The 3D Printing

Transformation

History

Materials

Technology Overview

Additive Manufacturing Advantage

Areas of Impact on Society and IndustrySimon Lancaster

January 17, 2014

History

Chuck Hull, Founder 3D SystemsInventor of 3D Printing

1st 3D Printed Part: eye-wash1984 - Stereolithography

1984 – Stereolithography (SLA)

1989 – Selective Laser Sintering (SLS)

1991 – Fused Deposition Modeling (FDM)

2001 - First desktop 3D Printer

Materials

Many many kinds of polymers

Steel, Aluminum, etc

Titanium Chocolate!

Multi-colored PLA filaments Sugar, etc!

Plastics Metals Foodstuff

Hershey’s Chocolate Printer

Overview of Techs

Type Technologies Materials

Extrusion Fused deposition modeling (FDM)Any material that can transition from solid to

liquid and back to solid

Wire Electron Beam Freeform Fabrication (EBF3) Almost any metal alloy

Granular

Direct metal laser sintering (DMLS) Almost any metal alloy

Selective laser melting (SLM)Titanium alloys, Cobalt Chrome alloys,

Stainless Steel, Aluminium

Selective laser sintering (SLS)Thermoplastics, metal powders, ceramic

powders

Laminated Laminated object manufacturing (LOM) Paper, metal foil, plastic film

Light

polymerisation

Stereolithography (SLA)

curable liquid photopolymerDigital Light Processing (DLP)

Inkjet/Polyjet

So how do all these techs work?

Many different types of 3D Printing, but in essence they all

“add” material layer by layer. Thus: Additive

Manufacturing.

Subtractive Manufacturing

•Material = Free (or Cheap)

•Geometry/Shape = $$$

•Lot size dependent

•Fast(er)

•Design for Manufacturing

Additive Manufacturing

•Material = $$$

•Geometry/Shape = Free

•Lot size independent

•Slow (today) 4-10 mm/hr

•Manufacturing for Design

The Additive Manufacturing Advantage

The Additive Manufacturing Advantage

Subtractive Manufacturing

•Material = Free (or Cheap)

•Geometry/Complexity = $$$

•Lot size dependent

•Fast(er)

•Design for Manufacturing

Additive Manufacturing

•Material = $$$

•Geometry/Complexity = Free

•Lot size independent

•Slow (today) 4-10 mm/hr

•Manufacturing for Design

3D Printing at It's Best

•Material = $$$

•Geometry/Complexity = Free

•Manufacturing for Design

→Minimize material: Hollow

→Crazy geometry: no problem

→No compromises on design

Klein Bottle Opener by Bathsheba

Impact on Society and Industry

Rapid Iteration & Prototyping

Design Evolution & Optimization

Batch-Size One, ex. Bio Medical, spare parts

Bio-Mimicry

Part Consolidation

Art & Jewelry

Visualization / Architecture

Reverse Engineering

Impact on Society and Industry

Rapid Iteration & Prototyping

Design Evolution

Batch-Size One, ex. Bio Medical, spare parts

Bio-Mimicry

Part Consolidation

Art & Jewelry

Visualization / Architecture

Reverse Engineering

Rapid Iteration & Prototyping

Extremely quick turn iterations allow for visualization, testing and feedback

Design Evolution & Optimization

FEA Structural Optimization Software for weight reduction.

Biomimicry

Extremely strong and lightweight structures

Bone structures, shell structures, honeycomb, organic trusses, etc

Part Consolidation

Fewer parts = less failure points, less assembly, less cost

Extremely complex assemblies reduced to single components