Additive manufacturing (AM) techniques produce low volumes of complex products with high quality and precision. These products typically include medical and dental prosthetics and implants. With engineering-quality materials, aerospace and automotive components can also be fabricated.
As a form of AM, 3D printing techniques have long been used for rapid prototyping. Some of these low-cost printers help speed the design process. Low-volume AM differs from 3D model and prototype printing in how parts are used and the number of parts produced. Volumes tend to be in the tens, hundreds, or even low thousands. Techniques include laser sintering (LS) and fused deposition modeling (FDM). Materials are generally thermoplastics, but some metals are sintered.
The right and left exhaust manifold, right and left rocker arm housing, and oil filter housing of this HR28TT Honda racing engine were foundry cast from metal using wax patterns made with 3D Systems' ProJet CPX 3000.
"Unlike models and prototypes, end-use production parts often must endure extreme temperatures, humidity, direct sunlight, and sometime abusive handling," Terry Wohlers, principal consultant and president of Wohlers Associates, told us in an interview. "They must hold up over a period of years, maybe even decades, such as in aerospace."
Standard subtractive manufacturing techniques and injection molding don't always make sense in some industries and applications. The high cost of injection molding tools must be amortized over several thousand units. AM can be competitive when producing only 2,000 units, and injection molds cost a lot, making the unit cost for tooling alone very high, says Bryan Crutchfield, managing director for Materialise USA. "With AM, you also have the flexibility to make a design change in CAD data, so you don't have to also change the hard tooling, and you can build on demand."
Injection molding processes run a huge batch at once, necessitating stockpiles of material, but AM saves on material obsolescence costs. Crutchfield says the process needs several hours to build up a part layer by layer, versus three to 40 seconds of cycle time per part in high-volume manufacturing. "But if you take into account all the costs -- including tooling, materials, and investment for shorter runs -- that's when you can favorably compare AM to traditional manufacturing. Stamping dies and injection molds are very expensive to produce up front and much more difficult to change."
Alex, the car engine parts made with AM surprised me, too. This is an indication of the sea-change that seems to be hitting AM. And I think custom medical devices, as RNDDUDE's commented, are also going to be a big deal. In fact, in terms of total volumes of products/parts made, I suspect these could exceed the automotive and aerospace objects per year, at least in the near term.
I definately agree with your last paragraph that extolls the huge potential of this technology for one-off custom medical devices. Customizing implants to the patients anatomy vs. adapting standard devices to the patient could be really a step forward. Also there is the reality that high-end medical products seem to be relatively free from cost restraint considerations for the time being.
Beth, I think materials are one of two major differences. The second is the process. The processes of all these higher-end low-volume parts and castings are different types of laser sintering or fused deposition modeling (FDM).
Great point about how this is filling a much-needed market niche. 3D printing and prototyping, as important as it is, is essentially a low volume technology for low-stress parts. When you see an auto engine in the context of additive manufacturing, you know that the rubber is hitting the road, to use a cliche.
This technique when used for medical and dental prosthetics and implants will definitely create better products hitherto not plausible. With the new generation intelligent implants we can really hope for products that will enhance quality of life.
Very thorough overview that sets the stage for how additive technologies are being used across industries. Question or perhaps clarification: It appears the big difference between these technologies outlined in your piece, Ann, and the blaze of low-cost 3D printers we've been writing about lately really boils down to a matter of materials. So if you're trying to produce something in low-volume that is the actual end product, addivitive techniques and these new materials are your go-to technology vs. many of the 3D printers which still use the powder-based materials that are really not functional, just well suited for prototyping purposes. Is that a fair assumption?
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