An Introduction to 3D Printing

Transcription

1 An Introduction to 3D Printing A whitepaper provided by pii September 2015

2 What is 3D printing and how does it work? 3D printing, also known as additive manufacturing, was developed in the 1980 s as a process used to make threedimensional objects. Additive manufacturing creates parts from the ground up by fusing together layers of material. Its counterpart, subtractive manufacturing, begins with material and removes excess until only the desired shape remains. Methods There are several methods of 3D printing. The most commonly recognized is called Fused Deposition Modeling (FDM). This method uses a single nozzle head to extrude melted material, typically plastic, layer by layer onto a build platform according to the 3D data that has been supplied to the printer. One of the most familiar printers in this space, the MakerBot, uses the FDM method. Other 3D printing processes, like Stereolithography (SLA), fuses together liquid material by curing it with a UV laser; while Binder Jetting fuses together powder material with a binding spray. Today, these methods are still more expensive and specialized than FDM. 1 Materials The materials used in 3D printing are often dependent on the method. Binder Jetting for instance, might use sandstone material, while SLA and FDM typically use plastic or resin. But what was once a small list of printable materials has been rapidly expanding. Plastics today include stronger substances Nozzle depositing plastic.

3 3D printing process DESIGN FILE PROCESSING PRODUCTION FINISHING SOCIALIZING Create the 3D part file for print from scratch, a digital scan or from a base file that was downloaded. Get the file ready for the 3D printer by slicing it using programs either installed locally or available in the cloud. Different technologies are used that vary in printing speed, accuracy, durability, finish quality and cost of materials being used. A variety of methods are used to give the part a final finish so that it is aesthetically pleasing but also more durable. Part files, renderings or photos of physical parts can be shared in social media outlets or free marketplaces. like nylon, as well as biodegradable plastic. Paper, ceramics, and metals are growing in popularity and helping to expand applications for 3D printing. Most recently on the scene are food materials like chocolate, sugar and even meat. Steps of 3D Printing It s important to note that the process of 3D printing has many steps and is not as automated as some might think. From file preparation (e.g., creation, conversion), to actual printing, to the finishing work post-print (e.g., sanding, coating, removing support material), the output of 3D printing takes time. However, open source file sharing on sites like Thingiverse and GrabCAD are making it faster for designers to get started. How is it being used today and what are the benefits? Big strides in both printer technology and material exploration have led to a variety of exciting applications across industries. In fields like design and architecture, 3D printing has long played a role in model and prototype creation. But more and more it is being used to produce end-products like jewelry, sculptures, and shoes. Barilla s 3D pasta design competition. Thanks to advances in 3D printed metal, automotive companies are now looking at the potential of 3D printing to fulfill aftersale parts on demand, rather than holding large inventories. As an early adopter of 3D printing for product development and prototyping, the aerospace industry is following suit, now experimenting with non-critical part production. In the marketing industry 3D printing is being used in both playful and functional ways. Barilla recently challenged customers to design a unique 3D pasta design, while McDonald s is rumored to be creating a 3D printing toys kiosk to print on-demand Happy Meal parts. 2 Source: Barilla

4 Consumer benefits Companies are not the only ones experimenting with 3D printing. As the technology moves from maker to mainstream, more and more people are playing with it at work, at school and at the library. According to OITP Perspectives, a publication by the American Library Association, more than 250 libraries in the U.S. offer the use of 3D printers to patrons. 3 Home use is growing as well. A 2014 report by research agency OnePoll found that one in three Americans would consider buying a 3D printer for their home. 4 Source: 3D Hubs In a study conducted by pii, twelve people with 3D printing experience ranging from one time use to weekly use, were asked to share about their 3D printing process and the intention behind their prints. Intricate 3D printed engine components While consumer applications of 3D printing spanned across dozens of applications one-of-a-kind gifts, prototypes, decorations, toys, jewelry, functional fixes the purposes behind 3D printing all ladder up to 5 key benefits: 1. Thoughtful Moments: I can capture the memories and connect to others. 2. Playful Creation: I can bring my imagination to life. 3. Design Control: I am in the driver s seat to design my products. 4. Confident Decisions: I can rest assured that I ve gotten it right 5. Immediate Access: I have what I want, when I want it. These consumer benefits are core to what differentiates 3D printing from other processes and why it appeals to consumers and companies alike. Company benefits 3D printing is transforming the way companies do everyday business. When the benefits of 3D printing are leveraged, the technology enables companies to reach new audiences, connect with customers, and capitalize on the efficiencies User-printed objects. Source: MakerBot

5 Speed of prints When standing in front of a 3D printer watching each layer print, the process may not feel fast, however, relative to traditional manufacturing methods, it is. Objects can be created in a matter of hours, whereas before, the time it takes to prototype, tool, and create a final product could take weeks. The speed has also enabled companies to leverage the technology to create prototypes in successive rounds in- house thereby reducing the wait time needed to refine prototypes overseas. Uniqlo launched the selfless selfie project that encouraged customers to share images of positive impact which were then printed in-store. Source: Uniqlo The future of 3D printing 3D printing is a nascent technology with big promise. While there are still many hurdles to ensuring the technology is affordable and practical, the rate at which the technology is evolving is rapid. Hurdles such as cost, speed, quality and accessibility are already being addressed today. the technology provides. While 3D printing has the potential to add value to businesses in numerous ways, there are unique technological benefits that make it stand apart from other processes: Complexity The layering process of 3D printing allows for a deeper level of complexity than traditional manufacturing processes, making it possible to print components with intricate shapes and complex geometry. Many 3D printers can print multiple materials meaning that multiple components can be fabricated as a single unit with no seam. Personalization In standard manufacturing processes efficiencies are gained as more pieces are printed due to the amortization of tooling costs. This results in large batch prints with little variety and no opportunity for customization. The cost of 3D printing is the same for the 100th print as it is for the 1st print. This allows companies to print small batches and highly customized goods without additional upfront investment in tooling. The ability to print one- off or small batch designs also opens up an opportunity to print custom goods that fit the exact size and need of the customer. Cost and Speed As more makers and companies experiment with the technology, new more efficient models are being launched. Experts predict 3D printing will become 50 percent cheaper and up to 400 percent faster in the next five years (Siemens, 2014). 6 In $ Billions D Printing Industry Growth Growth projection of 3D printing in billions. Source: Canalys 20145

6 Accessibility Software: A key challenge in 3D printing is creating the file in the right format for print without 3D modeling skills. Today the ability to build files is a specialized skill of engineers and designers. Software companies like AutoCAD are building intuitive software to make 3D file design and creation accessible to everyone. Programs like Tinkercad by AutoCAD are leveraging intuitive features like drag and drop. Hardware: As more companies create and evolve the 3D printer, the technology continues to become cheaper and better in quality. The average cost of a home 3D printer ranges from $500-$2500. At an enterprise level multiple models are available ranging in level of fidelity and price. How can you leverage 3D printing? 3D printing is a tool to support your marketing strategy, not the strategy itself 3D printing is simply one more tool in the toolbox to help you execute on your marketing strategy. Companies often see 3D printed goods as the solution to reaching more customers and engaging them more deeply. If the goods are not connected to a larger message and strategy they can often feel random and one-off. 3D printed products should deliver and support the strategic marketing messages of the organization in order to be relevant and impactful. 3D printing is more than a manufacturing process Instead of replacing a current process or product with 3D printing, take advantage of what the technology does best. 3D printing truly shines when it s focused on providing greater tangibility, increased complexity, hyper personalization, or speed. Leverage 3D printing to do more for you by focusing on its unique benefits in order to enhance or offer something new to customers. Give 3D printing a lasting purpose Similar to other new technologies, the novelty and buzz around 3D printing will eventually stabilize. Ensure your 3D printing strategy aligns with the benefits consumers are seeking, not just the spectacle. 3D printing works for prototyping because it supports decision- making so well, a very real benefit to anyone testing out an idea before it becomes real. Realizing this deeper purpose will drive your offerings and help you utilize the technology in a meaningful way. Sources 1 3D Printing Processes: The Free Beginners Guide. 3D Printing Industry, May Overview Over 3D Printing Technologies. Additively, n.d. 2 Plafke, James. McDonalds Wants A 3D Printer In Every Restaurant So They Can Print Happy Meal Toys. Geek, November Wapner, Charlie. Progress In The Making: 3D Printing Policy Considerations Through The Library Lens. American Library Association, Number 3, January McCue, TJ. 3D Printing In The Home: 1 In 3 Americans Ready For 3D Printer. Forbes, March D printing market to grow to US$16.2 billion in Canalys Press Release. March D printing Facts & Forecasts Siemens Makerbot at CES

7 Makerbot has sold 44,000+ home 3D printers since the company s inception. Source: MakerBot

8 The Power of Personalization whateverittakes.com Corporate Headquarters One Hardman Drive Bloomington, IL Pompano Beach, FL Lansing, MI Tianjin, China Tamil Nadu, India Cebu City, Philippines pii is a registered ISO 9001 company. V