to fine-tune product features such as lid retention and ease of pouring.

3D printing technology in color in various materials and metals continues to evolve, so the range and quality of products, including their components that can be quickly prototyped, continues to increase. So the company Nano Dimension demonstrated a desktop 3D printer - DragonFly 2020 , which can produce functional PCB prototypes. This equipment uses inkjet technology to output highly conductive "nano-ink" and can produce multi-layer boards, including all connections between layers. At a time when many companies wait days or weeks to get a prototype board from an outside vendor, the machine will print it in a matter of hours.

Molds and other manufacturing tools

In addition to prototypes, 3D printers are used to make molds and other fixtures for manufacturing equipment. A mold is needed in order to cast metals or plastics in it. Like prototypes, molds have traditionally been made by hand. Therefore, the use of 3D printers can save time and money for large manufacturers. For example, by using Stratasys' Fortus printers, Lyon-based automotive giant Volvo Trucks has reduced the time it takes to manufacture some engine components from 36 days to 2.

In August 2016, the American Oak Ridge National Laboratory 3D printed a 5.34 x 1.34 x 0.46 m trimming and drilling tool for Boeing. It is used in the construction of passenger aircraft, and was printed from carbon fiber reinforced plastic in about 30 hours. Previously, the production of such a part would take three months. As Boeing's Leo Christodoulou explained, “Additive manufacturing tools like the wing trim tool will save energy, time, labor and manufacturing costs. They are also part of our strategy to apply 3D printing technology to manufacturing areas.”

Another promising application is the production of molds used for casting metals. 3D printers are capable of producing the required shapes, as well as any additional rods needed to be placed inside them. The process is carried out by applying thin layers of foundry sand, which are held together with a binder. The resulting 3D printed mold is sent to the foundry, where molten metal is poured into it to produce the finished product.

ExOne is one of the companies specializing in the production of 3D printers for additive manufacturing using foundry sand. By 3D printing molds and foundry sand cores, manufacturers can not only save time and reduce costs, but also improve accuracy and mold more complex parts, the company says. This is because 3D-printed shapes and rods do not require post-processing, which could damage them.

Core molded from ExOne 3D printer

3D printers can also be used to make molds for injection molding plastic parts. Such molds typically cost tens of thousands of dollars and are traditionally made of aluminum. Technically, a 3D printer can already make aluminum die casting molds using metal powder. But nowadays printers make such molds from resin using photopolymerization. Plastic molds are not as durable as their aluminum counterparts. But they are cheaper, faster to produce, and can be used to make up to 200 plastic parts before replacement is needed.

Bi-Link , based in Bloomingdale, Illinois, 3D prints low-volume injection molds. It manufactures parts for electronics and medical device manufacturers around the world. The ProJet 3500 HD Max printer from 3D Systems creates a form in hours instead of weeks. As Director of Research and Development Frank Sieberna said: “Customers are delighted with this service. Previously, you had to wait two or three weeks to get just the tools - not to mention the test parts. The ProJet 3500 HD Max can produce four different designs for a single customer in six days, shipping 10-12 parts per iteration overnight. ”

Some companies are building machines that can print objects from wax (or wax substitutes) to create investment casting molds. The wax object is 3D printed, then molded around it using a material such as plaster. After the form is heated, as a result of which the wax “burns out” and flows down. Molten metal or other liquid material is then poured into the mold to create the finished product. The use of 3D printers to create wax models is quite common in the jewelry industry and other industries that specialize in complex and expensive items. Like injection molds, wax samples are consumable because the process of creating the finished product causes them to break.

Digital Direct Manufacturing

In several niche markets, 3D printers are already being used to produce finished industrial components and even consumer products. This development is referred to as "Direct Digital Manufacturing" (DDM - Direct Digital Manufacturing) and is becoming increasingly popular, for example, in aviation. Airbus and Boeing are installing tens of thousands of 3D printed components for their aircraft.

Other DDM industries include automotive, medical, jewelry, and footwear. One of the leading pioneers is Nike. According to COO Eric Sprank, the company "has made a number of breakthroughs in design and manufacturing through 3D printing that will enable the creation of an entirely new custom shoe cushioning system." To this end, Nike is building an "Advanced Product Creation Center" covering approximately 11,000 square meters to house 3D printing and other design and manufacturing technologies.

It is quite possible that in the future everything will be made using a 3D printer, including even human organs. This is most noticeable in dentistry: wax models, orthodontic applications, fittings, surgical guides and veneer models are now 3D printed.

In addition to creating inorganic prostheses, there are "bioprinters" that build up human tissue by laying down layers of living cells. Such technology could revolutionize the medical field, for example by cutting the queues in organ donation. Company Bioprinting pioneer Organovo already sells printed liver and kidney tissue for use in drug testing.

In addition to bioprinting tissues outside the body, bioprinting on the body or inside a wound is already under development. It involves printing layers of cultured cells directly onto the wound or even inside using keyhole surgery techniques. When such technology becomes advanced enough, the patient simply needs to insert an instrument into the wound, which will remove the damaged cells and replace them with new ones. These instruments will even be able to heal the wound caused by their introduction.

Individual production

In parallel with the growth of industrial 3D printing, there is an increase in individual production. These are all situations when an entrepreneur prints his own things on a 3D printer, bypassing the launch of production at a remote factory. There are already several hundred professional 3D printers on the market starting at $230.

In addition to the growing number of personal machines, there is a growing number of free and paid 3D models that can be downloaded for printing. On resource Thingiverse hosts over a million free models - some of them can be customized to the user's requirements. It is possible that the provision of such content will become the foundation for mass personal production, as it will eliminate the need for creative and engineering skills.

Currently, personal and professional 3D printers are limited in their ability to use thermoplastics or composites, as well as photopolymer resins. Therefore, the range and quality of products that can be manufactured on such equipment remain low. At the same time, an increasing number of cloud-based 3D printing services, such as Shapeways and i.materialise allow anyone to upload a 3D object to be printed on industrial equipment. It is likely that access to such a service – rather than the sale of personal 3D printers – will be the driving force behind the DIY revolution over the next five to ten years.

If the majority of people start making the products they need on their own, this will have a serious impact on many industries. Parts companies are already wary of the threat of mass-produced personal items. The representatives of the transport and logistics sectors are afraid of the same, because this will change the demand for their services.

In 2014, the IBM Institute for Business Value published a report highlighting four futures for custom manufacturing. And now we will briefly get acquainted with it.

• Two unknowns are the speed at which 3D printing technology will advance and the willingness of consumers to embrace custom production. If technology advances slowly and consumers don't embrace 3D printing at home, then we'll see "quiet revolution" with gradual changes.
• There is also an alternative: technologies are developing slowly, but consumers want to become producers - then we are waiting for "production revolution" , when more and more necessary things will be made by small entrepreneurs.
• Another option is that 3D printing technology will make a breakthrough, but consumers will leave it behind - then such printing will become the main technology in industrial production, and will not have a big impact on the consumer market.
• And the last turn of events: 3D printing is developing rapidly, and consumers are actively using it - then we will witness "rethinking consumption" . This means merchants large and small offering 3D printed products at your request. There will also be a lot of people "printing" in their homes, garages, kitchens or offices and hangars.

My guess is that consumer involvement in 3D printing will grow as technology improves, but at a slower pace. This means that over the next few decades, we will gradually move from a “quiet revolution” to a “manufacturing revolution” and then to a “consumer rethinking”.

The development of the 3D printing industry

There are different segments of the 3D printing market, and they are at different stages of development. The very first 3D printers began to make prototypes in the late 1980s, and the use of printing to create molds did not begin until a few years after that. Long before the early 2000s, the first finished products and works of art printed using this technology appeared. Finally, customization only became possible in 2007 with the introduction of the first "open source" 3D printers that private individuals could afford.

I estimate that half of all prototypes will be 3D printed by 2025. However, 3D printing is not the only rapid prototyping technology. There are cases where traditional methods are better suited for prototyping. It is inconceivable that inventors would stop sculpting things out of clay, wood, paper, metal, and everything else that is available in their kitchens, studios, labs, workshops, and sheds.

In terms of 3D printing of molds and manufacturing tools, this market currently lags behind rapid prototyping, but will very soon become the mainstay of additive manufacturing. I assume that it will take at least a decade to saturate it. After talking with manufacturers of industrial 3D printers, I was convinced of this. In most industries, 3D printing of molds and other tools represents the biggest market opportunity.

In digital direct manufacturing, this is just starting to happen, although it is currently a very niche activity. However, in the next ten years or so, many industries, primarily aerospace, automotive, healthcare, fashion, footwear and designer goods, will use 3D printing as one of their core manufacturing technologies. This will allow you to create completely new types of products and attract media attention. And even so, in 10 or 20 years, the vast majority of objects in our lives will still be produced by traditional methods.

Likewise, for decades to come personal items will be a niche market in both the 3D printing industry and global manufacturing. Currently, no more than 10% of the 3D printing industry's revenue comes from the sale of personal printers. Many of these machines are sold to companies rather than individuals. But this does not mean that the sale of personal equipment for home use does not represent a market opportunity.

It can be argued that home production will not be the driving force behind the 3D printing revolution - and many in the industry agree. However, I will look forward to 3D printers in 9$9 that will be able to make small plastic items based on a model sent from a tablet or smartphone.

Making new products in new ways

Like the Internet revolution that preceded it, 3D printing is enabling companies and individuals to achieve the previously impossible. And the reason is not only in the creation of prototypes and old things in new ways. It does so in line with new business models. Let's outline these key benefits.

Single and small batch production

With traditional methods, single and small batch production is expensive and often prohibitive. When things are printed on a printer, there is practically no difference in cost per unit - that is, it does not matter if 1, 100 or 1000 copies are required, since there are no costs for tools and workers. Therefore, in many situations where a few hundred or fewer components are needed, 3D printing will be the most economical way. It is for this reason that 3D printing is so widely used in rapid prototyping and is increasingly used in the production of molds and other tools.

Jay Leno, who enjoys collecting cars, is already using 3D printing for one-off production. As an example, when a rare EcoJet concept car needed to have some broken air vents replaced, it contacted 3D Systems . The company scanned the broken parts, digitally repaired them using a CAD program, and sent the resulting data to service provider Quickparts . There, the new vents were 3D printed from a lightweight, fiber-filled nylon material called DuraForm HST. The result is a reliable replacement part with a better strength-to-weight ratio than the original.

3D printing is being used to make props for TV shows, movies and theatrical productions. With this technology, SpaceX is printing the engine chambers of the Crew Dragon spacecraft, and NASA has printed about 70 parts for the rover.

Customization and personalization

In addition to facilitating the small-scale production of identical items, 3D printing allows products to be customized according to the tastes of the buyer and his physical needs. For example, company Robot Bike Co. uses technology to build a custom R160 mountain bike frame. It is created from carbon fiber passing between titanium ridges, which are printed on Renishaw 3D printers . On the Robotbike.co website, the buyer enters his height, leg size and arm span, which allows him to get a frame individually for him.

The R160 is a great example of a real product that combines 3D printed parts with other standard components. This makes it possible to offer a product according to individual requests in an economical way. I am sure that over time, many companies will realize the potential of "custom-made" by 3D printing certain parts.

Design and build optimization

Another key benefit of 3D printing is that it removes the limitations of traditional manufacturing methods. While a designer can come up with any design for a product, if its components cannot be molded, machined, and assembled, the product will never hit the market. And in the “brave new world” of 3D printing, you can create things that were previously impossible to make. For example, such a printer can produce a chain or necklace made up of links that do not have breaks and therefore will never come apart.

The TransFIORmers motorcycle racing team used a Renishaw metal 3D printer to produce a new, optimized suspension design. The original version was handcrafted from steel, and at the same time, twelve parts were required for assembly, which must be welded together. But with the help of 3D printing, the team was able to combine the structure into a single titanium component that required no assembly, resulting in a 40% weight reduction, a critical feature for racing.

Using plastic or polymer materials, some printers can create working, pre-assembled, composite mechanisms such as a gearbox. Traditionally, the production of multi-component products includes a final assembly step. But when things are printed on a 3D printer, this is not necessary.

Free access to the market

In addition to improving product performance, 3D printing will enable many more people to become manufacturers. This is because the cost of prototypes and production tools will no longer be prohibitive, so 3D printing is making small-scale production increasingly viable. But more importantly, the availability of 3D printing services will allow almost any talented artist or designer to find a market for their creations.

Today it is very difficult for an individual or even a small company to bring a product to market, let alone globally. One of the few exceptions is book publishing, where an author can create and distribute a print-on-demand product. For example, residents of the UK can order a printed book through Amazon and receive a book printed in the corporation's warehouse within eight hours. This innovation allows authors to sell books without pre-printing and distribution.

Similarly, 3D printing allows individual designers to bring products to market without investing in equipment and prefabricated copies. For example, more than 8 thousand designers have already opened online stores on the site of a 3D printing service provider - Shapeways . As an example, consider the store of the famous bot creator Kidmechano. His creation is Modibot, which is an ever-expanding line of 3D printed action figures with an articulated design. You can compare Modibot with Lego or Transformers.

Kidmechano uses the Shapeways platform to sell over 400 different ModiBot figures and accessories, including armor and weapons. Prices start at a few dollars, and when an order is placed, Shapeways prints whatever is required, sending the finished product to the customer, and Kidmechano his share of the proceeds.

Digital storage and transportation

In addition to enabling small-scale production, cost-effectiveness and democratization of market access, 3D printing will facilitate the storage and transportation of digital objects. This means that in the future there will be two options for sending a parcel. The first is to send the physical product by courier or mail, and the second is to transfer the digital file over the Internet for 3D printing on site by the recipient.

Many people regularly post texts, photos and videos on the Internet, and thanks to 3D printing, digital objects will soon be added to social networks. Thus, by making digital storage and transport possible, 3D printing will do to things what computers and the Internet have already done to store and transmit information.

In some industries, digital object storage is already starting to make a difference. For example, most dentists have traditionally had to store huge amounts of plaster casts taken from patients' mouths. Although they were only used once, there was no way to predict if they would be needed in the future, which led to archives with boxes and cabinets littered with plaster models. But now dentists are moving to digital technologies: 3D scanners and 3D printers are replacing alginate molds and plaster casting. This allows you to save impressions of the patient's oral cavity in digital form, for future 3D printing if necessary.

Material savings and environmental impacts

In addition to the benefits mentioned above, 3D printing saves materials for manufacturers, which is especially important for sustainable development. Today, factories begin production with a block of metal or other raw material and then cut it: lathe it, file it, drill it, or otherwise, to form the final product. In contrast, 3D printing is an additive activity that takes as much material as the finished product. Therefore, we get significant savings in raw materials if we make things using this technology.

In addition, 3D printed products can have an internal structure optimized to use the minimum amount of materials. For example, plastic or metal parts printed on printers can be produced with internal cavities or an open grid - something that is almost impossible to achieve using most traditional technologies. Again, this results in material savings as well as lighter parts, which, for example, will reduce the fuel consumption of aircraft and other vehicles.

3D printing could be the cornerstone of the future transition to Local Digital Manufacturing (LDM). Today, most of the production is carried out in factories remote from their customers. As a result, huge amounts of oil and other resources are being spent on storage and transportation. Given declining natural resource stocks and climate action within a decade or two, these modes of transportation and storage may not be feasible or culturally appropriate. Thus, environmental protection may be a force to stimulate the mass adoption of 3D printing to facilitate the production of goods in local industries.

Some industries could also benefit from the spread of 3D printing. Last but not least, the logistics sector is already aware of these opportunities. For example, in July 2014, in Publication 9U.S. Postal Service 0091 noted that the service provider could "benefit enormously" from the spread of 3D printing due to the expected increase in small package deliveries. In particular, it was predicted that the technology could lead to an increase in the income of the local parcel delivery service by 486 million dollars a year. The forecast was based on the assumption that most 3D printed goods will be made in local service bureaus, from where they will need to be delivered to people's homes.

In addition to the impact on employment, there are two other problems: infringement of intellectual property rights and the use of 3D printing for criminal purposes. It is already possible to use consumer equipment to scan an object, such as a model of Mickey Mouse, and then print a plastic copy of it. Similar to the impact that mp3 music and the internet have had on the music industry, 3D printing can impact intellectual property rights.

Even more disturbing, it is already possible to 3D print firearms. Currently, a $230 personal 3D printer can only make a disposable plastic gun. But when the ability to print from metal becomes affordable, we will have serious problems.

The latest minefield with 3D printing and personal effects is health and safety. Today, almost all the products we buy meet certain standards and are tested. However, manufacturers are responsible for any accidents and injuries that may occur as a result of their failure or malfunction. But who will be responsible if, for example, a child downloads a free toy from the site, prints it out and gives it to the younger one - and he swallows a piece broken off from it and suffocates? Will the fault lie with the person who developed the object; the site through which it was published, the manufacturer of the 3D printer, the supplier of the consumables, or the parent that allowed it? Now there is no answer to this question. And pretty soon, we won't be able to ignore it.

In the world of pioneers

The 3D printing revolution, like any other technological revolution, is the product of action, energy and the vision of those people who are brave enough to make it happen. Over the past few years, I have had the pleasure of interviewing many of the pioneers of 3D printing. And since my goal is to capture your imagination and not focus on details and technical details, so I asked them the fundamental question: “Why did you choose this particular technology?”.

One of the first people I spoke to was Anssi Mustonen , the head of the Finnish 3D printing and design company AMD-TEC .

“We live in a hectic world, but with this technology, we can deliver quality service to our customers,” Anssi said. As for prototypes: I don't have time to code and send orders to external vendors for details. 3D printing is not the only way to fabricate, but it is faster at creating complex shapes and configurations than traditional methods. ”

Konstantin Ivanov , co-founder and CEO of 3DPrintus.ru , told me how technology allows us to offer new types of products and services:

“3D printing provides solutions that are at the intersection of manufacturing and the digital technologies of the Internet. Our customers have discovered an easy way to create and produce just about anything. I'm sure the main advantage for them is the ability to use a simple interface to get their product."

Gary Miller , Managing Director of 3D Print Bureau Print Services in the UK, told a similar story, albeit with caution in the forecasts:

“We use 3D printing because it’s faster: faster lead times and almost any geometry is available! I started with the Objet printer over ten years ago when there was only one material. Years have passed, and now there are about 2 thousand materials for printing. Just imagine where we will be in ten years! True, no matter how much raw material you have, you need to transfer it to reliable hands. You need experience in your industry to understand where this technology is suitable, and where it will only increase the cost. I used to be skeptical that 3D printing would move into manufacturing, but in the first half of 2016 we saw progress and an increase in orders. It's great to see how 3D printing develops and new materials emerge."

One of the most interesting conversations was with John Cobb , EVP Corporate Affairs of 3D printing giant Stratasys in the US. Shortly after starting the conversation, John focused on the technology's potential to redesign and distribute products:

“In 3D printing, there is a lot of focus on adapting it to traditional manufacturing processes. The fundamentals of design are changing, allowing for a change in the way products are made and then methods of distribution. Imagine there is a problem with the plumbing. You take a picture of it with your smartphone and send it to the Home Depot And after an hour or two, you assemble the pipeline - replacing a non-standard part. It may take another five years, but we are already moving in this direction.”

Miranda Bastins , director of Belgian 3D printing service i.materialise , focused on new market opportunities from a different perspective:

“3D printing helps to create a world where products meet our expectations or individual style, and where everyone has the opportunity to own something unique. Things not only better meet the needs and interests of consumers, but it also becomes possible to sell their own goods to others. For example, a jewelry designer might propose a new ring to a global audience and test the demand for the design. If there are no orders, this is no longer a problem (printing only on demand) - and if there are, then the rings will be printed, delivered to the customer, and the creator will receive his share of the proceeds.

Lucy Beard , founder of Feetz , also recognizes the potential of 3D printing to create "better fit" products. Feetz is a "digital shoemaker" that uses 3D printers to make custom shoes. As Lucy told me:

“This technology is changing the way we produce and consume things. We can make personalized products with fewer resources, and it will be much easier to recycle them.”

Mark Saunders is Director of the Global Solutions Centers at Renishaw , a 3D printer manufacturer. He also focused on the opportunities the technology offers manufacturers:

“More and more companies are looking to use the potential of 3D printing to improve product performance, making it more efficient and better adapted to the application. The unique ability to create complex geometries from high-quality materials opens up huge potential for innovation in both product design and business models. We expect additive manufacturing to play a key role in further developing processes and improving products.”

Finally, Sylvain Premont , founder of iMakr 3D printer shops and 3D content website My Mini Factory , noted how technology unleashes the imagination:

we will be able to invent, design and manufacture almost everything - in the shortest possible time and at a low cost. You will also be able to download content that is ready to print and easily adaptable to your own needs. The next generation will ask their parents: How did you get along without a 3D printer before?

A new frontier

As you can see from the interview, 3D printing continues to generate interest among its pioneers. And many large manufacturers using traditional technologies are already changing direction towards this technology.

Nobody can predict the future of 3D printing. However, there is good reason to believe that the technology will have a drastic impact on many manufacturing sectors.

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