Effects Of Implementing 3D Printing Technology

3D Printing Technology

Discuss about the Effects of Implementing 3d Printing Technology.

ABC is a medium-sized manufacturing company headquartered in Melbourne, Victoria that was established in established in 2008. ABC specializes in manufacturing computers and printers for business organizations in Victoria. Currently, ABC Company has several retail branches located within Victoria and caters to corporate and retail clients. ABC is presently looking into ways of expanding its processes and products to other states in Australia as well as moving its operations online. To be able to implement the expansion, the company wants to look for a cheaper and more effective way to manufacture computers and printers for clients. Therefore, it is imperative for ABC to understand 3D technology and applications for industries especially manufacturing companies. Additionally, it is crucial to research and understand whether ABC Company can benefit from 3D technology implementation, as well as know the resulting implementation impacts, limitations and challenges.

3D printing refers to emerging printing innovations where printing material including liquid or powder molecules is added together, joined and hardened using computers to create a three-dimensional objects (Cummins, 2010). 3D printing technology is not merely new. The technology dates back to 1980 when research about functional rapid prototyping solid models using polymers were published, printed and built up layer after layer with the layers corresponding to a respective slice in the model (Goldberg, 2018). Few years later, the stereo lithography was invented allowing designers to create 3D models using computers which would then be used to develop solid physical objects (Goldberg, 2018).  Stereo lithography technology encompasses using processes used in additive layer fabrication according to Prabhu (2016), and occurs in three phases. The first one includes the transfer of digital data from computers to form printed structures directly through repeated positioning of a printer’s head in three directions in order to print solid objects object layer by layer (Ramya & Sai leela, 2016). In the printing process, the first design is usually made using computer aided design (CAD). Afterwards, the design is printed into a prototype through two dimensional slices assembling that represents the 3D object and then printed layer by layer until completion (Ramya & Sai leela, 2016).  The second phase, which is the manufacturing process is then done using coating and fusing processes where material is laid on the surface and energy remitted to do the printing  (Lu & Reynolds, 2008).  The raw materials and energy source usually depend on the type of technology selected. 3D printed prototypes help manufacturers examine product design effectively and test it out before mass manufacturing of goods. Additionally, they allow manufacturers to produce prototypes much quickly only spending hours or days instead of months unlike conventional printing methods. Today 3D printing has continued to evolve and is now used to create and print sophisticated structures in solid pieces. 3D printing processes are becoming more efficient, cheaper and faster and 3D printing materials have increased to now include ceramics, metals and more (Crawford, 2018).

3D Printing Processes

Several processes can be followed to enable 3D printing technology including the following:  

In liquid based processes, 3D printers create object layers by selectively coagulating a mastic liquid called a photopolymer which then hardens when exposed to light or laser technology (Ramya & Sai leela, 2016). Other photopolymer 3D printers build object layers using liquid containers. Still, others splash out a resin in a single layer and utilize ultraviolent light to solidify it before adding the subsequent layer. Furthermore, several 3D printers have the capability to combine different photopolymers in one printing job which   allow them to create prototypes made up of varied compound materials (Ramya & Sai leela, 2016).

Solid based procedures are used with types of 3D printers that generate prototypes by producing molten liquid material from a printer nozzle head (Ramya & Sai leela, 2016). As such, solid based processes encompass extruding semi liquid thermoplastic that solidifies on leaving the print head. Additionally, there are other solid based 3D printers that create object prototypes by producing molten metal, clay or concrete.

There also includes powder based 3D processes where 3D printers create object prototypes by sticking together sequential layers of powder. To bind powder granules together, an adhesive is jetted on every layer of powder or fused on powder layers using heat or laser technology (Ramya & Sai leela, 2016). Also, some 3D printers melt and then bind together powder granules on an object material which is then deposited onto the created surface. Several forms of adhesions can be used to print 3D objects using powdered processes including nylon, ceramics, bio-plastics, titanium, bronze, wax, stainless steel and more.

3D printers can also use paper-based procedures. In paper based processes, succeeding  layers made up of paper, plastic or metal  are bundled  together to create solid objects (Ramya & Sai leela, 2016). Although layers of paper are used in such processes, they are normally cut using laser or blade and glued together. Additionally, they can also be jetted with ink during printing in order to build low cost, colored 3D printed products (Jabbar & Alaa Jabbar Qasim, 2015).

Product designers and engineers from various industries have now been using 3D to create product prototypes, models and patterns for more than 10 years according to Technopolis Group (2013). As such 3D printing can be applied in various fields including automotive manufacturing, consumer good printing, health, dentistry, biomedical engineering aerospace and more(Oluwole, 2017). Popular industries where 3D printing has been applied include the following:

Liquid Based Processes

According to an article published by Sydney Morning Herald, the Manufacturing Technology Institute Limited (AMTIL) in Australia already launched an Additive Manufacturing Hub in order to increase 3D printing collaboration in the industry (Stuart, 2014). The Australian government is also in full support of funding additive manufacturing research centre (Stuart, 2014). The Australian 3D manufacturing association is also actively researching and help develop the manufacturing industry in the country.

The health industry is increasingly benefitting from 3D printing as more and more medical applications are being developed using the technology and are greatly transforming health care. The technology is being used to print actual body organs and tissues through fabrication and creation of tailored prosthetics as well as implants (Ventola, 2014).  The only difference is body organs are not printed with clay or plastics but use real biological cells grown in laboratories. In the dental industry, the technology is used to print customized jawbones and dentures in case of fractured jaws or loss of teeth through accidents. 3D printing applied in medicine can therefore provide many benefits including drug development, medical, and medical equipment. As result, it brings efficiency, effectiveness, cost savings and increased in the field.

Automotive designers and engineers have not been left behind as they are already implementing 3D printing innovation to design car and motorcycle parts. For instance, a 3D printer was used to help design and develop a 920nm torque supercar (Javelin 3D Printers , 2018). Another example is that of a motorcycle maker who has enhanced engine design using FDM 3D printing technology (Bekiaris, 2015). Besides, Tesla, a leading electric cars manufacturing company actively use 3D to generate car components (Oko Institute for Applied Ecology, 2013). 

The aerospace industry is also implementing 3D technology.  For instance, leading aerospace enterprises such Honeywell and Lockheed Martin are integrating the technology to do their designs (Flanagan, 2014). Companies such as Alabama factory has invested in 3D and is using 3D printed nozzles for their jet engine.  For the aerospace industry, parts that used to require about 20 components now need one to work.

The food industry is also greatly benefiting from 3D printing technology. 3D food printing works in a similar manner to ordinary 3D Printing. Typically, food material is extruded and placed layer after layer on a surface and edible raw materials are put in a syringe like container and used to make food products with customized shapes (Manya, 2016). Food 3D printing permits precise food measurements and places nutrients and calories as the food is getting ready.  Additionally, it allow multiple food ingredients to be combined together in many varied forms. In Australia, Meat and Livestock Australia have started printing 3D meat to help in waste reduction and production costs (Clarke, 2016). 

Solid Based Processes

Stereo lithography is the most extensively used 3D printing technology. Invented by Charles Hull, stereo lithography was the first form of rapid prototyping methodology that is now used for producing prototypes, models, and producing object layers using photopolymers (US Patents , 2018). It produces high-quality detailed and accurate polymers. It works by building object prototypes parts one layer after the other by outlining a laser beam on the surface of a liquid photopolymer. The photopolymer speedily solidifies as a laser beam strikes the liquid surface (PhotoLabs , 2018).

Advantages of SLA

1. Speed – prototype parts can be produced in a day
2. Accuracy

• Produces strong designs and prototypes

1. Can be used to make very many patterns for injection molding, blow molding, thermoforming, and other metal casting processes
2. Can be used to produce large sized objects
3. Good surface finishing

Disadavntages of SLA include:

1. The process is costly as polymers are expensive costing about $800 a gallon and SLA machines costing approximately $250000.
2. Limited materials

Developed by Stratasys, FDM is the second most popular type of rapid prototyping. It is a process, whereby wax or plastic material is removed through a print nozzle that drops layer after layer in form of cross sectional geometry (Stratasys, 2018). During the printing process, a plastic strand is undone from a coil that supplies the material to a nozzle which is heated to melt the plastic. It then deposits layers of thin plastic to form layers which harden immediately. The coil can support different types of material.  

Advantages

1. Uses efficient machines developed with accuracy and  high resolution
2. Produces high-quality  machine tensile strength

• Fast – can produce many products in a short time

1. Can be used to create multiple colored objects  
2. Used for producing machines that can withstand a lot of heat
3. Can be used to produce all kinds  of designs using computer aided design(CAD)  

• Provides automatic scaling so that parts can  fit in the machine

Disadvantages

1. Has limited raw  material  – only works with ceramics and few  plastics
2. Cannot be used for extremely large sized objects

• Initial costs of investment is expensive

LOM was designed and developed by Helisys Company (Elizabeth, 2013). LOM manufacturing systems contain a feed mechanism where materials are inserted into a roller. The roller is then    heated to apply pressure to layers and a laser beam that cuts the outline components to make sheet layer (Azom, 2002). After the cutting, a sheet of layer is laid on top of another where a heated roller spreads pressure to bind the layers together. The laser is used to cut layer outlines and the process repeated until all parts are done.  

Advantages

1. Manufacturing components don’t require support structure
2. High manufacturing speeds

• Processes only the necessary components hence does not waste a lot of material

Disadvantages

1. It is a challenge to produce  good bonds within object layer
2. Poor surface finishing

• Difficulty to manufacture hollow components

SLS was developed by Carl Deckard and his colleagues at the University of Texas, Austin and later traded it to DTM Company. It was then acquired by 3D systems (Deckard, 1989). The method uses thermoplastic powder that is spread using a roller over a cylindrical surface area. The cylinder moves up and down to accommodate every new layer addition and a piston moves upward in order to supply a specific amount of powder for every layer (Crawford , 2018). A laser beam then passes over the surface to melt and join the powder granules tightly together to form compacted object layers.

Advantages

1. Method is entirely self-supporting
2. Provides strong and stiff components

• Good finishing capabilities

1. Good chemical resistance
2. Can accommodate several materials

Disadvantages

1. Printed components may get porous surfaces

3D printing technology will enable ABC to:

1. Lower manufacturing and production time because it reduces prototype production to only a few hours or days. If ABC used to take months to develop a computer prototype, 3D technology will enable the same prototype to be developed in hours or few days increasing productivity
2. Minimize production costs

• Test product design  and prototype before embarking on mass  manufacturing

1. ABC will be able to customize products to suit specific user requirements
2. Improved products quality
3. Waste reduction

3D printing technology could be affected by the following limitations:  

1. Costly machinery investments and skills expertise investments for ABC
2. Costly 3D printers

• Limited printing materials

Conclusion and Recommendations  

Conclusion 

3D technology is increasingly transforming major industries across the globe. It is enabling faster development of product designs and prototypes. It has enabled the development of customized consumer goods and products. It has improved product testing and greatly reduced waste production. Its effects can be felt in every field from food, to complicated industry solutions such as manufacturing.

Powder Based Processes

The researcher recommends ABC to invest in 3D printing using stereo lithography technology to manufacture printers and computers for their clients.

By doing so,

• ABC will be able to design and fully test their design prototypes before mass manufacture which will this reduce product defects and errors
• ABC will be able to speedily manufacture products as 3D takes much lesser time
• The company  can incorporate other materials not previously used for manufacturing
• The company will be able to expand to many states in the country since they will increase their production and retail processes 

References 

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