Direct digital manufacturing is making fast strides for low-volume applications requiring complex detail, but some significant issues remain. Design engineers require process verification, particularly for high-end parts. For example, the widespread adaption of closed-loop process controls about a dozen years ago provided verification that required process parameters in the injection molding process were being maintained. Direct digital manufacturing systems were originally developed by companies in the rapid prototyping business, where such requirements were not necessary. Parts were simply required for form and fit, and not so much for functional testing. There is often considerable process variation in the new additive fabrication systems being developed for manufacturing directly from digital files. Improvements will come, however, and the new systems are certainly worth a look in several situations, particularly those where there are constant design change orders.
Dow Chemical and several other companies have launched a program in Omaha, Neb. to divert about 36 tons of plastics from landfills in its first phase, and convert it into energy used for cement production.
A make-your-own Star Wars Sith Lightsaber hilt is heftier and better-looking than most others out there, according to its maker, Sean Charlesworth. You can 3D print it from free source files, and there's even a hardware kit available -- not free -- so you can build one just in time for Halloween.
Some next-generation bio-based materials are superior in performance to their petro-based counterparts, but also face some commercial challenges. This is especially true of certain biopolymers, adhesives, coatings, and advanced materials.
Cars and other vehicles, as well as electronics and medical devices, continue to lead the use cases for the new plastics products we've been seeing, as engineers design products for tougher environments.
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