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3D Printing Reaching Its Limit?

Posted December 30, 2010 7:00 AM

In just two decades, 3D printing techs have leaped from prototype tools to manufacturing processes able to produce high-end finished parts. They've escalated from outputting bench-top sizes to large components, even car bodies. So, have we begun to close in on the upper limits of 3-D printing — or are we just now scratching the surface of its potential? Will additive manufacturing's slow speed or other tech barriers ultimately suppress the role it can play?

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#1

Re: 3D Printing Reaching Its Limit?

12/30/2010 10:26 PM

We are scratching the surface. no question.

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Re: 3D Printing Reaching Its Limit?

12/31/2010 3:22 AM

I agree with chris. New discoveries in materials science as well as the underlying physics have an almost boundless future. Try to compose a general definition of "3D printing" and as you think through it and test it against various scenarios that it would embrace you will see a wealth of applications that are not even spoken of today.

3D printing is constrained primarily by materials technology. The practical materials in use today are still very primitive. Other technologies in a 3D printer such as motion control and software are mature technologies with capabilities far beyond what the current generation of machines require.

I do think the high volume production applications of 3D printing will be generally limited. But prototype, low and even medium volume production as well as toolmaking and arts and crafts applications have extensive future possibilities even if significant new materials technologies are slow in coming.

For example in the world of model building there is a market ready and waiting for some entrepreneur to put the technology in the right package at a realistic price. Not a hint of it at the moment; but I can think of two or three small US companies that are imaginative enough to be watching closely. To me the key would be standardization of software and control interfaces into a piece of universal hardware that could control any 4 axis tool moving fabrication machine. Usability on a variety of machine platforms could well produce the manufacturing volume to drive the control costs into the consumer hobbyist range. Around $500.

At the other end of the cost range we have semiconductor process equipment that selectively positions energy or material application beam patterns to micron levels of resolution. There are some very surprising materials these process can deal with not the least of which are those common materials that exhibit unusual properties in the nano size ranges.

Thermal spray processes put metal, ceramic and some plastic materials on rather than taking it off. Current computerized pattern generation capability in these processes is generally vested in robots similar to those used for complex production welding. The application stream of melted ceramic powders is generally in the range of millimeters diameter. Suppose we were to develop plasma spray heads that could produce a stream an order of magnitude smaller? This could lead to a capability of printing high property 3D metal alloy or ceramic parts. We may see the first applications of this stuff in the medical world.

Gotcha thinking now? ..........Ed Weldon

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Re: 3D Printing Reaching Its Limit?

01/01/2011 2:05 PM

Good points! And don't forget the custom applications that are possible, with the 3D bioprinters for tissues and (eventually) organs to match your own DNA and other immune factors. This is not about speed or mass production, but about the capacity to produce very customized and ideal solutions to medical needs.

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#3

Re: 3D Printing Reaching Its Limit?

12/31/2010 7:30 AM

Get a portable one made big enough and you could print a house, complete with wiring - using different materials instead of/as well as different colours. Eventually it could be easier than an old container??

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#5

Re: 3D Printing Reaching Its Limit?

01/03/2011 11:23 AM

The sky is the limit in my opinion. I was with 3D Systems when they formed their sales force and began widespread sales of rapid prototyping Stereolithography.

Today I'm building my own open source Reprap Mendel literally in my bedroom. The kit I bought cost me US $800. I could've sourced it out for a couple hundred dollars cheaper but I just didn't want to take the time.

The system is somewhat currently limited to PLA or ABS materials and has a max volume of about 1 cubic foot but with the broad user base, I forsee, with the opensource community involved, great things over time.

Hooker

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#6

Re: 3D Printing Reaching Its Limit?

01/03/2011 4:19 PM

Long as we're seeming to have an intelligent discussion for now I'd like to bring up one more aspect of this 3d printing market.

A lot of the early optimism over stereolithography came from the ability to produce physical prototypes that would aid in aspects of product development, particularly where it involved non-engineering people and outright internal corporate PR efforts to gain political support for a project.

Solid modeling has become so much of the mainstream of engineering product development in the last 10 years that it is a cultural norm. That means that any serious participant will be reluctant to admit that he/she cannot completely understand the model's presentation on a flat screen or printed image and requires a 3 dimensional faux object. The resources of project time and material cost that must be taken to produce such models for internal use become questionable in the face of tight time and money budgets and will likely be preserved for presentations to high ranking non technical corporate staff and customer executives.

In addition the closely related technology of CNC machining and the software that controls it has reached a level of mainstream sophistication as to be able to produce prototypes in materials that not only deliver the form of the design but also the engineering performance and physical properties the design requires. This is often achievable with the same or better project lead time and material cost than the comparable 3D printing process provides.

Conclusion here seems to be that 3D printing will tend to be a fabrication technology best suited for niches where the common fabrication technologies are unsuitable. That doesn't mean, however, that we will never see an application in the world of home building. Matter of fact I can see some interesting applications for custom interior trim pieces for locations that could first be accurately measured by a 3D scanning device. Especially in remodeling where the structure is no longer perfectly "square".

Ed Weldon

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