3D Printing and the Future of Manufacturing - Coursework Example

3D Printing and the Future of Manufacturing 3D printing also called additive manufacturing has the potential to vastly accelerate innovation, minimize materials and energy usage, compress supply chains, and reduce waste. It creates solidifying layers of deposited powder using a liquid binder. According to Fogliatto and Da (2011) it will be an extremely versatile and rapid process accommodating geometry of varying complexity in hundreds of different applications and supporting many types of materials. 3D printing is a new way of making products and components from a digital model. 3D printer create components by depositing thin layers of material one after another, only where its required, using a blueprint until the exact component has been created. The technology has grown from rapid prototyping to the production of end user products. The equipment use composites, metals, polymers, or other powders to print arrange of functional components, layer by layer, including complex structures that cannot be manufactured by other means. It reduces cost by 90%. Its use can benefit a wide range of industries including automotive, metals manufacturing, defence, aerospace, consumer, products and biomedical. This paper describes the core technology of 3D printing and the future manufacturing. Keywords: 3D Printing, Additive manufacturing, customization Table of Contents Abstract 0 List of tables 2 1.0 Introduction 2 1.1 Research questions 2 2.0 Literature review 2 2.1 History of 3D printing. 2 2.2 3D printing technology 3 2.3 Why 3D printing is special 5 2.3.1Customisation 5 2.3.2 Complexity 5 2.3.3 Sustainable and environmentally friendly 5 2.3.4 Tool-less 6 3.0 Methodology 6 3.1 Project Design 6 3.2 Metals and products used in 3D printing 6 4.0 Findings 8 5.0 Discussion 8 5.1 Effects of 3D printing on manufacturing 8 5.2 The future of manufacturing 9 5.2.1 Rocket engine 9 5.2.2 3D Bio-printing 10 5.2.3 3D printing in space 10 6.0 Conclusion 11 6.1 Recommendations 11 6.2 Limitations 12 References 12 List of tables Table 1: Table of Type and Prices of 3D Printers List of Figures Figure 1: Stainless Steel and Aluminium finely-powdered metals Figure 2: 3D printed product from a melted mixture of Stain less steel and Aluminium Figure 3: 3D printed rocket engine Figure.4: shows the way of creating a living tissues with 3D printed model Figure 5: the image of astronauts with made in space 3D printer 1.0 Introduction In the recent years many different manufacturing world have become very passionate about the 3D printing technology with some talking about the next industrial revolution. 3D printing is an additive manufacturing process through which hundreds or thousands of material are printed layer upon another layer using a range of inks or some other materials most commonly polymers and metals. The manufacturers have been using additive process for prototyping since 1980s which seems to contrast with outmoded subtractive manufacturing process based on removal of materials to create products (Naboni & Paoletti, 2015). This paper review several literature to evaluates what 3D printing means, identifies what’s special about 3D printing, analyses why the 3D printing technology is better than the 2D printing, the potential risks and opportunities of using 3D technology, and the change and future manufacturing of 3D technology. With the increasing old age in western economies, growing global population, and increasing health care, and supper manufacturing industries demands, the additive manufacturing and 3D printing presents a compelling solution to responds to these ever-changing global mega-trends. 1.1 Research questions As initially stated from the abstract the research project shall address questions like; what’s 3D Printing? What is special about 3D Printing? Why is it better than 2D Printing? What are the metals used in 3D Printing? What is products that can be printed in 3D Printing? What effect will 3D printing have on manufacturing? And how 3D printing will change the future of manufacturing in the world? 2.0 Literature review This part of the paper will give detail concepts and information on the history of 3D printing, 3D printing technology, and give reasons why 3D printing is preferred for 2D printing 2.1 History of 3D printing. Charles Hull in 1984 developed the first 3D technology for printing physical 3D objects from physical data, in which he named it stereo lithography and obtained the patent for its innovation in 1986. Some other similar technology were also established such as the Selective Laser Sintering (SLS), and Fused Deposition Modelling (FDM) while the stereo lithography had become popular by the end of 1980s. 3 Dimensional Printing techniques similar to 2D printer inkjet technology was later patented in 1993 by the Massachusetts institute of technology (Bold Company, 2013). It was later in 1996 that three major products like "Z402" from Z Corporation, "Actua 2100" from 3D Systems and, ‘’Genisys" from Stratasys were introduced. Finally, another break through emerged in 2006 which came with the initiation of an open source project called Reprap, which led to the establishment a self-replicating 3D printer (Naboni & Paoletti, 2015). 2.2 3D printing technology The first step for any 3D printing process was found to be the creation of 3D model using 3D software programme. The model was sliced into layers to convert it into a readable file by 3D printer. The printer layer the material according to design and process. Functional plastics, metals, sand, and ceramics are used for industrial production and prototyping applications. The widely used material at the moment is the plastic such as ABS or PLA. Different 3D printers process differently, for example some process powdered materials like metals, nylon, ceramic, and plastic which uses heat/light sources to melt/fuse/sinter layers of the powder together in the defined shape (3D Printing is the future, 2012) 3D printers and prices The prices of 3D printers depends on the model and their size. Proffessional ones cost $10,000 and more while the small ones for home use are not expensive. The 3D printers prices depends on the type of technology used in making the printer such as Fused Deposition Modeling (FDM), Laminated Object Manufacturing(LOM), Selective Laser Melting(SLM), Stereolithography(SLA), Electronic Beam Melting (EBM), and Selective Laser Sintering(SLS). The table below shows a few 3D printer types and their prices. Table 1. Table of Types and Prices of 3D Printers No. Type Price 1 PJP 3D Printer, DIY Kit, ABS, PLA, build volume 5.5 x 5.5 x 5.5 $1008.94 - $1008.94 2 FDM 3D Printer, DIY Kit, ABS, build volume 9.9 L x 7.8 W x 5.9 H $2899.00 - $2899.00 3 SLA 3D Printer, DIY Kit, Liquid resin, build volume 4.9 L x 4.9 W x 6.5 H $3299.00 - $3299.00 4 Printrbot Simple Metal 3D Printer, PLA Filament, 1.75mm Ubis Hot End, 6" x 6" x 6" Build Volume $599.00 2.3 Why 3D printing is special The 3Dprinting, whether at personal or local level, or at an industrial brings a lot of benefits to the manufacturers or to the host that the traditional (2D printing among them) methods of manufacturer cannot. It was therefore found to be special due to the following: 2.3.1Customisation 3D allows users to develop and revise a product severally or rapidly before undertaking the costly process that may be associated with the traditional manufacturing due to the application of the vast technology in the process (Naboni, & Paoletti, 2015). The nature of 3D printing allows for manufacturing of numerous products at the same time according to the end user requirement at no additional process cost within the same build chamber. 2.3.2 Complexity According to Evans (2012), the 3D printing techniques allows for the manufacturing of complex products that could otherwise not be developed by the traditional means. Applications can be developed to materialize complex components that are both lighter and stronger. Artists and designers can easily improve on the products visual effects. 2.3.3 Sustainable and environmentally friendly The project research argue that technology has emerged as one of the most energy efficient technology that provide environmental efficiencies 3D in terms manufacturing process and utilization, in which case utilising about 90% standard materials and therefore creating minimal waste. Additionally, additively manufactured products that are stronger in design reduces the carbon footprint emission into the atmosphere. It also eliminates huge inventories and unsustainable logistics for transporting high volumes of products around the globe by just producing products on demand (Materials and Processes for Medical Devices Conference & Gilbert, 2008). 2.3.4 Tool-less The study argue that 3D printing will eliminate the need and demand for tool production hence reduce the cost of production since one of the most time, and labour intensive stages in the product development process is the production of the tools for industrial manufacturing process. Moreover, due to the complexity advantages, components and products can be designed specifically to a void assembly requirements with complex and intricate geometry features further removing labour and cost related to assembly processes. 3.0 Methodology The project will entail intensive reviewing of the literature from the newspapers, magazines, journals, and books and data collected from the manufacturers and industries dealing in 3D printing technology. It will therefore give a detailed outline of how the objectives of the research project will be achieved. 3.1 Project Design This project will entails evaluating the 3D printing and its future in the manufacturing industry from the literature reviewed and come up with the findings. As a result, the project will be designed to meet the objectives set out by the researcher. The project will entail visiting different 3D printing companies and additive manufacturing industries, administering questionnaires and conducting desk research (Gibson, 2014). 3.2 Metals and products used in 3D printing A great number of printing materials will be used for industrial grade 3D printing. The most common metals that will be used are cobalt derivatives and aluminium. The most common metal that will be used for3D printing will be the stainless steel in powder from for melting/EBM processes. Wijk, Wijk and IOS Press (2015) argue that the metal used was naturally silver but it can be mixed with other materials to bring the Bronze or Gold effect. Strong materials such as Gold and silver processed in powder form have been applied in jewellery sector. Another metal that will be used for 3D printing is Titanium, one of the strongest material supplied in powder form and used for sintering/melting/EBM processes (Wijk , Wijk & IOS Press, 2015). Figure 1 bellow shows metal of aluminium and Stainless steel in powder form. Figure 1: Stainless Steel and Aluminium finely-powdered metals These metals are mixed in a proper ratio and melted to produce a 3D printed product as shown bellow Figure 2: 3D printed product from a melted mixture of Stain less steel and Aluminium. 4.0 Findings It was found that the very nature of 3D printing creating a part, layer by layer will make it lower the cost of raw materials since it will be cheap. Additive manufacturing shall only print what you want and where you want it. It was found that 3D printing will be the ultimate just in time method of manufacturing. Additionally, one will be able to offer almost infinitive design options and customs products as one may require. Additive manufacturing will open up design to a new level since complex walled parts, undercuts, and complex geometry were found to be a piece of cake in 3D printing. 5.0 Discussion This section of the project will discuss the effects of 3D printing on manufacturing, and the future of manufacturing in relation to the development of 3D printing. 5.1 Effects of 3D printing on manufacturing 3D printing was found to be already having effects on manufacturing on the way the products are manufactured and the nature of the technology already permits and introduces new ways of thinking in terms of environmental, security, economic, and social implications of the manufacturing process with universally positive results. Lipson& Kurman, (2012) have argued that 3D printing has the potential of bringing closer the production to the end user or consumer hence reducing the current restriction in the supply chain. Ability of 3D printing to produce smaller production batches on demands and the customization value will be a sure way of engaging consumers and reducing inventories and stock piling. Gibson (2014) argued that shipping of spare parts and products from one part of the world to the other will be obsolete as spare parts will be possibly printed on site on the other side of the world. The ultimate goal of any consumer or user of a product in the manufacturing industry will be to operate their own 3D printer at home or within their vicinity whereby digital design of any customised products are available for download over the internet and printed over the printer with accurate and correct materials. The project research argue that adoption of 3D printing will lead to re-invention of already invented products in a way that impossible shapes and geometrics will be created with a 3D printer (3D Printing is the future,2012). Additionally, use of 3D printing technology will have potential effects on the global economy if adopted worldwide since it will reduce the imbalance between the exports and imports countries by shifting the production from the current models to localised production models. The industrialized world, would benefit possibly the most from 3D printing, where the growing aged society and shift of age demographics has been a concern linked to production and work force. Also the health bene fits of the medical use of 3D printing would cater well for an aging western society 5.2 The future of manufacturing Scientist are exploring the use of 3D printers at the international space station to make spare parts on the sport. There are 3D parts which are structurally stronger and more reliable than conventionally crafted parts, for the space launch system. 5.2.1 Rocket engine The first attempt of NASA using 3D printed parts for rocket engines have passed its biggest and hottest test yet. The largest 3D printed rocket part built to date, a rocket engine injector survived a major hot fire test. The injector was found to be generating 10times more thrust than any injector made by 3D printing before, space agency announced (NASA’s New Innovation Mission, 2012). Figure 3: 3D printed rocket engine 5.2.2 3D Bio-printing It’s the process of generating spatially-controlled cell patterns using 3D technology, where the cell functions and its viability are preserved within the printed contract. It actually involves dispensing cells onto a biocompatibe scaffold using succcessive layer by layer appraoch to generate tissue-like three dimensional structures. Some of the methods used for 3D bio-printing of cells are; direct cell extraction, photolithography, stereolithography, and magnetic bio-printing (Zhang, Fisher & Leong, 2015). Figure.4: shows the way of creating a living tissues with 3D printed model 5.2.3 3D printing in space According to Boeing Company (2011), astronauts will be able to make plastic objects of almost any shape inside a box about the size of a microwave oven enabling them to print new parts and replace the broken ones and even invent useful tools. Scientist have argued that the promise of 3D printing is real but it comes with a long way from the hypes that surrounds it (Toriya, 2008). There will be a made in space 3D printer which will be able to perform in a zero gravity by spraying individual layers of materials that builds up to be a complete 3D object. The figure bellow shows a model of a 3D printer that will be made on space. Figure 5: the image of astronauts with made in space 3D printer 6.0 Conclusion It’s clear that the world will get huge benefits from 3D printing and its transition will impacts positively to the development of manufacturing. The enormous products from 3D printers was found to be require potential markets which will need radically incorporation of different frameworks and infrastructure for them to work. Additionally, 3D printing was found to be disruptive technology that will place strains on the economic and legal conventions that shall require the support of governments of every nation. The policy questions that 3D printing raises should be addressed with a lot of urgency since 3D printing will shake up the world economic geography to a new different higher level. According to Barnatt (2013) comparing the numerous advantages, applications, and future scope we can conclude that 3D printing technology will be able to create the next industrial revolution. 6.1 Recommendations While the world must take care not to stifle the 3D printing market, developed countries and world over must demonstrate that they can listen to the emerging business and become very proactive. In moving 3D printing towards the world market the project recommends the following: i. Creation of a 3D printing task force, controlled by business department, skills and innovations. A body that will bring together the academia and business and coordinate the levels of policy that will affect 3D printing such ii. Provision of funding for competitions through Nestea or technology strategy board to enhanced development of new materials for 3D printing. iii. Exploration of the viability of a digital design exchange iv. Scope out the review of the intellectual property implications of 3D printing such as commissioning to review the IP implications of 3D printing. v. Commissioning feasibility and research studies into ways of regulating 3D printing markets so that it will not be used for the production of illegal and dangerous goods 6.2 Limitations It was found that the number of challenges associated with additive manufacturing or 3D printing as follows; The intellectual property questions and disputes, whereby prolonged legal wrangled and confusion issues will slow implementation and pose complex questions for the law makers. Limitation in relation to speed compared to conventional production processes and therefore manufacturing of large quantities of certain goods may find it difficult to do production. Moreover, the choice of materials to be used as the feedstock was found to be still limited Finally, it was found that post processing pose a great challenge since it would not be done by additive manufacturing. References “Additive Manufacturing in Aerospace, Examples and Research Outlook”; Brett Lyons, The Boeing Company, National Academy of Engineering, Frontiers of Engineering 2011, Additive Manufacturing; 19 September 2011 http://www.naefrontiers.org/File.aspx?id=31590 “NASA’s New Innovation Mission,” CIO.com, 27 July 2012. http://www.cio.com/article/711437/NASA_s_New_Innovation_Mission 3D Printing is the future: “Chocolate printer to go on sale after Easter”. 2012. http://www.3dfuture.com.au/2012/04/chocolateprinter-to-go-on-sale-after-easter/ (accessed: September 16, 2015). Additive Manufacturing: Strategic Research Agenda (SRA), AM Platform, 2013 http://www.rmplatform.com/linkdoc/AM%20SRA%20Consultation%20Documen t.pdf Fogliatto, F. S., & Da, S. G. J. C. (2011). Mass customization: Engineering and managing global operations. London: Springer. Gibson, I. (2014). Additive manufacturing technologies: 3d printing, rapid prototyping, and direct digital... manufacturing. S.l.: Springer. http://desktop3dprinters.net/773374/3d-printing-technologies http://net.educause.edu/ir/library/pdf/DEC0702.pdf http://www.boldeconomy.com/aktuell-3d-waffengesetz; 12 May 2015 http://www.explainingthefuture.com/3dprinting.html http://www.inventioncity.com/intro-to-3-d-printing.html http://www.mahalo.com/3d-printers/ Lipson, H., & Kurman, M. (2012). Fabricated: The new world of 3D printing. Hoboken, N.J: Wiley. Naboni, R., & Paoletti, I. (2015). Advanced customization in architectural design and construction. Pettus, E. L., & Air University (U.S.). (2013). Building a competitive edge with additive manufacturing. Toriya, H. (2008). 3D manufacturing innovation: Revolutionary change in Japanese manufacturing with digital data. London: Springer. Wijk, A. ., Wijk, I. ., & IOS Press. (2015). 3D printing with biomaterials: Towards a sustainable and circular economy. Zhang, L. G., Fisher, J. P., & Leong, K. (2015). 3D bioprinting and nanotechnology in tissue engineering and regenerative medicine. Read More