3D Printing and the Power to Create Things Out of Thin Air

Just as the printing press helped democratize knowledge in the 14th century, today 3D printing is helping democratize the ability to materialize ideas as we perceive them—in unbelievable detail:

3D printing, or additive manufacturing (AM), started off as a rapid prototyping solution, aimed at creating parts layer by layer, using a resin that could be polymerized by UV light.

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Born at the very fortuitous junction of mechatronics and computer science, 3D printing remained relatively underground for the most part of the 80s, used only by academia. The 1990s though saw a great deal of growth for the early 3D printing industry, with new companies founded and new additive manufacturing technologies being explored. It wasn’t until 2006, however, that the first SLS printer became commercially available.

Today the market is absolutely chock full of 3D printers of all shapes, sizes and budgets. But perhaps most importantly, organizations have continued to integrate AM into their production operations to mitigate supply chain risks, enhance product design flexibility, and reduce manufacturing costs.

On the operations side, workflow automation is necessary for largescale, industrial 3D printing. While software has allowed for the automation of individual 3D printing processes, the promise of industrial 3D printing requires the automation of the entire workflow from order intake to delivery. Software platforms like Materialise’s CO-AM platform are enabling manufacturers to achieve this level of automation.

Data security and data integrity are also critical components of 3D printing in a digital, distributed production environment. Data is a key asset in such an environment, and its security and integrity are paramount. In addition to data security, companies must ensure that all 3D-printed components have the same quality, regardless of where they are produced. This requires a complex and timeconsuming process, but it allows companies to gain a competitive edge in the market.

One advantage of the completely digital, end-to-end manufacturing process enabled by 3D printing is the ability to optimize machines, periphery, and post-processing to maximize throughput and minimize cost. The optimization of an AM production line can move a business case from an unviable to viable scenario or increase the potential for profit and design innovation. Moreover, with additive manufacturing, manufacturers can connect the physical supply chain with a digital thread that allows them to manage products more efficiently from concept to end-of-life. This decentralization enables a more collaborative, transparent, and efficient supply chain, as was highlighted by the role of AM during the Covid-19 pandemic in overcoming supply chain challenges.

Efforts are being made to make machines and materials more energy-efficient and sustainable, supporting the circular economy model with improved recyclability and biodegradability. Going forward, we will continue to see an acceleration of the synergy between material science, manufacturing, and technology, unlocking innovation opportunities that have not been conceived before. While substantial investments in all parts of the AM ecosystem are fueling growth, materials play a significant role in driving innovation in 3D printing.

In the consumer realm, the trend for customized goods has led to an increase in the adoption of 3D printing technology by manufacturers to meet the rising demand.

This technology enables companies to personalize products, making them more appealing to customers and helping to maintain a competitive edge in the market. To illustrate, HP is collaborating with various firms in diverse industries, such as footwear, orthotics, prosthetics, and sporting goods, including golf clubs and ski goggles, to provide customized products through 3D printing. Additionally, 3D printing allows for sustainable mass production of bespoke items, reduces the need for multiple machines and parts, and is cost-effective.

Moreover, digitization will continue to enhance 3D production, making it more attractive to manufacturers, not only for polymers but also for metal manufacturing. This will enable brands across various fields, such as industrial, automotive, consumer, and healthcare, to access the benefits of additive manufacturing on a larger scale. As 3D technology advances, newer solutions will emerge to meet the growing demand for data application and digital technology while increasing mass production capabilities.

Despite the progress made so far, it is important to note that additive manufacturing is still an emerging technology in the manufacturing world. Early adopters are showing success, but industrial 3D printing has yet to demonstrate its full potential. Companies are waiting and watching to outline the real value of such technology for their business.

However, as engineers and manufacturing companies gain a deeper understanding of how to leverage the variety of technologies available to them, 3D printing will become another tool in the toolbox. Engineers will have more confidence in the technology and know exactly when something needs to be 3D printed, when parts should remain machined, and when a system should be optimized for cost and performance. This will mark the definitive change from the wait-and-watch era to a more recognized, commoditized market. In 2023, 3D printing technology will bridge the gap between budding technology to standardized equipment, resulting in better workforce development and supplier qualification.

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