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.
3D printing or additive manufacturing 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 in which material is deposited, joined or solidified under computer control, with the material being added together (such as plastics, liquids or powder grains being fused), typically layer by layer.
In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping. As of 2019[update], the precision, repeatability, and material range of 3D printing have increased to the point that some 3D printing processes are considered viable as an industrial-production technology; in this context, the term additive manufacturing can be used synonymously with 3D printing. One of the key advantages of 3D printing is the ability to produce very complex shapes or geometries that would be otherwise infeasible to construct by hand, including hollow parts or parts with internal truss structures to reduce weight while creating less material waste. Fused deposition modeling (FDM), which uses a continuous filament of a thermoplastic material, is the most common 3D printing process in use as of 2020[update].
