Johannesburg, 08 May 2018
The answer is a definitive "yes", according to Pauline Bullock, a director at Rapid 3D.
"3D printing and the technology that enables it, including the software, the printers and the substrates, are continuously evolving and becoming increasingly specialised. These advancements are being driven by demand for more complex and more durable objects, with new applications for the technology being realised on an ongoing basis."
As a technology, 3D printing - also known as additive manufacturing - is revolutionising the way products are designed, developed, tested and manufactured. It's called additive manufacturing because three-dimensional objects are built by gradually adding thin layers of substrate to create the desired item. The file for the object to be printed is based on a scan of an existing object, and a design created using CAD software or even downloaded from an online repository.
Bullock explains: "There's a misconception that 3D printing is a single technology but, much like other printing technologies, it's evolved into various fit-for-purpose applications. So just as you get wide-format, office and production printers, you also get a wide array of 3D-printing technology specifically suited to specific types of printing in specific industries. These printers range in cost from R10 000 to R20 million, and the substrates/materials that they can print with are equally diverse, varying from plastics and polymers to metals."
From medical and aerospace, to jewellery and industrial, as demand grows, so the technology evolves to keep pace. Ranging in size from desktop to production systems, 3D printing is adapting to market demand. Substrates range from ceramic, resin, sand, metal, carbon fibre, biological components and woven fibre composites. On the quirkier end of the applications scale, there are even use cases where food is printed using a 3D printer - a quick Google search reveals a pizza vending machine, customised confectionary and even sushi.
"Choosing the right substrate and additive manufacturing process for your needs comes down to three things. It's all about accuracy, surface finish and speed," says Bullock.
The printers
3D printers are being designed to solve real-world problems. They have different process technologies and are tailored according to the substrate they print with as well as the sector that they're designed to serve. Ranging from desktop to production machines, they're able to print everything from small parts for hearing aids or jewellery manufacture to larger objects such as vehicle components. This raises the question: are there size constraints when 3D printing? "Sure," says Bullock, "it depends on the type of 3D printer and substrate that you require for that particular application. The material chosen for the object will dictate which type of printer is most suitable. And that printer's build area dictates the size of the object that it can print."
The different types of 3D printing technology include:
* Stereolithography (SLA)
* Digital Light Processing (DLP)
* Fused Deposition Modeling (FDM)
* Selective Laser Sintering (SLS)
* Selective Laser Melting (SLM)
* Electronic Beam Melting (EBM)
* Laminated Object Manufacturing (LOM)
* Binder Jetting (BJ)
Some of these are more suited to producing prototypes, others for specific substrates, yet others to manufacture specific items. It's all about choosing the right technology for the job at hand.
The substrates
When it comes to substrates for additive manufacturing, the choice is virtually limitless, with materials that are suitable for prototyping and those that are specifically developed for end use. Bullock explains: "3D printing substrates are highly specialised, particularly when it comes to medical applications. We're even seeing metals such as stainless steel and titanium available today, to enable final-use parts or tools to be produced."
The variety of materials used in 3D printing is very broad and includes plastics, ceramics, resins, metals, sand, textiles, biomaterials, glass, food and wax. It's even possible to 3D print in multiple colours. The type of substrate used is dependent on the process to be used, available budget, and design and function of the object.
The applications
As the technology evolves, so do the possible applications. From printing a human ear to perfectly match the patient's own, to customising a vehicle's dashboard, 3D printing is making its mark in a variety of industries. In the medical field, it's being used to manufacture items for the dental field, including orthodontics, while advances are being made in 3D-printing medical devices such as components for hearing aids and even prosthetic limbs. Bio-printing using living cells is also being explored.
In manufacturing, it's revolutionised the creation of prototypes and the way objects are designed, enabling geometries that can't be created using conventional manufacturing methods. It's also being used to create final products on demand, reducing the burden on warehousing facilities. Industrial applications include parts for aircraft and automotive components, as well as prototypes of new designs, while the jewellery sector is also using additive manufacturing to design and manufacture items.
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