It’s hard to believe that 3D printing has already been around for over 30 years. It sparked public and business interest at the time due to the enormous benefits it offers. One of the primary benefits of 3D printing is the ability to produce complex geometries. And it can make complex pieces that don’t need to be assembled.
Rapid prototyping and 3D printing are now referred to as additive manufacturing. In AM manufacturing material is applied layer by layer to construct the final geometry. AM technology made it easier to use CAD models for manufacturing.
In comparison to other traditional manufacturing techniques AM is comparatively simple. Traditional manufacturing techniques take substantial time and effort to examine geometry and plan whole processes.
With AM, engineers just need the CAD model and knowledge of how the machine works. Of course, this knowledge is mostly about what materials to use for the finished object as well as how to select tools to make fixtures and program the processes.
With the advancement of technology, additive manufacturing has progressed from a prototyping process to a modern method of producing actual parts.
Revolutionising Prototyping and Rapid Product Development
The ability to 3D print anything from prosthetics to aircraft parts proves additive manufacturing is rapidly changing. 3D printing was a rapid prototyping method when it was first introduced. Design engineers used 3D printed plastic models to test the part before actual manufacturing. These printers can now print bigger parts with a wide range of material options.
With a greater range of materials available, AM becomes less expensive and more functional. It is now common for a computer to transfer a design directly to a 3D printer. The item is then built with fewer parts using a 3D printer. Using traditional manufacturing methods a single assembly might contain more pieces.
Several forms of additive manufacturing require melting plastic or metal wire in order to produce a product. Electron rays among other things can be used to melt metal wire. Some machines use lasers to melt metal particles in repeated layers to make a part.
All of these technological advances have a substantial impact on how additive manufacturing is employed. Now that many various materials are available they can be used to create functional physical parts. Furthermore, the forms of these components may be quite complex.
Materials Advancements: Unlocking the Potential of 3D Printing
Initially, polymeric materials such as waxes and paper laminates were used to create parts using AM technique. Today metals such as titanium aluminum inconel and other nickel alloys can be utilised in 3D printing which is popular in the aircraft industry.
Another novel idea that received a lot of interest was the use of biomaterials in additive manufacturing. Biomaterials have the potential to improve people’s health and quality of life. There are already many prostheses built from common polymeric materials.
3D printers can now create objects from many materials. These methods can make use of the qualities of various materials. There is little doubt that AM will be adopted in more industries in the near future.
From Aerospace to Healthcare: Diverse Applications of Additive Manufacturing
AM also called “3D printing” has become a solid technology that can be used in many fields. As we’ve already said there are different ways to use 3D printing which involves building up parts from digital designs layer by layer. Here are some of the AM methods:
- Fused Deposition Modeling (FDM)
- Stereolithography (SLA)
- Selective Laser Sintering (SLS)
- Direct Metal Laser Sintering (DMLS)
- Electron Beam Melting (EBM)
Aerospace is one field where AM is used a lot. It is an excellent tool for making parts that are light but complex. And each drop in an airplane’s weight saves fuel which makes the plane more appealing to airlines. You can learn more about the usage of 3D printing on rocket engines at NASA here.
On the other hand, it is altering the manufacturing of prosthetics and implants in the healthcare industry. When 3D printing is combined with 3D scanning technology, prosthetics can be customised to fit the patient. And because 3D printing makes it easier to create these parts, more people can use them.
These are only two examples of how 3D printing will be used in the future. It’s an excellent method for producing small-batch parts. It works well, can be adapted to diverse industries, and aids in the production of complex parts.
3D Scanning Combined with Additive Manufacturing
3D scanners have improved to keep up with the rapid growth of the 3D printing sector. As input, additive manufacturing can use data from high-accuracy scanning instruments that produce very accurate 3D models. We’ve already talked about how 3D scanners can aid with reverse engineering.
In reverse engineering, 3D scanning is used to create a replica of an object or part. However, 3D printing works well with scanning technology to create replicas of scanned parts. Many older machines are sitting idle in factories because the manufacturer no longer provides replacement parts. If one could scan what was broken and quickly print a new piece, the device would work again.
In addition, combining 3D scanning with additive manufacturing aids in inspection and quality control. As previously said, the introduction of 3D printing has made it much easier to create complex objects. When a part’s geometry is complex, however, measuring its qualities precisely becomes more difficult. Modern scanners can generate a digital replica of the object, making it easy to determine whether it matches the standards.
Catalyzing Industry Transformation
3D printing innovations have transformed numerous industries from aerospace to healthcare and have enabled the use of 3D printing in novel and interesting ways. Manufacturing will most likely evolve considerably more as materials and accuracy improve. The future of 3D printing has many exciting possibilities.
When 3D printing and 3D scanning are coupled it is feasible to copy, alter or “reverse engineer” real-world items with incredible accuracy and speed.
As engineers, it is critical to keep up with these changes in order to remain competitive and take advantage of new opportunities. Whether you want to use 3D printing as a career path or a competitive edge you must recognise its ability to change things.