How 3D Printing is Changing the World?

3D printing is changing the world one industry at a time. There is a growing demand for 3D-printed components and parts in diverse segments. What started as an abandoned project at a Japanese research lab has transformed into affordable, sophisticated, technology-backed manufacturing. The early 2010s witnessed a rise in 3D printing firms as the Fused Deposition Modelling (FDM) patent expired and became available in the public domain. It opened roads for tech enterprises in the 3D domain to work on a wide range of plastic materials on the printer. Innovation continues, and beginner 3D printers start at under £200, affordable for hobbyists and first-timers.

What is a 3D printer?

A 3D printer has different goals from a conventional printer at home or in an office. The raw material consists of filaments and powders of distinct combinations. Most 3D printing processes involve a nozzle or a laser that melts the filaments to create the desired shape of the object inside a chamber. 

Instructing a 3D printer is also less straightforward than pressing Ctrl+P on a keyboard. First, the slicer software takes in the user input design files in STL, OBJ and FBXC formats. Then, it converts them into language readable by the printer, G-Code, containing the X, Y and Z coordinates. 

Modern 3D printers come in different sizes, starting from small units that can be kept on tables to the industry-ready size of a car. The cheaper ones do not need special preparation apart from buying the material. 

A design file from the internet with a lightweight slicer is enough to get started. Every 3D printer has a set of support materials, detailed in the specification column. Professional printers require set-up by the manufacturer and a suite of software to utilise the total capacity with optimal efficiency.

What is 3D printing?

3D printing in the manufacture of three-dimensional objects, parts and accessories using computer-aided designs in various file formats, including STL, OBJ and DAE. 

3D printing requires a select range of raw materials to form the base of the objects. Trials and home tests typically use ABS and PLA, as these are the most durable and cheapest materials to handle for novices. Jewellery and accessories manufacturing enterprises use metal filaments.

Nylon and polycarbonate are the perfect candidates if an object needs structural strength. When moving to heavier materials, the nozzles will require an upgrade to enhance the product quality and reduce the printing time. The factory-fitted equipment on lower-end 3D printers are showpieces that crumble quickly.

3D printing technologies have matured in the last decade. Vat polymerisation and stereolithography are laser-based printing methods which have been replaced by more efficient and reliable processes like Digital Light Processing (DLP) and Masked Stereolithography (MSLA). 

The right 3D printing technology is based on individual manufacturing goals and budgets. Most small businesses rely on FDM, owing to its lower maintenance and production costs. 

Real-life usage of 3D printers

3D printers have transformed the world with their scalability and rapid adjustment to changing requirements. It makes manufacturing easier to adapt to the change in demand without requiring heavy assembly restructuring. The business cycle costs are lowered with newer innovations in 3D printing.

The business world is starting to realise the potential of 3D printing, and it's merely scratching the surface with a long path ahead. Some real-life applications of 3D printers are mentioned below.

1. Medical applications

The medical field is benefitting from 3D printers with improved and more affordable care available as the cost of equipment and fixtures has reduced by a factor of 10. In addition, surgeons are ordering special patient-specific surgical instruments for a fraction of the cost, which has brought down the costs involved.

Amputees benefit from 3D printed prosthetic limbs for an affordable cost with a custom design available on the internet. They take a couple of hours to manufacture and offer a perfect fit with a personalised design. 

Plaster casts are being replaced with 3D-printed mesh design braces that offer proper ventilation and are lighter, thus delivering better mobility. In addition, healing is noticeably better with these newer designs.

2. Automotive and aviation industry

Auto giants GM, Ford, Volvo and BMW are the frontrunners of the 3D printer evolution in the automotive industry. They use it for pre-designs, pre-development trials, validations and testing the concept cars in shows and labs. Auto companies rely on 3D printing technology to produce spare parts, accessories and assembly essential tools.

In the last few decades, Ford has printed more 3D printed than 500,000 spare parts, saving billions in cost and millions of man-hours. 

The aviation industry is seeing a surge in 3D printing adoption. Boeing, in recent years, have tested their 777X with more than 300 printed parts.

3. Packaging industry

Ecommerce and the accompanying logistics sector are rapidly growing. Consequently, the packaging industry is booming on a parallel track. Companies are working on ways to streamline packaging and cut down processing time and costs. 

Custom 3D printed packaging can help in that area as it is lighter, and customised boxes for specific items save space and cost. 

4. Construction

Infrastructure companies were quick to realise the economic upsides of the new technology. 3D printed walls, tiles and components are cheaper to produce and lighter, offering better durability and mobility. They are quickly produced and immediately available for construction work without delay. 

5. Eyewear

Precision eyewear is a reality with 3D printing, cutting down on manufacturing time and cost while offering personalisation to the users. Manufacturers can produce a large number of frames and lenses according to individual requirements in a short period. Then, users can order them online and get them delivered the next day. 

Different types of 3D printer materials

A 3D printed object is as good as the material used. The selection depends upon the manufacturing, and economic goals, so take a closer look at the most common 3D printing materials. 

1. ABS

Acrylonitrile Butadiene Styrene is ideal for creating product prototypes and durable components. The material is easy to mould and print through smaller nozzles, minimising wastage and reducing costs. In addition, it can withstand high temperatures and gives a high threshold for wear and tear. No wonder it’s used for creating LEGO!

2. Nylon

Everybody is familiar with nylon as a durable and consistent material, used widely for zip ties, plastic gears, nuts and bolts, and wear-resistant parts. Moreover, the material can easily be coloured in different shades. In addition, nylon is used in FDM-based printing in a moisture-free environment. 

3. PLA

Popularly known as green plastic, Polylactic Acid is made from cornstarch and sugarcane. It is suitable for cosplay props, sustainable packaging, decorative parts and accessories. The recyclable material is ideal for indoor use as it has lower heat resistance.

4. Polycarbonate

Polycarbonate is chosen for its high heat resistance and durability. It can withstand temperatures north of 150° and still be bent into distinct shapes without compromising structural integrity. Polycarbonate is used for bulletproofing cars and in electronic cases, high-tensile parts, CDs and DVDs.

5. Metal filaments 

Metal filaments consist of brass, bronze, copper, or stainless steel in powdered form. When mixed with a base material, they offer a metallic finish to objects. Such filaments allow printing with a standard extruder without requiring extreme temperatures. Metal filaments are ideal for jewellery and ornaments, sculptures, and automotive parts.

6. Resin

Resin is amongst the most widely used 3D printing materials worldwide, relying on Digital Light Processing and Stereolithography printers for an optimal finish. It is used for manufacturing toys, ornaments, precision equipment and neon lighting cases. Different colours can be added without degradation, offering high precision printing with low shrinkage. 

Types of 3D printers

A large number of 3D printer technologies are available, depending on individual manufacturing goals. Some are expensive to install and operate, ideal for large businesses. Others are affordable and are ready to be set up in small garages or even on tables at home. 

1. Stereolithography (SLA)

The oldest 3D printing method is still in use today. Stereolithography relies on vat polymerisation to print three-dimensional objects. The process generally involves selectively exposing a tank of liquid resin to ultraviolet rays to harden one layer at a time. Stereolithography is used in the craft, medical, automotive and aerospace industries.

2. Fused Deposition Modelling (FDM)

FDM is the most popular 3D printing process globally, owing to its affordability and portability for smaller projects. 3D pens apply this method for portable three-dimensional printing. A 3D object is created as a nozzle moves around the printer platform for layering molten thermoplastics. It often requires post-processing finishing for polishing the edges and general smoothing. 

3. Digital light processing (DLP)

Digital Light Processing, similar to SLA, is a 3D printing technology that works with polymers. It works with two light sources illuminating the resin vat, which hardens when exposed to bright light (protons), building the objects one entire layer at a time. DLP is used for creating parts with high-level dimensional accuracy.

4. Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS)

Both these printer techniques rely on the principles of Selective Laser Melting. SLM fuses industrial materials by melting them at high temperatures. 

On the other hand, DMLS moves slowly across the metal powder to sinter each layer without heating the powder to its melting point. The typical materials used here are titanium, copper and aluminium alloys.

5. Metal Binder Jetting (MBJ)

MBJ is a metal printer technology that can produce large volumes of large parts quickly. First, the powder material is spread on the printing bed, and then a binding agent acting as the glue is selectively sprayed to stick the powder together. The process is repeated for each layer until the object is built. 

Conclusion

As 3D printing is becoming cheap and efficient for individuals and large businesses alike, there will be a gradual shift to this technology for manufacturing in the coming years. However, HP© is a pioneer in the field, with its wide range of dependable 3D printers.