The rapid prototyping industry is growing a robust 32% a year, but has not realized the potential first envisioned when it emerged in the 1980s. Complexity and cost of ownership slowed its growth. It became almost cult-like with enthusiasts obsessing on fine details of machine technology. The industry needs to do a better job of reaching out to design engineers. It could be a perfect fit. Many engineers, particularly in the medical device industry design what they need, and then have to make compromises because of manufacturing constraints. The additive fabrication developed originally to make prototypes now has the potential to bust those constraints wide open because no molds are used and complex internal geometries are easily achieved. I’m thinking, for example, of jaws made for surgical instruments. Now, they are often injection molded from powder metal. New additive technology now allows parts such as jaws to be from laser sintering with internal channels of almost any design. Sure there are some drawbacks: less than perfect surface finish out of he machine, weak industry-wide standards, and lack of closed loop machine controls. But this is a marriage waiting to happen.
A new compression molding compound material combines the light weight, strength, and rigidity of carbon fibers with the flexibility and lower cost of glass materials in a composite compatible with automotive production.
Plastic bearings are real and millions of them are in use doing heavy-duty jobs we used to think only metals could do. Some of Germany-based igus's bearings are traveling around the world as functional parts in a car to demonstrate what they can do.
Baxter showed off his 2.0-derived moves at ATX West this year. The big red guy still looks pretty much the same, but has some new abilities, mostly due to software. The research robot version is now being used in corporate R&D departments as a design platform.
End-production using 3D printing, including objects made of multiple materials in one pass, is getting closer to reality as we saw on the exhibit floor at the recent Pacific Design & Manufacturing Show.