The Power of 3-D Printing

For a lot of businesses the deliverable item is a physical part, not just software, and in today’s digital landscape there’s a good chance that a 3-D printer was involved in its manufacture. For all the years that 3-D printing has been around, these machines continue to evolve and people continue to find novel variations that expand the capability of this technology. Here are a few of the “tricks” that have been developed over the years that make 3-D printing a “must have” tool in manufacturing and automation.

Topology Optimization

Often a machined part is heavier than it needs to be, mostly due to the constraints imposed by using conventional machine tools to manufacture the part. It is really difficult to machine complex interior features using conventional drills and mills. Those types of features add little to the strength, but do increase the weight. With 3-D Printing (also called Additive Manufacturing or AM), a designer can draw up the perfect part and the 3D- printer can print exactly the shape of the part that is needed to do the job. This technique is commonly used in aerospace and automotive industries – places that are very weight sensitive.

Embedded Components

Now here’s a clever way to build parts. Many consumer products consist of plastic housings with embedded electronics. But, by designing the finished product in sections that have built-in holders or sub-assemblies, it is possible to build as you go; adding a series of 3-D printed sub-assemblies so that by the time you add the last part of the housing, the finished part is complete.

Using this technique, it is possible to build parts that have embedded electronics, sensors, magnets, RFID tags, even fluid channels. It’s just a simple matter of pausing the printer mid-build, inserting the next part in the assembly and then pushing a button to resume.

Multi-Material Printing

Some 3-D printers are designed specifically to handle a variety of material in a single build. Since this requirement is highly specialized, there are fewer material choices. Nonetheless, by paying close attention to the material properties it is possible to construct a part that uses polymers, metals and ceramics in a single build. This is a way to create a part with a variety of characteristics; different textures, variations in conductivity; softer and harder adjacent sections and so forth.

Molds and Tooling

Part of the manufacturing process can include molded parts, dies or jigs for holding parts in alignment. These can often take on complex geometries since they will be used to create a custom assembly. Here is a technique that can be used with certain 3-D printers that rely on a sacrificial material that can be used to support a piece during manufacturing. It can then be dissolved away using a solvent, leaving behind the inverse surface. This can be a very economical method of creating complex parts while maintaining precise dimensions.

Effective Repairs

Some parts just naturally wear down or lose their integrity over time. Using the original drawing of a part it is possible to machine away the worn section to create a fresh new surface then build it back to its original dimensions through 3-D printing. This is especially effective for expensive parts or ones that are exposed to critical environments. Parts made of exotic metals or alloys are a particularly cost effective situation to use this repair method.

Biologic Lattices

A lot of research work in the biomedical industry is being done at the microscale and it involves mimicking biologic structures to accelerate the regrowth of damaged tissues. The concept is that if the microstructures that underlay skin, bone, or organs can be replicated, then those structures will help the body heal more quickly by giving the tissues a “blueprint” to follow for regrowth. This could be especially helpful for burn victims.

Spare Parts

Similar to the use of 3-D printers to repair parts, is the concept to use such a printer to build exact replicas of entire spare parts. This could be especially effective if your products need periodic repairs, or changes, by adding upgrades. This gives a means to have continued life on a product that might otherwise need to be declared as obsolete.

Hybrid Printing and Machining

As described in the name of this process, this is a way to use the best characteristics of the conventional machining process with the flexibility of 3-D printing. This allows for the use of the parts printing technology where it will see the most benefit and conventional machining where precision shape and surface finish requirements are needed. The 3-D print process takes place first to build a near net shape. Then it is given a final machining for finished shape and a high quality surface finish. These hybrid machines often have both the 3-D printer and the conventional machining center built within the same work space.

There are many other configurations of 3-D printers, even those that are intended to build houses, but for the average small business that sells a physical device, most of the common variations have been described above. In sum, 3-D printers can reduce outsourcing in favor of “make on demand”, allow you to try designs through rapid prototyping, and offer customization of products. In addition, small batches become more cost effective, and waste is reduced along with stocking inventory.

These are compelling arguments for having a 3-D printer available. Ultimately it provides more control, flexibility, and speed to a small business that relies on those factors to capture, support and grow their business.

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