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The 10 Principles of 3D Printing

Posted January 08, 2014 1:00 AM by larhere

In a recent blog post I raised the question Are You Ready for 3-D Printing? This revolutionary technology is changing the way we make "things", and I use this term intentionally, because we are not limited to plastics, metals and common production materials but are seeing materials we would not have envisioned for production processes. Each day brings new breakthroughs and products as the race to capture competitive advantage heats up.

Many paradigms are falling by the wayside and many more to come. To help break down these mindsets and help us see the new opportunities a new set of guidelines is needed. A great source of this guidance is in the recently released book titled "Fabricated: The New World of 3D Printing" which was reviewed in Industry Week under title of The Ten Principles of 3-D Printing. I've provided a condensed version of the ten principles below which should encourage you to read the more detailed review at IW, or better yet get a copy of the book.

Principle one: Manufacturing complexity is free. In traditional manufacturing, the more complicated an object's shape, the more it costs to make. On a 3-D printer, complexity costs the same as simplicity.

Principle two: Variety is free. A single 3-D printer can make many shapes. Like a human artisan, a 3-D printer can fabricate a different shape each time.

Principle three: No assembly required. 3-D printing forms interlocked parts.In current factories, machines make identical objects that are later assembled by robots or human workers, sometimes continents away. The more parts a product contains, the longer it takes to assemble and the more expensive it becomes to make. Less assembly will shorten supply chains, saving money on labor and transportation.

Principle four: Zero lead time. A 3-D printer can print on demand when an object is needed. The capacity for on-the-spot manufacturing reduces the need for companies to stockpile physical inventory.

Principle five: Unlimited design space. Traditional manufacturing technologies and human artisans can make only a finite repertoire of shapes. A printer can fabricate shapes that until now have been possible only in nature.

Principle six: Zero skill manufacturing. To make an object of equal complexity, a 3-D printer requires less operator skill than does an injection molding machine. Unskilled manufacturing opens up new business models and could offer new modes of production for people in remote environments or extreme circumstances.

Principle seven: Compact, portable manufacturing. Per volume of production space, a 3-D printer has more manufacturing capacity than a traditional manufacturing machine.

Principle eight: Less waste by-product. 3-D printers that work in metal create less waste by-product than do traditional metal manufacturing techniques. As printing materials improve, "Net shape" manufacturing could be a greener way to make things.

Principle nine: Infinite shades of materials. Combining different raw materials into a single product is difficult using today's manufacturing machines. Since traditional manufacturing machines carve, cut, or mold things into shape, these processes can't easily blend together different raw materials.

Principle ten: Precise physical replication. A digital music file can be endlessly copied with no loss of audio quality. In the future, 3-D printing will extend this digital precision to the world of physical objects. Scanning technology and 3-D printing will together introduce high resolution shapeshifting between the physical and digital worlds.

Looking at these ten areas of opportunities the area that first comes to mind is compressors -scroll, screw, centrifugal and others. The second could be the supply chain, accelerating the "re-shoring" trend underway.

Where do you see the opportunities?

Editor's Note: CR4 would like to thank Larry Butz, President of GEA Consulting, for contributing this blog entry.

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Power-User

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#1

Re: The 10 Principles of 3D Printing

01/09/2014 12:03 AM

If I were a younger individual, I believe this would be a great opportunity to get in on the ground floor of a fairly new technology. My idea would be to seek employment with an employer who is already fairly well established, as well as versitile in the field, learn as much as possible on the technical aspects of the trade as well as the materials side of the business. If things looked promising and the competition was reasonable, (I'm thinking China with $1 day school children manning the printers) a few 3D printers in my garage might work out quite well as small R&D job shop. Fairly low initial investment (compared to CNC machines) as well as low overhead. A few work benches and standard electrical service.

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#2

Re: The 10 Principles of 3D Printing

01/09/2014 1:08 AM

I disagree with principle 6

The raw materials still need to get to the printer, and be put in the correct feed compartment, in the correct quantities for the product. And there will be maintenance, cleaning of feed lines between batches of different designs, etc, etc.

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#3

Re: The 10 Principles of 3D Printing

01/09/2014 10:01 AM

Counterpoints to each issue from my experience of 40 years in design and manufacturing, and 3 years as a 3D Systems

applications engineer:

1) From a purely manufacturing standpoint, this is true. Unfortunately, associated costs (design, time to print, post

processing, assembly, reliability and maintainability) may skyrocket if only this principle is considered. In particular, the

costs of mechanical simulation computer systems (CAD) required to produce manufacturable complex shapes is not inconsiderable.

2) The value of this feature of 3D printing is variable depending on the volume of parts required. CNC machines can also

provide variety but dedicated high speed machinery brings costs down.

3) This will only be a preferred value if the product is purely throwaway with no maintainability required. Thus, the

manufacturing genre (such as consumer electronics) limits the value of this principle.

4) The value of this depends on the complexity and size of the object being printed. It has little value if the object is

needed immediately but takes 2 days to build.

5) This principle's value has to be evaluated per the requirements of the project. The vast majority of design and

manufacturing projects tend to avoid "unmanufacturable" objects, if only to allow maintainability. (See also Item 1)

6) To acquire the benefit of this principle means expanded costs up front in the planning and design phase. Unskilled labor

use generally means a higher cost and skill at the front end.

7) This principle is arguable at many levels and is highly dependent on the product being manufactured. Capacity is measured

by many factors including throughput. It would be hard to believe that a 3D printer would have higher "capacity" than, for

example, an injection molding machine.

8) Again, depends on the industry and the product. Production, handling and storage costs of many 3D printing raw materials

outweighs many traditional materials.

9) Depending on the industry and product this is very often not an advantage. In aerospace, for example, many assembly

processes that involve dissimilar materials requires metal finishing processes that must be accomplished before assembly.

Airplane aluminums require acid etching, alodining and priming before assembly with other materials. Corrosion control and

dissimilar material interaction are issues that 3D printing doesn't address.

10) Moot point. This principle has been available for many years in more traditional manufacturing processes such as CNC,

injection molding and dedicated high speed production machinery. Most of our manufacturing data today comes directly from

digital simulation (CAD/CAM) systems.

In a nutshell, competitive manufacturing requires far more due process and diligence than the capability of a single process

or machine type. I guess I'll have to read this book to see if it expands on the inclusion of 3D printing in a more realistic

framework than this blog presents.

Hooker

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#4
In reply to #3

Re: The 10 Principles of 3D Printing

01/09/2014 12:06 PM

Hooker,

Thanks for taking the time to share your experience and expertise on this interesting topic. Where 3-D finds its best applications will take time as well as a good amount of trial and error. One of the biggest challenges will be the ability to see past current "best in class" manufacturing processes and develop a new set.

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#6
In reply to #4

Re: The 10 Principles of 3D Printing

01/09/2014 1:57 PM

You're welcome. I am just getting a little annoyed that so many people are starting to equate 3D printing as a panacea for every established manufacturing procedure in the known universe (ok, so I'm exaggerating. I really mean earth)

When I was an AE at 3D Systems we spent many an hour with prospective customers coming up with ROI's to justify the purchase. There were relatively few positive ROI's for most manufacturers outside of the sales/marketing and prototype engineering departments.

There have been major inroads in some niche manufacturing areas like investment casting in aerospace/automotive and in the jewelry industry, with newly emerging apps in the medical and food industries.

I suspect the next "major" sales market is for home use, but I don't see really widespread use until they reach the level of Star Trek replicators. And, even then, they're not likely to be used for high volume manufacturing.

But, then, I have been wrong before. Circa 1980, I predicted computer aided design would be accomplished inside of full scale holograms by the mid 90's.

Hooker

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#7
In reply to #3

Re: The 10 Principles of 3D Printing

09/10/2016 1:58 AM

Cool.

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#5

Re: The 10 Principles of 3D Printing

01/09/2014 1:45 PM

Nice discussion.

What excites me most about 3D printing is that someone like me, who's created a fine career out of nothing more than stacking bits of logic together, can actually make something real... out of a thought.

That's the high concept. The reality is much more complicated, as evidenced by this thread.

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