Introduction and Terminology - 3D printing is the construction of a three-dimensional object from a CAD model or a digital 3D model. - It can be done in a variety of processes, typically layer by layer. - 3D printing was initially used for prototyping but has now become a viable industrial-production technology. - It allows for the production of complex shapes and geometries that would be otherwise infeasible to construct by hand. - Fused deposition modeling (FDM) is the most common 3D printing process. - Additive manufacturing (AM) is the umbrella term for 3D printing and other additive technologies. - Subtractive manufacturing refers to machining processes with material removal. - The terms 3D printing and additive manufacturing have evolved to be used interchangeably. - Agile tooling is the use of modular means to design tooling produced by 3D printing.

History of 3D Printing - The concept of 3D printing was described in a 1945 short story by Murray Leinster. - Raymond F. Jones mentioned a similar concept in a 1950 story, referring to it as a molecular spray. - Johannes F Gottwald patented the Liquid Metal Recorder in 1971, describing 3D printing with rapid prototyping. - The patent mentioned the use of ink and the salvaging of materials for reuse. - David E. H. Jones discussed the concept of 3D printing in a 1974 journal column. - Early additive manufacturing equipment and materials were developed in the 1980s. - Hideo Kodama invented two additive methods for fabricating three-dimensional plastic models in 1980. - His research results were published in 1981, but the project was terminated due to lack of interest. - A US patent in 1982 described using powdered metal and a laser energy source for 3D printing.

Applications and Future Developments - 3D printing has various applications in industries such as aerospace, automotive, healthcare, and consumer goods. - It is used for prototyping, manufacturing end-use parts, and creating customised products. - Medical applications include the production of implants, prosthetics, and surgical models. - 3D printing is also used in architecture and construction for creating complex structures and models. - The precision, repeatability, and material range of 3D printing continue to improve. - New materials, such as metals and ceramics, are being used in 3D printing. - Advances in software and hardware are making 3D printing more accessible and efficient. - The technology is expected to revolutionize supply chains and enable decentralised manufacturing. - Research is ongoing to enhance the speed, scale, and capabilities of 3D printing processes.

Early Development and Commercialization of 3D Printing Technology - Bill Masters filed the first 3D printing patent in history in 1984. - Alain Le Méhauté, Olivier de Witte, and Jean Claude André filed a patent for the stereolithography process in 1984. - Robert Howard started Howtek, Inc. in 1984 to develop a color inkjet 2D printer. - Richard Helinski formed C.A.D-Cast, Inc. (later Visual Impact Corporation) in 1991, using Howtek inkjet technology. - Herbert Menhennett formed HM Research in 1991, introducing Howtek inkjet technology to Ballistic Particle Manufacturing (BPM). - Chuck Hull filed a patent for stereolithography fabrication system in 1984. - 3D Systems Corporation was formed in 1986 and released the first commercial 3D printer, the SLA-1. - S. Scott Crump developed fused deposition modeling (FDM) in 1988. - Stratasys commercialised the first FDM machine in 1992. - Owning a 3D printer in the 1980s cost upwards of $300,000.

Applications of 3D Printing in Aviation and Sustainable Development - AM is being used by large OEMs like Pratt and Whitney and General Electric in the aviation industry to reduce costs and nonconforming parts. - In 2016, Airbus delivered the first jet engine with 3D printed fuel nozzles, reducing parts from 20 to 1 and achieving a 25% weight reduction. - PW delivered their first AM parts in the PurePower PW1500G to Bombardier, focusing on low-stress, non-rotating parts like compressor stators and synch ring brackets. - AM is still playing a small role in the total number of parts in jet engine manufacturing, but it offers a high return on investment in terms of reduced parts, rapid production, and optimised design. - The integration of AM in jet engines allows for optimised design of complex internals and the production of highly complex shapes. - Filabot developed a system in 2012 that allows for the use of a wider range of plastics in 3D printing, contributing to sustainable development. - In 2014, Benjamin S. Cook and Manos M. Tentzeris demonstrated the first multi-material, vertically integrated printed electronics additive manufacturing platform (VIPRE), enabling 3D printing of functional electronics. - The drop in the price of 3D printers has increased access to the technology, enhancing its potential for sustainable development. - 3D printing can aid in sustainable energy generation and distribution by producing battery energy storage systems. - The technology's ability to produce complex geometries with high precision and accuracy makes it valuable in fields like microwave engineering.