BigRep Industrial 3D Printers

3D Printing in Education: The BigRep STUDIO Takes Learning Out of the Box

May 6, 2024May 2, 2024

Integrate 3D printing in education with the BigRep STUDIO, a large-scale printer that sets students and researchers up for success with its state-of-the-art technology trusted by industry leaders.

3D printing is rooted in hands-on learning, a pedagogical tool for ambitious students and researchers to take them from concepts to physical models, preparing them for real-world success. The technology is widely used to ensure promising research outcomes through high-accuracy parts in a wide range of materials for studies ranging from engineering to art and design. While most entry-level 3D printers in the market comfortably fit on a desk, the unrestricted freedom to explore new ideas manyfold as the build volume gets BIGger.

Built with a generous build volume of 1000 x 500 x 500 mm, the BigRep STUDIO is 10 times that of a standard desktop 3D printer. It is a massive, reliable, and education-ready 3D printer built to graduate students from desktop learning to a professional industrial-grade machine. Many leading universities around the world house the STUDIO and discover applications across almost all academic and research disciplines.

Join the Ranks of Top Universities by Integrating Large-Scale 3D Printing into Your Curriculum

WHY THE STUDIO IS THE BEST-IN-CLASS
EDUCATIONAL TOOL

A Generous Build Volume

A 1000 x 500 x 500 mm build chamber for students and researchers to explore and test their ideas in full-scale.

A Safe, Fully Enclosed Build Chamber

The temperature-controlled build envelope for consistent prints and safe, controlled access to the print bed.

Open Material Platform

Freedom to print with compatible 3rd party materials including carbon-fiber-reinforced plastics enabling the widest variety of applications in any academic field.

Uninterrupted Productivity

The STUDIO allows for around-the-clock non-stop printing so students can schedule print projects back-to-back and experiment efficiently even during the busiest periods.

Training and eLearning Platform

Students have complete access to online courses on the BigRep ACADEMY and in-person training from fundamentals to expert-level in 3D printing.

Space Conscious Machine Design

Built with a sleek body, the STUDIO is at home in any workspace. The machine runs on a convenient standard electrical outlet and has relatively low power consumption.

Intuitive 3D Print Software

Easy-to-use cutting-edge software suite gives students complete control over the print process, from design to print monitoring: BLADE, FLOW, and CONNECT.

Large-Format 3D Printing Applications Across Different Academic Fields

The natural intersection between the STUDIO and education lies in the shared focus on large-scale experimentation, critical thinking, and creativity. The 3D printer imparts practical learning by being a testbed for experimentation, prototypes, physical models, and real-world applications.

The most common educational fields that benefit from the STUDIO’s large-scale capabilities are:

1. Engineering

The significant advantage of the STUDIO for engineering and advanced manufacturing students is its ability to effortlessly print large parts with complex geometries. Designs that would be challenging or even impossible to build with traditional manufacturing methods are second nature for the 3D printer.

Engineering students can quickly test, iterate, and refine their ideas and experiment with different filaments thanks to the open material system. They can gain insight into how material properties influence design and how manufacturing processes impact the final product. This experiential learning helps students develop an intuitive understanding of materials science and manufacturing principles, equipping them with valuable skills for their future careers.

Here are some of the use cases of Universities employing BigRep 3D printing systems in their research labs.

Helmut Schmidt University's Eleven-O-Six Racing Team 3D printed the steering wheel, entire bodywork, and a nose cone prototype.

High-performance car production process
Eleven-O-Six Racing Team, a motorsport team at Helmut Schmidt University in Hamburg, Germany uses a BigRep 3D printer to see what it could bring to their high-performance car production process. Prof. Dr.-Ing Jens Wulfsberg, the Chair of Production Engineering (LaFT) and leader of the project underlines a key advantage of their BigRep 3D printer:

"Using a BigRep 3D printer is a fast solution to produce a fast car because we have short cycles for optimizing the parts. In every iteration cycle, the car is better, and faster. This is one of the direct consequences of using the machine."

Rapid prototypes
Dr. Mario Oertel and his team at the advanced hydraulics engineering lab at Helmut Schmidt University are transforming weir designs with BigRep 3D printing systems.

End-use parts
Aalborg University Engineers 3D printed a functional bicycle frame in one go.

At Aalborg university, a fully functional bicycle frame was 3D printed, thanks to the BigRep 3D printer's large build volume.

Aerospace engineering
Aix-Marseille Université, one of the largest universities in France, developed a unique accredited degree program in aerospace engineering with BigRep 3D printing systems.

Using their BigRep 3D printer, Aix-Marseille’s technical aeronautical training school, POLYAERO introduced 3D printed mockup parts for an ideal training solution.

2. Sciences

Thanks to the large-build volume, the STUDIO can create anatomically accurate representations for biology and medicine students ensuring a realistic and immersive learning experience. The 3D printer can play a crucial role in medical device development, allowing researchers to prototype and test cutting-edge healthcare solutions.

The other area that additive manufacturing contributes significantly is in the visualization of concepts. Beyond healthcare and biology, they support environmental studies and geoscience research by creating models for studying ecosystems, geological formations, and natural phenomena.

The STUDIO can easily create complex components and prototypes for advanced physics research projects tailored to specific objectives. Students can experience experimental design, data collection, and analysis. Be it fabricating models that are tested by being subjected to natural forces, or designing innovative sensors, students can leverage the capabilities of FFF 3D printing to push the boundaries of scientific exploration and discovery.

The 3D-printed rotor blades at TU Berlin designed by Jörg Alber, and Laurin Assfalg with a BigRep machine.

TU Berlin’s Ph.D. student, Jörg Alber, and Master’s student, Laurin Assfalg, 3D printed a wind turbine rotor blade to experiment, evaluate, and improve its performance. By creating and optimizing rotor blades on a smaller scale with BigRep’s 3D printer, they could explore different infills, shapes, and materials and test them against simulated real-world conditions.

Laurin Assfalg:

"3d printing was a compelling option to produce the rotor blades as it can create complex forms and enhance performance. The idea was to come up with the science that can somehow be used for big rotor blades too."

3. Art

In art and design education, the STUDIO empowers aspiring artists with the freedom and practical skills needed to breathe life into their creative visions. Students can explore new techniques and experiment with materials, overcoming the limitations of traditional art mediums. Some of the areas where the 3D printers give the students a leg-up are with props and special effects, fine art creation, sculptures, installations, and art preservation.

The machine’s high level of precision helps students create intricate artwork, allowing them to delve into digital fabrication techniques and integrate technology into mixed-media art projects. Welly Fletcher, an Assistant Professor of Sculpture in the Department of Art at the University of New Mexico, built a bridge to prehistoric cave art with a massive 3D printed mixed-media lion-like figure with a BigRep printer.

Welly Fletcher’s sculpture ‘Trans Time’, an abstract depiction of a lion-like animal printed using a large-format BigRep 3D printer.

4. Architecture and Construction

Studying architecture and construction at a university with access to a large-scale FFF 3D printer offers students the opportunity to prototype their designs at scale. This helps with a detailed analysis of spatial relationships, structural integrity, and design aesthetics of the building. The physical model can be quickly iterated to find the perfect solution to architectural challenges.

From complex architectural features to intricate building elements, integrating a STUDIO in the process fosters interdisciplinary collaboration and innovation. Architecture and construction students can collaborate on projects that combine architectural principles with engineering expertise.

The elaborate, contemporary “Ancora Villa” printed on a BigRep printer, is a complex architectural design with a fragile overall structure and many highly intricate details.

BigRep 3D Printed an elaborate architectural model, Villa Ancora, in 1:50 scale in just 5 days.

5. Archaeology and Paleontology

FFF 3D printing can turn back time by recreating lifeforms that have gone extinct and artifacts that have been damaged or lost forever. The physical models are profoundly engaging, offering an unparalleled experience by allowing students to learn about the past by holding it in their hands. Creating singular pieces of small to large scale parts comes easy for the STUDIO and students have a wide variety of materials to choose from. Post-processing techniques like painting and wrapping the part ensure a more realistic representation.

CDM STUDIOS in Australia 3D was commissioned to create sculptures and models of dinosaurs and extinct sharks on short notice. With a BigRep 3D printer, they were able to accurately recreate 110 models in just 9 months.

A shark model 3D printed on a BigRep 3D printer by CDM:Studio.

6. Product Design

The iterative nature of 3D printing allows students to test and refine their ideas, gaining valuable insights into form, function, and manufacturability. By experiencing the entire design cycle—from concept development to prototyping—students develop critical problem-solving skills and design thinking methodologies.

The STUDIO enables the intersection of design, engineering, and materials science by collaborating with peers from diverse backgrounds to tackle complex design challenges. Through this collaborative approach, students gain a deeper understanding of the multifaceted nature of product design and develop the ability to integrate technical, aesthetic, and user-centered considerations into their designs.

Next-Gen AM Technology for Next-Gen Graduates

The STUDIO provides a solution for educational institutions that’s equal parts reliable and open for experimentation, engineered with state-of-the-art technology trusted by industry leaders. The 3D printer ensures successful research outcomes by printing high-accuracy parts with an open material platform rooted in a user-friendly, professional-grade full-solution AM eco-system.

In today's competitive job market, hands-on experience with professional 3D printers provides students with a valuable edge, offering a tangible representation of their ideas and enhancing the learning process. Prepare students for the real world and set them up for successful careers in any field, all within an accessible price range and unlimited experimental opportunities.

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In this webinar, we discuss with some of the top universities, the projects and research they’ve conducted using large-scale 3D printing.

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3D printers support scientists and students conducting research in universities
AM is crucial in fast-paced experimentation and rapid iteration
To unleash creativity through AM technologies
3D printers are an ideal tool in educational institutions to test new ideas.

INSPIRE STUDENTS & INNOVATE FASTER: INTEGRATING LARGE-FORMAT 3D PRINTING IN UNIVERSITIES.

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

The BigRep STUDIO G2 gets 3D printing off your desk and takes it to the next level. Operating with the same ease as a desktop 3D printer and with 10 times the build volume, the STUDIO G2 provides large-scale industrial manufacturing capabilities in a compact “fits everywhere” build.

Explore the STUDIO

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

Explore the STUDIO

About the author:

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

Xuberance Breaks the Mold with 3D Printed Furniture and Lifestyle Products

April 20, 2024April 18, 2024

Xuberance 3D printed furniture - hero image

Hailing from Beijing, China, Xuberance is a product design firm that leverages 3D printing technology to create unique furniture pieces and accessories. By embracing BigRep’s large-scale 3D printers, Xuberance is writing a new design narrative that combines sustainability and unparalleled design freedom.

From steam-bending woodworking techniques in the 19th Century to injection molded plastics in the 20th Century, advances in production technologies have continually reframed the creative possibilities. Product designers are looking to innovate and push the boundaries of their craft with cutting-edge technologies that allow them to support their vision.

In the 21st Century, design firms such as Xuberance are proving that there is scope for an entirely new conversation - one that empowers the unbound imagination of the product designer thanks to 3D printing technology.

Xuberance is making complex, intricate, and lightweight structures made possible by 3D printing objects from digital designs. The design ranges from furniture pieces to wearable fashion accessories and has become a symbol of a new age of digital expression.

The Form is More Than Function

With products such as the 3D printed Cloud Lamp, a luminaire that garnered the team the prestigious SaloneSatellite Award at the Milan Design Week in 2015, Xuberance has developed a distinctive design language; a language inextricably bound to the digital process of 3D printing.

The resulting intricate, organic forms of its 3D printed products are so unique, that they are virtually impossible to reproduce with conventional production methods such as molds.

Xuberance 3D printed furniture - BigRep 3d printed chair

“3D printing forms the backbone of our entire design and production process,” comments Leira Wang, Managing Director of Xuberance.

“Our designers can fully translate their digital designs into physical products using 3D printers such as BigRep’s. It offers unparalleled design freedom while pushing the boundaries of what’s technically possible.”

Large Scale Printing Creates Unique Design Possibilities

Although 3D printing was traditionally utilized by manufacturers to produce specific parts, Xuberance was one of the pioneers to embrace the medium as its primary tool to produce entire products from the ground up.

Having the ability to print larger single products such as chairs and stools with 3D printers such as BigRep’s ONE and STUDIO has enabled Xuberance to focus on building its product design niche.

The resulting products are not only strong, durable, and lightweight, but also unique in their form.

“Large-scale printing has had a transformative effect upon our overall ability to create distinctive designs,” continues Wang. “The BigRep large scale printers are instrumental in this, and unlock new possibilities by reducing time and costs.”

As evident with Xuberance products such as the Madame Butterfly chair - a single-piece 3D printed chair consisting of ethereal, organic, and intricately printed patterns, BigRep’s 3D printers allow the production of larger objects while retaining the intricate design.

“BigRep's dual extrusion printing offers a crushing advantage with its super accurate printing quality. We’re now able to faithfully translate our designer’s compositions into finished Xuberance products without losing any of the intricacies of the original design.”

says Wang.

Responding to Customer Demand

Unlike traditional manufacturing, where modifications require mold changes or adjustments to tooling, Xuberance has built its business around the flexibility of 3D printing, which allows for quick iterations to final product designs.

Not only has this allowed the team to eliminate the time and cost associated with physical adjustments in texture, structure, or color gradients can also be quickly executed depending on the customer’s requirements.

3D Printing in a Circular Economy

Product design and furniture industries have been plagued by non-sustainable practices, especially with nonbiodegradable plastics and other materials. But Xuberance is proving that 3D printed products have earned their place within the circular economy with their choice of materials.

With BigRep’s open material system, Xuberance can select the appropriate materials according to the requirements of each design, and set up printing parameters for each geometric model.

In addition to citing BigRep’s PRO HT and ASA filaments as exceptional with regards to their material composition and heat resistance qualities, Wang also highlighted the importance of their biodegradability in underlining the ethos of the company.

A Future Filled with 3D-Printed Possibilities

By embracing 3D printing technology, Xuberance has proven that it’s possible to create stunning, customized products whilst paving the way for a more sustainable future in design. Key to achieving this are the BigRep large format printers, which Wang believes are fundamental to achieving the company’s vision.

"There is an ancient Chinese saying," concludes Wang, "' When brothers are united in purpose, their strength can cut through metal.' We believe in the future of large-scale printing, and we will work together with BigRep to achieve this greater development."

As Xuberance continues to explore the unprecedented creative possibilities of 3D printing, its designers are forging a radical new language formed around the desire to celebrate form and organic beauty.

This approach echoes a historical truth: form isn't dictated by function, but rather, by the tools and technology available to the designer at any given time. With the tools of 3D printing at its disposal, Xuberance is at the very cusp of redefining the possibilities of product design.

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Want to Learn More about 3D Printing Bespoke Furniture?

Download the eBook, RH-Engineering & manoFigura 3D Print Luxury Furniture.

Find out how RH-Engineering and manoFigura design and create custom furnishings. Deep dive into their breakthrough product, the Magna Patero Ortus – a 3D-printed end-use sink.

Read this additive manufacturing case study to learn:

How businesses are manufacturing custom products with 3D printing
Why additive manufacturing is the perfect solution for custom and low-volume production
How large-format 3D printers unlock creativity and opportunity
Unique post-processing systems for end-use products

HOW RH-ENGINEERING & MANOFIGURA 3D PRINT LUXURY FURNITURE

About the author:

Patrick McCumiskey

Author

Patrick has over a decade’s worth of experience writing about design and technology. After first encountering 3D printing on a project while studying a Masters Degree in design, he’s taken a keen interest in the development of 3D printing and its impact on the world of design and tech.

3D Printing Accelerates Innovation in China’s Commercial Vehicle Industry

April 18, 2024March 28, 2024

Large 3D Printing Transforms Commercial Vehicle Industry

China's commercial vehicle market accounts for over 40% of total global sales. Playing a key role in China’s success is the industry’s willingness to adopt new disruptive technologies like industrial 3D printing to pave the way for a new generation of production in custom commercial vehicle manufacturers such as CNHTC.

At the helm of this transformation is Dr. Dong, a visionary engineer, who established one of China’s largest 3D printing centers within CNHTC, the third-largest commercial vehicle manufacturer in the country.

With Chinese domestic demand for commercial vehicles projected to increase 10% year on year by 2028, Dr. Dong and his team could no longer exclusively rely on traditional manufacturing methods to meet the constantly evolving industry’s requirements.

Thanks to industrial 3D printing, the company has been able to advance prototyping and production processes for its heavy-duty trucks, haulage, and transport vehicles.

Embracing the Open 3D Printing System

Dr. Dong's approach to 3D printing is centered around being able to explore new applications and materials that are fundamental while innovating with the technology. While some of the 3D printer providers only sell closed material and software systems which limit application freedom, industrial 3D printers, like BigRep’s, are open for innovation. Being able to use any 3D print filament and software enabled CNHTC’s designers and engineers to leverage any technically compatible material.

It also helped CNHTC save costs as typically when companies are locked to the 3D printer provider’s materials, they’d have to forgo applications, outsource the print, or if the part warrants the investment, buy a new 3D printer that supports the material. CNHTC also had a better return on investment as they discovered the machine could be used for new applications with other materials.

Dr. Dong explains,

“Having an open-source 3D printer like the BigRep PRO is vital for our workflow. Open-source materials not only reduce production costs, they allow us to explore diverse material possibilities to achieve any number of desired outcomes”

Cost and Time Savings with Rapid Prototyping

CNHTC's traditional reliance on CNC machining and milling for prototyping translated to lengthy testing and iteration phases, often taking weeks. As a result, this slow process hurt the company’s ability to innovate within its design team.

“Since we’ve adopted 3D printing into our day-to-day work processes, we’ve witnessed a remarkable 50% reduction in both time and cost compared to traditional manufacturing methods for our projects to date.”

says Dr. Dong.

CNHTC 3D printed parts with the BigRep PRO

With the introduction of 3D printing, CNHTC’s workflow has undergone a total transformation. Now it takes just a few days, not weeks, for Dr. Dong and his team to turn digital designs into functional parts. "3D printing has enabled our designers and engineers to perform iterative optimizations with much faster turnaround times." Say Dr. Dong "While bypassing the mold-making stage entirely, we can directly 3D print structures that could not be created by the traditional processes.”

This kind of efficiency has allowed for the introduction of faster iteration and feedback cycles, ultimately allowing the design team to create products more in line with current market demands.

Large-Scale 3D Printing for Heavy-Duty Trucks

While previous generations and some of the current 3D printers have a smaller build limiting the size of the parts, Dr. Dong and his team have embraced industrial 3D printing with the BigRep PRO to produce large singular parts suitably sized for custom commercial trucks.

Following the same path as European commercial vehicle specialists like Zoeller Kipper, large 3D-printed parts such as customized panels and covers are being integrated as end-use components in CNHTC’s commercial trucks.

The BigRep PRO at the 3D printing CNHTC center

The high level of precision and dimensional accuracy in the large, robust prints meet CNHTC’s need for high-quality functional end-use parts. Printing sizable parts helps CNHTC eliminate the time-consuming and manual process of assembling smaller parts that might have errors in assembly.

He elaborates, "The quality of the larger printed parts makes it easy to integrate them directly into our vehicles. This not only increases production efficiency but also allows us to respond better to the demands of the market."

The Future of 3D Printing in Custom Commercial Vehicles

"What excites me most about the future is the possibility of using 3D printing to create more batches of end-use parts that can be directly used for manufacturing.” comments Dr. Dong.

The future of heavy duty vehicle customization with 3D printing for CNHTC

Confident in this blueprint for the future, Dr. Dong sees even greater potential for integrating 3D-printed parts directly into CNHTC’s production facilities. He concludes,

The application of 3D printing in commercial vehicles is one of the most significant technological events to have occurred in the automotive industry. The rules of the game have changed for the better, and we are using this to our full advantage

Want to Learn More about 3D Printing for Emergency and Commercial Vehicles?

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Large-format 3D printing and customer applications
How BigRep is supporting the trucking industry
Customer success stories from prototyping to end use parts
Benchmark breakdown

IMPROVE TIME TO MARKET FOR CUSTOM COMMERCIAL VEHICLES

About the author:

Patrick McCumiskey

Author

3D Printed Spare Parts: On-Demand Solutions for Aerospace, Defense, and Industrial Manufacturing

March 18, 2024March 11, 2024

A broken or defective part could mean a reduction or even a total halt in production while waiting for the replacement to arrive – an expensive inconvenience for manufacturers.

One of the areas where 3D printing has been most disruptive is in the fabrication of temporary spare parts. These printed components can often meet functional requirements until a longer-lasting solution can be sourced or produced. This allows industries to continue production, which increases machinery uptime and minimizes supply-chain uncertainties.

In this article, we'll examine some common challenges for aerospace, defense, and industrial manufacturers, and how 3D-printed temporary solutions enable a more seamless production workflow.

1. Emergency Repairs

Imagine the scenario: You’re an industrial manufacturer relying on a machine to complete a lucrative contract for a client. Suddenly, a crucial part of the machine breaks, and production grinds to a halt.

If the replacement part isn’t at hand, you’d have to contact external suppliers for troubleshooting, components, or services. Inevitably, the time spent waiting for the part to arrive introduces an element of uncertainty into what is already a stressful situation, with an added layer of potential delays and costs.

Why 3D Printing is a Solution

With the introduction of an in-house 3D printer, on-demand production gives industrial manufacturers the ability to produce temporary spare parts or tooling as and when required, which buffers the wait time. The range of high-performance industrial-grade 3D print materials ensures the temporary spare parts are strong enough to bear the loads and stresses until the replacement part can be sourced.

3D printers such as the BigRep PRO enable aerospace and defense manufacturers to print with engineering-grade materials, such as carbon fiber reinforced polymers, and high-performance materials like flame-retardant Polyetherketoneketone (PEKK). These materials are better suited for parts that endure fluctuations in temperature or operational stress.

2. Unavailable Spare Parts

A spare part might be inaccessible for a number of reasons. For example, it could be out of stock or it may no longer be in production. In situations where defense or aerospace manufacturers are operating in remote locations or are deployed in field operations, they could be out of reach of the traditional supply chains.

In these scenarios, the manufacturer's hands are tied, with no immediate solution to getting that all-important spare part installed to get production back up and running.

How Large-Format is Changing the Way We Produce Parts

Why 3D Printing is a Solution

In these scenarios, the manufacturer's hands are tied, with no immediate solution to getting that all-important spare part installed to get production back up and running.

3. Surrogate Parts for Training

The production timeline of complex machinery might be long and at times operators might require training to handle it. Stand-in parts replicating the original designs are needed for training before the final assembly arrives so the operations can start without delay. This scenario often arises in the aerospace industry where complicated equipment is often used and time is a crucial factor given the testing, validating, and certification process of the tightly regulated sector.

Why 3D Printing is a Solution

By fabricating components, these stand-in parts offer employees a hands-on approach to familiarize themselves with the procedures and intricacies of the final machinery. This ensures operators are well versed in the assembly and servicing of the machines and allows manufacturers to accurately implement operation timelines.

Several government aerospace agencies have successfully integrated 3D printing into their operations training programs, a fact that underlines the unique advantages associated with AM. Industrial manufacturers can also leverage 3D-printed surrogate parts for a smoother workflow transition ensuring employees are brought up to speed with potentially complex operations.

Advantages of 3D-Printed Temporary Spare Parts

1. Minimized Disruption in the Production Process

3D printing spare parts on-demand addresses equipment breakdowns or component failures immediately. Defective components can be swiftly replaced, reducing downtime and enhancing operational efficiency.

One of 3D printing’s biggest strengths, quick design iterations, allows for the customization of parts to meet specific requirements, ensuring optimal performance and compatibility. This in-house solution streamlines the production timeline by decreasing the wait time for the original part to arrive, enabling industrial, aerospace, and defense industries to meet their typically tight schedules and customer demands more effectively.

Full length portrait of engine and landing gear of passenger aircraft with pilot in the wing isolated on the sun background

2. Reduces Downtime thereby Saving Money

Simply put, the more time that elapses between a part breaking down and its replacement being fitted, the higher the financial implication.

In this sense, traditional methods for purchasing and sourcing spare parts from external sources for industrial machinery can lead to extended periods of equipment downtime and lost productivity. Stocking replacement parts might be the obvious solution, but it comes with increased costs and additional logistics to purchase, store, and maintain the parts.

3D printing on-demand minimizes the disruption of the production process by being an immediate stand-in. This decreases the downtime and keeps the machinery moving, adhering to operation timelines. This results in positive financial implications for manufacturers within the aerospace and manufacturing sectors, who are ultimately looking for reliable solutions to unforeseeable machinery breakdowns.

3. On-Site Manufacturing is the Only Viable Option in Remote Locations

The ability to manufacture replacement solutions in any location is particularly appealing within the fields of defense and aerospace. In scenarios where on-site production is the only viable solution, for example, mountainous terrains, deserts, or at sea, having the ability to print replacement parts in-house is a game-changer. These locations are typically far from areas under operational coverage for geographical reasons, and the time for the part to arrive might be unpredictable or the logistics might be impossible.

CNE Engineering with SAS Scandanavian Airlines

4. Saves Time by Eliminating Traditional Production Steps

Where traditional manufacturing methods involve lengthy and often manual fabrication processes, 3D printing enables the direct production of parts from digital designs. This democratization of the manufacturing process skips the tooling process, reduces the dependency on skilled workers, and eliminates the maintenance of inventory and logistics. These steps in the time-consuming outdated process pile costs and 3D printing have the transformative power of directly printing on demand resulting in the economical production of spare parts.

5. Surrogate Tools for Operator Training

Time is money in most industries, and it rings particularly true in aerospace. The machinery, tools, and parts used in spacecraft and airplanes are often complicated, and operating or handling them requires training. With 3D-printed surrogate parts, they can learn how to effectively use machines before their arrival. This preemptive measure ensures accurate operational timelines, a crucial workflow addition to minimize the likelihood of inefficiencies during the production process.

6. Digital Inventory Replaces Physical Inventory

Managing a physical inventory involves stocking up the approximate number of parts in the right environmental conditions by anticipating future needs. This may not always be a feasible option for spare parts as there are a lot of components involved in the production process that may break down. With 3D printing, the part design files are digital and can be transferred to any corner of the world and produced with a 3D printer. This digital optimization of inventory minimizes the effects of supply chain bottlenecks and potentially costly storage solutions.

7. Large-Scale Singular Prints Requiring no Assembly

Massive parts in airplanes and other aircraft demand large-scale MRO equipment. Traditional manufacturing processes often relied on the fabrication and assembly of multiple separate components which increased production time and the risk of assembly errors or inconsistencies. With 3D printing, the production of large, complex components in a range of materials, in a seamless integrated unit is second nature. By drawing on advantages such as accuracy, precision, and repeatability, the production of spare parts as fully assembled entities aids swift and cost-effective solutions.

8. A Full-Spectrum of Industrial-Grade 3D Print Materials

From eco-friendly filaments made with recycled ocean waste to high-performing carbon fiber-reinforced materials suitable for aircraft components, there’s a wide range of materials that fit the bill for different spare parts and budgets. 3D printing offers the freedom to select the filament based on the specific function of the spare part. This allows for the choice of materials that best embody the physical, chemical, and structural properties needed for optimal performance. While not all industrial 3D printer manufacturers support 3^rd party filaments, some of them like BigRep have open material platforms that cater to the user’s requirements, whether it is prioritizing high performance or cost-effectiveness.

Empowered In-House On-Demand Solutions

3D-printed spare parts have unlocked an agile, responsive, and adaptable localized production workflow which is vital for the aerospace and defense industries that demand highly individualized components that may not be readily available.

By printing spare parts on demand instead of storing them in inventory, these industries can significantly save time, reduce costs, and find reliable solutions internally till the permanent part is sourced. These developments have critical advantages for the day-to-day operation of machinery, especially in remote locations where self-sufficiency is essential.

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Want to learn more about how Low-Volume Production Empowers the Aerospace and Defense Industry?

Discover how the aerospace and defense industry leverages 3D printing to deliver purpose-built, qualified tools to explore the skies and beyond.

In this eBook, we deep dive into:

How 3D printed parts are instrumental in transforming the aerospace industry.
The rigorous tests and certifications that validate the performance and safety of the 3D-printed parts.
FEA analysis that helps build robust aerospace-grade parts.
3 use cases of aerospace industry giants that thought out of the box with 3D printing.

FROM THE PRINT BED TO THE SKY: 3D PRINTING AEROSPACE-GRADE PARTS

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

BigRep PRO: Large-Format 3D Printer showcasing advanced technology and high-quality printing capabilities

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

Explore the PRO

About the author:

Patrick McCumiskey

Author

Symbiosis of Art and Technology Through Large-Format 3D Printing

March 28, 2024February 9, 2024

US contemporary artist Welly Fletcher builds a bridge to prehistoric cave art with a Large-Format 3D printed sculpture made with the BigRep ONE.

40,000 years ago, cave-dwelling Homo sapiens carved out a sculpture of a lion man into an ivory tusk using primitive chisels and tools.

The sculpture, which was discovered almost 100 years ago in a cave in south Germany, remains the earliest known example of Homo sapien art - and serves as a stark reminder of the extraordinary cognitive traits which have allowed our species to develop societies, religions, and technologies.

After experiencing the prehistoric sculpture in the Museum of Ulm in Germany firsthand, Albuquerque-based artist Welly Fletcher was inspired to create a sculpture for their latest exhibition SLANT at the Richard Levy Gallery in New Mexico. The sculpture explores the historic symbiosis of art, technology, and our species' kinship with animals.

Adding 3D Printing to the Palette

Fletcher’s sculptural centerpiece ‘Trans Time’, measuring 0.9 × 2.1 × 0.7 mts (36 × 86 × 28 inches), is an abstract depiction of a lion-like animal printed using the large-format BigRep ONE 3D printer.

Beginning as a clay model produced by the artist, the piece underwent a transformative journey as it was digitally scanned before emerging as a 3D printed object, made using the University of New Mexico’s Art Lab BigRep ONE 3D printer.

“The more I learned and experimented with the 3D printer, the more magical the results became. The printer gave both myself and my students the chance to understand the process behind translating analog techniques into digital.”

commented Fletcher, who teaches sculpture and digital technology at the University of New Mexico.

Trans Time, a large format 3D printed sculpture by Welly Fletcher printed on the BigRep ONE

Paying homage to the manner in which the original Lion Man sculpture is presented in the Museum of Ulm in Germany, Fletcher’s 3D printed animal head sculpture sits proudly upon an outline of a steel animal skeleton, which itself is fixed to a plasma-cut steel base.

While the orange-coloured sculpture is both visually and physically impressive in its proportions, Fletcher's deliberate choice of BigRep's PLA bioplastic aligned perfectly with the exhibition's theme of human-animal kinship and the body’s resistance to the environmental destruction of our species. Perhaps most significantly, the absence of carbon processes and toxic oils in PLA enhances the narrative of the artwork, further emphasizing our species' complicated relationship with the planet.

“When I started reading about the non-carbon-based processes of PLA, I was even more convinced of its ability to reinforce the environmental aspect of my work”

added Fletcher, who recently added the malleable bioplastic to her palette of materials.

Large-Format 3D Printing for Sizeable Sculptures

Trans-Time-a-3D-printed-sizeable-sculptures-by-Welly-Fletcher-at-the-exhibition-SLANT-at-the-Richard-Levy-Gallery-in-New-Mexico

Fletcher was also eager to highlight the practical benefits of incorporating the BigRep ONE printer into their artistic process.

Where traditionally, artists and their teams face numerous logistical hurdles in the transportation and in the assembly of separate heavy pieces; the BigRep ONE 3D printer enabled Fletcher to print the entire Trans Time sculpture as a unified whole, thus minimizing the complexity of production and assembly.

Describing the experience as transformative, Fletcher emphasized how the seamless printing of the entire sculpture marked a significant shift in their artistic process.

While the original cave sculpture stands as a testament to the imaginative prowess of early Homo sapiens, the primitive tools of that era made its production a complex and time-consuming task, with some estimates suggesting it could have taken a group of humans around 400 hours to complete.

Welly-Fletcher-and-her-sculpture-TRANS-TIME-at-her-exhitbition-SLANT-at-the-Richard-Levy-gallery

Thanks to BigRep ONE, however, contemporary artists now have the ability to effortlessly produce much larger and more complicated forms at the touch of a button - a sentiment that further underlines the enduring alchemy of the medium of sculpture.

“3D printing grants artists working with sculpture a significant advantage. It enables the creation of objects that simply aren't feasible by hand. Witnessing the final object materialize before your eyes has a magical quality to it.””

Fletcher elaborated.

Analog Roots in a Digital World

There’s a comforting circularity associated with Fletcher’s Trans Time sculpture. On one hand, its prehistoric connotations draw our attention to the elasticity of time and the prevalence of human creativity. On the other hand, we’re reminded of the powerful symbiosis between art and technology, and, ultimately, are left with an overwhelmingly positive impression of our species thanks to the sculpture’s use of eco-friendly materials.

With digital technologies such as 3D printing proving invaluable to the field of sculpture, Fletcher’s advice to artists wanting to incorporate 3D printing into their work is simple: let the process inform the results.

Want to Learn More About Large-Format 3D Printing Applications in Exhibitions?

Whether it's fine art, museum displays, or innovative installations, BigRep 3D printers are essential for large-scale creative projects.

Unlimited Creativity in 3D Printed Exhibitions

Your imagination is the only limit to what you can create with a 1m3 building volume of BigRep 3D printers
Keep on schedule to manage tight deadlines by avoiding manual labor and outsourcing
3D printing can reduce costly material waste and replace expensive skilled labor

LEARN MORE

About the author:

Patrick McCumiskey

Author

Finished to Perfection: Post Processing Techniques for 3D Printed Car Parts

April 18, 2024February 5, 2024

From upgrading vintage cars to powering high-performance race cars, 3D printing caters to a range of automotive applications replete with professional-grade finishes. While some prints are good to go fresh off the print bed, some need finishing touches before reaching their final functional form.

3D printing builds parts by laying layer upon layer of melted plastic leaving pronounced ridges, especially with lower print resolutions. Also, support structure removal can leave behind a marred surface that needs to be further processed. Different post-processing techniques smoothen and treat the surface to make the final part not only visually stunning but also structurally robust blending form with function.

In this guide, we explore the 3 primary post-processing types - additive, subtractive, and property-changing methods and combinations of these techniques for the finishing of the 3D-printed car parts.

Post-Processing Methods

1. Additive post-processing

adds material onto the 3D printed parts to fill in the irregularities, smoothen the surface, and enhance mechanical and functional properties.

Examples: Filling, priming, brush coating, spray coating, foiling, dip coating, metal plating, powder coating, and ceramic finishes like Cerakote coating.

2. Subtractive post-processing

takes away part of the surface to create a uniform look and feel. It is the most common post-processing method used for 3D-printed car parts.

Examples: Sanding and polishing, tumbling, abrasive blasting (sand blasting), CNC machining (milling), and chemical dipping.

3. Property-changing post-processing

rearranges the molecules of a 3D print’s surface to improve the strength and evenness of the object. It doesn’t add or take away from the print resulting in cleaner and stronger parts achieved from thermal and chemical treatments.

Examples: Local melting, annealing, and vapor smoothing.

While each of these methods treats the surface in different ways, depending on the function, there are tried and tested combinations for different car parts that are advantageous for aesthetics and functionality.

Aesthetic and Functional Post-Processing Techniques for 3D Printed Car Parts

Automotive Customization with 3D Printed Car Parts

The 3d printed car parts can go through a combination of finishing techniques to achieve an enhanced surface finish, geometric accuracy, aesthetics, added mechanical properties, and improved usability. While some car components like dashboards might need only sanding and coating, other parts that are load-bearing such as a wheel accessory might require sequential finishing treatments for optimal performance. Apart from the improved look and feel, the post-processing steps have added benefits such as strengthening, UV resistance, tolerance towards higher temperatures, and protecting the part from regular wear and tear like bumps and scratches.

Some of the key advantages are:

Smoothing the surface of printed parts to achieve roughness values acceptable for end-use parts.
Certain post-processing methods strengthen the prints so that they may withstand increased stress and pressure.
Specific additive post-processing methods can change the material properties of the surface (e.g. waterproofing, UV resistance, corrosion resistance).

The most common sequences of post-processing techniques for the printed car part are:

1. Coating or Filling, Sanding, Painting, and Sealing

This process employs coating or filling to address surface imperfections, sanding to refine the texture, painting to add color and protection, and sealing to ensure durability.

Some of the 3D-printed car parts that are post-processed with this method are console elements, custom brackets and mounts, plate covers, fenders, and speaker covers.

3d-print-post-processing-sanding-polishing

THE PROCESS

1. Coating or Filling
The coating or filler depends on the type of 3D printing filament used as they differ in surface texture, porosity, and adhesion properties. Fill the visible layer lines, gaps, or imperfections, and allow enough time for the coating or filler to cure.

2. Sanding
Start with a coarse grit such as the 220-grit sandpaper and progressively move to finer grits. Sand the entire surface and focus on areas that are particularly notched, ensuring they are smoothened.

3. Priming
A primer adds a protective layer and preps the surface for paint adherence while also ensuring the durability of the coating. Make sure the primer is compatible with additional layers you might add later.

4. Painting
Choose automotive-grade paints for the specific 3D printing material and apply multiple coats spaced between sufficient drying time. You can explore painting techniques such as fades, gradients, or stencils to detail the part.

5. Sealing
Pick a clear automotive sealant to protect the painted surface creating an additional layer of defense against moisture, UV rays, and other environmental factors.

THE ADVANTAGES

Surface Quality

Coating and filling smoothen visible layer lines and blemishes resulting in a print with an even, aesthetic surface.

The painting process enables designers to customize the appearance, match the vehicle's aesthetic, or even integrate branding elements.

Customizable Design

Enhanced Durability

Most 3D printing materials such as PLA can degrade when exposed to elements over time. The sealant serves as a protective layer against environmental factors, maintaining its visual appeal over the long run.

A sealant creates a barrier against moisture, especially for the 3D-printed exterior car components.

Water Resistance

2. Gluing and Upholstery

Upholstering is the quickest way to make a vehicle’s interior look incredible and make a world of difference in the comfort level. Different types of upholstery such as fabric, leather, or other materials not only protect the surface but also add softness, comfort, and warmth. Depending on what the part is used for, a layer of padding or cushion is inserted in between and glued, stitched, or stapled to reinforce the parts together. This process creates a durable bond that can withstand loads and stressors while also offering customization, durability, and tactile comfort.

Some of the car parts that are upholstered are usually interior panels on the door, dashboards, central consoles, and other parts such as car trunks.

THE PROCESS

1. Select the Material
Choose a high-quality upholstery depending on the 3D-printed car part. Leather, vinyl, or Alcantara are commonly used for door panels and consoles, and polyester felt roll for the headliner or trunk of the car.

2. Adhere the Foam or Cushion to the 3D Printed Part (optional)
Measure and cut the foam or padding and use compatible glue while considering the properties of both the foam and the 3D printed part. Foam and padding are usually used for door panels and seats as they make them soft to the touch.

3. Measure and Cut the Upholstery
Trace a 2–3-inch gap on the material around the part and cut it so that there’s enough room for the material to stretch and adhere snugly to the part.

4. Apply the Adhesive
Glue the upholstery with the foam or the 3D print by applying adhesive to both parts.

5. Reinforce the Adhesion by Stapling and/or Sewing a French Seam
Stapling and stitching are other techniques that secure the material in place while also creating visual interest.

6. Trim the Excess Material
Carefully cut off any leftover upholstery, paying close attention to the corners and edges.

Types of Upholstery

The finished dashboard is installed in the car.

Leather wrapped around 3D-printed parts upgrades the overall aesthetic and tactile comfort of the part.
Vinyl is a popular choice as it is highly abrasion, water, and UV resistant. It mimics the look and feel of leather and is a popular choice for upholstery as it’s affordable and easy to maintain.
Alcantara is a synthetic suede-like material, it's soft, durable, and frequently used for interior surfaces such as seats, door panels, and steering wheel covers.
Fabrics such as cloth, microfiber, mesh, and nylon come in a wide range of textures, patterns, and colors. They are known for their comfort and abrasion resistance properties making them a good fit for interior car parts.
Polyester fabrics also come in a wide range of patterns and colors and their biggest strength is that they don’t wrinkle easily.
Polyester Felt Roll is made from polyester fibers that are entangled and compressed to form a non-woven fabric and are commonly used in car trunks.

THE ADVANTAGES

Tactile Comfort

Upholstery like leather or Alcantara has a texture that makes the car part soft and ergonomic, improving the user experience.

Upholstering brings different components together applying the same look and feel to the car interior creating a unified design language.

Visually Cohesive

Protection and Durability

Quality upholstery materials form a protective layer that can withstand regular usage, and resist stains, fading, and damage, ensuring a lasting visual aesthetic.

Upholstery can be designed with logos, labels, or a color scheme and tie the vehicle together visually.

Branded Customization

3. Foiling or Wrapping

Wrapping or foiling is typically for exterior parts of the car, or the entire vehicle adhered with a thin, adhesive-backed material such as vinyl. Foiling can change the vehicle's color, add graphics, or create a protective layer. If you are looking to automate the process, vacuum foiling produces quicker, precise results ensuring the material wraps around the part as perfectly as possible.

3D-printed car parts that are commonly foiled and wrapped are spoilers, fenders, side skirts, grilles, and mirror covers, as well as interior parts like the dashboard and center console.

THE PROCESS

1. Prepare the Surface
Ensure the surface of the 3D-printed part is clean and free of any dust, debris, or contaminants so it doesn’t come in the way of adhesion.

2. Pick the Material
Choose your foiling or wrapping material based on the finish, color, or texture you are going for.

3. Measure and Cut the Foil
Similar to the upholstering method, trace a 2–3-inch gap on the wrap around the part and cut it so that there’s enough room for the foil to be wrapped around and adhered to the part.

4. Apply it to the Part
Starting from one edge and working towards the opposite side, smooth out the wrap with a squeegee onto the 3D-printed part to avoid air bubbles or wrinkles.

5. Use a Hot Air Dryer (Optional)
Complex shapes are more difficult to foil, and it might be easier to conform the material using a heat gun or a hot air dryer set to around 70 to 85 degrees. The heat makes the wrap more flexible and bends into little nooks and crevices.

6. Trim the Excess
Once the material is applied, trim off the excess using a cutter knife, paying close attention to corners and edges for a clean finish.

Types of Wraps and Foils

Carbon Fiber Wrap mimics the appearance of real carbon fiber and is often used for interior trims, exterior accents, and spoilers. While they don’t have the structural benefits of real carbon fiber, these wraps are a lightweight and cost-effective alternative.
Vinyl Wraps are thin and adhesive-backed, offering flexibility and durability. They are available in a multitude of colors and finishes making them one of the most commonly applied treatments for customized car parts.
Paint Protection Films (PPF) are transparent, self-healing urethane film that protects against chips and scratches while preserving the original paint color.
Hydrographics or Water Transfer Printing transfers designs or patterns onto 3D printed parts by immersing them in water.
Brushed Metal Wraps exude the appearance of a brushed metal surface delivering an industrial finish to the 3D-printed car part.
Reflective Wraps enhance visibility in low-light conditions and make it safer to drive in the dark.
Chrome Wraps are reflective, and mirror-like having a highly shiny surface. They are used to accent certain parts or at times wrap the whole car.

THE ADVANTAGES

Quick Installation

Wraps can be treated onto the car part relatively quickly compared to other post-processing methods as they involve fewer steps.

If the wrap gets damaged or the client has a change of heart, it can easily be swapped out within a short time and at a low cost.

Reversible Customization

Lack of Downtime

Unlike traditional painting, wrapping does not need extended periods in the workshop, allowing it to be on the road sooner.

Wraps are easy to clean and maintain, simplifying the process of keeping the vehicle looking fresh.

Easy Maintenance

4. Sanding and Epoxy Coating

This technique pairs a subtractive post-processing method with an additive one to finish a part that requires a short downtime before taking its final form. The 3D-printed part’s surface is sanded to a uniform base to build upon. Epoxy, especially self-leveling epoxy, is particularly easy to use as it strikes a balance—neither too drippy nor too thick—resulting in parts with a reflective aesthetic finish and also a reliable grip.

3D-printed car parts that are sanded, and epoxy coated are mirror housings, door handles, dashboard elements, and control panels.

THE PROCESS

1. Sand the Surface
Lightly sand the surface to refine and create a gritty base the epoxy can easily adhere to.

2. Sit the Part on an Elevated Level
Using a sacrificial block or a similar tool, set the part at an elevated height so it can be painted from all sides.

3. Prepare the Epoxy Mixture
Mix the resin and the hardener in a plastic container and take care not to let the mixture sit too long before the application.

4. Apply with a Brush
With a right-sized brush, coat the epoxy evenly onto the part to a consistent finish.

5. Allow it to Cure
Give the finish enough time to become tacky before applying additional layers. As epoxy cure times can vary widely, the curing time between layers or after a final coat should be checked in the technical data sheet for the epoxy you use. Keep in mind that epoxy will cure faster in warm environments or may not cure at all if the temperature is too low. Room temperature is usually recommended for proper curing.

THE ADVANTAGES

Straightforward Process

The process of sanding and epoxy coating doesn’t require an array of tools, intricate techniques, or a high level of skill making it an easy process to execute.

The epoxy coating enhances the grip on the surface of the car part, giving you a secure and tactile surface while using it.

Improved Grip

Durable & Glossy Finish

The finish lends a long life to the coated part and imparts a glossy finish, enhancing the overall aesthetic.

This post-processing method forms a protective barrier, guarding the 3D-printed car part against wear, abrasion, and external elements. It also can penetrate porous substrates making the car parts more waterproof.

Guards Against Wear & Tear

5. Post Processing Molds for Car Parts

3D-printed molds for car parts are produced for materials like fiberglass or carbon fiber. While post-processing them, the main goals are to have a high-quality surface finish on the final molded part and to make it easier to release the molded part. For this, the finishing process follows a sequence of steps such as filling, sanding, and sealing.

Commonly 3D-printed molds post-processed for car parts are bumpers, body panels, spoilers, side skirts, grills, and air vents.

The final carbon fibre part created with a 3D printed mold.

THE PROCESS

1. Filling
Filling or coating smoothens out any imperfections or layer lines and creates a uniform surface on the mold. It is essential for the inside of the mold to have an even surface as any irregularities will reflect on the molded part.

2. Sanding
The mold surface is further refined by sanding with coarse grit such as the 220-grit sandpaper and you can achieve smoother finishes by advancing to finer grits.

3. Sealing
A sealant wraps up the process forming a protective layer ensuring durability, keeping moisture away, and creating a polished surface that makes it easy to release the molded part.

THE ADVANTAGES

Enhanced Surface Quality

The post-processed molds result in a smooth and refined surface delivering a higher quality impression onto the molded parts.

Sealants and coatings enhance the durability of the mold, protecting it from regular use.

Improved Mold Durability

Easy Part Removal

The smooth interior of the mold along with a mold release agent makes it easy to release the part. This safeguards the mold and the part during the removal stage.

Sealants act as a barrier against elements, preventing distortion or degradation of the mold which is particularly important when using materials sensitive to humidity.

Prevents Moisture Absorption

Time and Cost Efficiency

Investing time in post-processing molds pays off in the long run by extending mold life and reducing the need for frequent replacements.

Perfection to the Finish Line

Post-processing parts are more than just the surface level.

They are no longer an afterthought but a strategy to stay ahead of the curve and deliver top-notch aftermarket services by producing quality end-use car parts with professional-grade finishes. Leveraging finishing techniques improves functionality, saves time and money, strengthens parts, and ensures superior 3D printed products and services for the automotive car aftermarket.

Want to learn more about Post-Processing 3D-Printed Car Parts?

From fabricating carbon fiber molds to perfectly finished speaker enclosures, the automotive aftermarket explores all avenues of 3D printing applications. Hear from JT Torres, owner of Automotive Entertainment, about how 3D printing takes the front seat in delivering bespoke interior door panels, center consoles, and a range of custom car parts.

IDEATION TO INSTALLATION: 3D PRINTED PARTS FOR AFTERMARKET CAR CUSTOMIZATION

About the author:

Natasha Mathew

Copywriter

3D Printing Powers Wind Turbine Research at TU Berlin

January 15, 2024January 12, 2024

On average, wind turbine blades are a massive 80 meters long. When it comes to reengineering these towering blades, no other technology offers the freedom, precision, and adaptability to scale parts quite like 3D printing. While replicating them in a university lab might be near impossible, a scaled prototype with 1 meter blades is very much in the wheelhouse of a large-build volume 3D printer. Here, researchers go big by starting small.

Based on 3D-printed rotor blades, TU Berlin offers a course - Wind Turbine Measurement Techniques that imparts skills to measure the performance of the blades at different operating points. The students learn how to gauge the speed of the wind while at the same time assess the power generated by the turbine. The course revolves around comparing the performance of a traditionally made, hand-carved, 2 meter wooden blade with a 3D-printed 1 meter rotor blade with the gyroid infill.

The additively manufactured blade is the fruit of the research conducted by a Ph.D. and a Master’s student of TU Berlin, Jörg Alber, and Laurin Assfalg , respectively. During the study, they discovered that with 3D printing, experimenting with different infills, shapes, and materials, the sky's the limit.

Laurin Assfalg:

"3d printing was a compelling option to produce the rotor blades as it can create complex forms and enhance performance. The idea was to come up with the science that can somehow be used for big rotor blades too."

3D Printing Breathes Life into the Blades

The research's objective was to find alternative ways to fabricate wind turbine rotor blades. By creating and optimizing rotor blades on a smaller scale with 3D printing, Jörg Alber and Laurin Assfalg sought to develop insights that could be useful for additively manufacturing life-sized full-scale rotor blades in the future.

The conventional way of creating wind turbine rotor blades is through subtractive methods such as hand-carved wood, computerized milling, or molding. These processes, although time tested and well established as the gold standard in the wind turbine industry, weren’t an ideal choice for the research as these blades don’t allow customizable complex structures needed for testing. Their decision to design and produce the 3D-printed blade was the technology’s ability to create more intricate forms and infills (the internal structure of a 3D-printed part) compared to traditional subtractive methods.

3D Pinted Wind Turbine Blades for TU Berlin Research

3D printing offered efficiency in printing the blades and could easily accommodate a wide range of shapes and structures that would eventually be subjected to rigorous testing. The size of rotor blades to be printed were 1 meter in length which made the large-format industrial BigRep ONE the perfect choice. The one-cubic-meter build volume BigRep ONE is designed to manufacture massive 3D prints for the most demanding and geometrically complex applications. Housed at the maker space of the TH Wildau, the BigRep ONE produced the blades in a single seamless print, the entirety of the blades was printed horizontally without any support in less than a day.

For the design, the blades were developed using freely available intelligent software and BigRep’s BLADE. The vital settings for the print like the printing direction, layer height, wall thickness, infill structure (gyroid), and infill density were easily customizable on the BLADE software. The open access principles 3D printing is based on were yet another reason that made additive manufacturing a compelling choice in the framework of a low-budget university project.

Structural Considerations: Infill and Material

The structural design of the wind turbine blades was based on both the study of different infill structures and 3D printing material.

1. Gyroid Infill

Components such as wind turbine blades often experience a constantly changing load because of aerodynamic and inertial forces during rotation. After extensive infill research, gyroid’s isotropic properties made them an obvious choice as they endure loads that constantly fluctuate.

The gyroid infill is made of a complex network of twisted and interconnected tubes forming a repeating pattern that extends infinitely in all directions without intersecting or overlapping. The result is a continuous lattice structure resulting in extraordinary stability at very low density which were the mainstays necessary for lightweight rotor blades. While designing this complex pattern manually might take ages, 3D printing software simplified the process automatically and implemented it in the rotor blades.

The rotor blade’s gyroid infill printed by the BigRep ONE at the maker space of TH Wildau.

Apart from its strength, gyroid infill is also known for its material efficiency. Because of the interconnected channels, it reduces material usage without compromising structural integrity. This aspect was a huge advantage while printing the blades which might have otherwise ended up being heavy and consumed a substantial amount of material.

2. BigRep’s Industrial Grade PRO HT

The research team printed the rotor blades with PRO HT as it checked the boxes: easy to print, high strength, and has the ability to withstand high temperatures. The user-friendly filament doesn’t warp often and delivered aesthetic prints with a smooth matte finish.

The team also considered the ecological footprint of the blades, and the industrial grade PRO HT being a biopolymer, has a reduced environmental impact when compared to filaments derived from fossil fuels.

Putting the Blades to the Test

Testing the 3D-printed blades involved structural and wind tunnel tests to evaluate how they hold up under a range of parameters.

1. Structural Testing

The prototype rotor blades were exposed to the ULCs (Ultimate Load Cases) with the Universal Testing Machine (UTM) at HTW Berlin.

Ultimate Load Cases (ULCs) encompass extreme loads applied during testing, while a Universal Testing Machine (UTM) is the device used to simulate or apply ULCs in structural testing. The machine evaluates how materials behave under controlled forces or strains.

What are Ultimate Load Cases (ULCs)?

The conditions under which a material or structure experiences the maximum anticipated load, stress, or forces it might encounter in the real world. By subjecting materials to these ULCs, you can gather data on how they behave under stressors which helps in the design and validation of the rotor blades for safety and reliability.

What is a Universal Testing Machine?

A Universal Testing Machine (UTM) is a device used to test the mechanical properties of materials or parts, such as tensile strength, compression, bending, and hardness. It applies controlled forces to the subject to measure how it responds under different conditions, providing valuable data for material analysis and quality assurance.

The stress tests analyzed potential damages within the 3D-printed shell like buckling and cracks when it was under certain forces. The ultimate root bending moments (maximum bending forces experienced at the root section of the rotor blade) were tested with point forces (concentrated forces exerted at specific areas) at three blade positions and in both bending directions. The blades were also tested under an intense centrifugal force of Fmax = 3000 N by a heavy-duty crane.

Despite the rigorous and thorough structural testing, the blade remained unscathed, reverting to its original shape, with absolutely no signs of cracks or buckling.

2. Wind Tunnel Tests

Wind Tunnel for the 3d printed rotor blade tests

To help the researchers find insights into the rotor blade’s aerodynamic efficiency, structural stability, and whether the wind turbine could extract wind energy, the wind tunnel tests were crucial. The tests simulated and analyzed the wind turbine blades in controlled aerodynamic conditions within the large closed-loop wind tunnel at the HFI of the TU Berlin.

The wind turbine blades were designed to work best at a certain speed, but when they tested it, the researchers realized it worked better at a higher speed than what they had initially planned. Its maximum efficiency was at 5.4 times the speed of the wind, rather than the 4 times it was designed for. This was because the turbine was engineered based on natural wind flow, not the conditions inside the wind tunnel where it was tested.

The Future of Wind

The culmination of Laurin Assfalg and Jörg Alber’s research, the wind turbine with 1 meter 3D-printed rotor blades, currently resides at TU Berlin. It is the pillar of the course “Wind Turbine Measurement Techniques” and is a constant test subject for the experiments that determine what the future of harnessing wind energy might look like.

Apart from the enhanced performance of the 3D-printed blades, the study revealed other promising outcomes for the environment. The 3D-printed prototype blades produced for the Ph.D. thesis weren’t coated as part of the post-processing, so they can be easily recycled and upcycled. The research paves the way for further studies into enhancing the efficiency of wind turbines to harness clean, green, renewable wind energy.

Want to Learn More About Gyroid Infill?

Explore the innovative use of gyroid structures in wind turbine manufacturing and biomedical applications with expert Jörg Alber from TU Berlin. Don't miss out, watch the webinar now:

THE 3D-PRINTED GYROID: IMPROVING STRUCTURALLY DEMANDING APPLICATIONS

About the author:

Natasha Mathew

Copywriter

Winds of Change for Vestas: 3D Printed Tooling Transforms Wind Turbines

January 8, 2024January 4, 2024

3D printed tooling for vestas windmills.jpg

There aren’t a lot of technologies that can propel towering wind turbines to new heights of time and cost efficiencies, but large-format additive manufacturing rose to the challenge and delivered with its eclectic range of applications.

Vestas, a global leader in sustainable energy solutions, designs, manufactures, installs, and services wind turbines across the globe. With more than 160 GW (billion watts) of wind turbines in 88 countries, the renewable energy giant has harvested more wind power than anyone else in the game.

When Vestas needed to replace the jigs and fixtures that help construct their wind turbines, BigRep’s large-format additive manufacturing system was tasked to produce the tooling they needed. The everyday wear and tear of industrial work on traditional metal jigs and fixtures could deform tooling in ways that cause faulty construction. The BigRep STUDIO produced resilient plastic tooling that performed flawlessly and soon Vestas found more applications for the machine than what they had initially invested in.

Ultra Precise Large-Scale Additive Tooling

Vestas' primary requirements were to create jigs and fixtures to position a vital component, the lightning protection system, within the wind turbine's blades. Accuracy is paramount because these blades endure constant inclement weather conditions and are highly susceptible to lightning strikes. The conventional approach is to use steel jigs and fixturing tools but they came with inherent limitations. These metal tools, although robust, faced challenges with deformation and undetectable damages.

lightening-protection-system-tooling-vestas

The plastic tooling, engineered through additive manufacturing, spelled remarkable advantages over its steel counterpart. Particularly, its lightweight properties, resistance to deformation, and unique ability to yield or break under stress. Fracturing under duress was paramount as these ensured faults were detectable early on which is critical in turbine assembly.

Transitioning from traditional steel tools to advanced polymer-based 3D-printed tooling was one of the highlights of this collaboration with BigRep. The modularity of the newly designed 3D-printed tool simplified Vestas' manufacturing processes, offering versatility to accommodate different configurations with a single adaptable design.

Vestas' tooling for the installation of the lightning protection system being 3D printed on the BigRep STUDIO.

The switch to 3D printed tooling led to significant improvements in both efficiency and cost reduction. Vestas observed a remarkable three-week reduction in lead time and an impressive 72% cost reduction in manufacturing these crucial components. The tooling proved to be highly precise, lightweight, and surpassed traditional manufacturing's accuracy standards by holding measurements down to a couple of microns.

The stability of High-Temp CF material used for the tools resists changes due to temperature and humidity fluctuations making them reliable. This in turn lowered costs, reduced carbon footprint, and eliminated additional transportation expenses associated with conventional manufacturing methods.

Jeremy Haight, Principal Engineer at Vestas:

"By having Additive Manufacturing in our pocket, we were able to flood the floor with quality tooling, by which we enable our regular production workers to do more of the important spot checks, which results in better quality."

Optimized Manufacturing Efficiency and Field Service Operations

The transition from physical to digital part inventory, enabled by 3D printing, delivered fundamental advantages for Vestas. Additive manufacturing excels in production on demand, small-scale production, and swift iterations in designs, resulting in reduced costs, streamlined logistics, and mitigated expenses linked to conventional manufacturing methods. Additionally, Vestas incorporated smart fixtures, integrating sensors and circuits into their 3D-printed tools to enhance functionality and accuracy.

Given the extensive global reach of Vestas' operations across continents, the challenges associated with lead times for spare parts and expedited costs further underscored the compelling nature of AM solutions. Aligned with Vestas' IoT strategy and Industry 4.0 initiatives, 3D printing bolstered supply chain agility—an essential factor, especially when relying on suppliers in distant countries.

This shift towards digital inventory not only eliminated tax burdens but also significantly enhanced the value of the manufacturing process. The reduced mean time to repair (MTTR) metric served as a marker for increased efficiency and reduced downtime in both manufacturing and field service operations.

3D Printing in Response to COVID

During the COVID-19 pandemic, Vestas produced over 5,000 personal protective devices with their BigRep STUDIO for frontline workers in healthcare facilities. They designed and produced AM face shields and door claws to help reduce the spread of infection and create safe, hygienic working conditions. The design was made open source which resulted in more than 1000 downloads.

Circularity and Sustainability

Vestas turns their scrap carbon fiber from the manufacturing process into additive manufacturing feedstock. With BigRep's open environment ecosystem, they can upcycle waste into 3D-printed parts and prolong the life of what would otherwise go to waste. The process repurposes and transforms carbon fiber into 3D printing material by grinding, compounding, and filament extrusion:

Grinding: The waste carbon fiber undergoes a grinding process to break it down into smaller particles. This grinding process reduces the carbon fiber scraps into finer granules, creating a more manageable form for further processing.
Compounding: The ground carbon fiber particles are then combined with a suitable thermoplastic matrix material. This compounding step involves mixing the carbon fiber granules with the thermoplastic polymer, often through methods like extrusion or compounding machines. This mixture forms a composite material, combining the properties of both the carbon fiber and the thermoplastic.
Extrusion: The compounded material is then heated and melted before pushing it through a nozzle to create a continuous filament of uniform diameter. This filament, now containing recycled carbon fiber, can be used as feedstock for 3D printing.

Apart from recycling its waste carbon fiber, Vestas also substantially minimized its carbon footprint by maintaining a digital inventory of components and printing them on demand with the BigRep STUDIO. Maintaining physical inventories of components and the logistical burden associated with transporting them across continents are no longer an issue as they are printed at the location required.

Reshaping Wind Energy

By replacing traditional steel tooling with resilient plastic counterparts crafted through additive manufacturing, Vestas advanced its manufacturing capabilities in wind turbine construction. What started as a project to create tools for blade assembly and QA, then extended to the production of spare parts, streamlined supply chains, and later supported COVID initiatives.

With 3D printing, Vestas aligned their production process with their vision: sustainable energy solutions powered by sustainable manufacturing practices.

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Why 3D printed plastic tooling improved Vestas’ production quality
How in-house production helps to improve factory equipment on demand
Why manufacturing equipment is the “sweet spot” for 3D printed low-volume mass production
How hybrid 3D printing can bridge the gap for ultra-high-strength applications
The health and safety benefits of lightweight 3D printed parts

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About the author:

Natasha Mathew

Copywriter

3D Printing Reinvents the Bass Drum Without Missing a Beat

January 5, 2024December 21, 2023

What possesses someone to reinvent a musical instrument that’s been around for thousands of years?

Oliver Deeg, a product engineer, and musician will tell you: boredom, curiosity, and a firmly rooted knowledge of additive technology. His dream? To create drums that aren't confined by traditional manufacturing limitations. His tool of choice? Large-format 3D printing.

https://www.youtube.com/watch?v=XWWZEfa-Y00

Defying Conventional Constraints

Oliver Deeg is a man of talents and passions; CAD design, additive 3D printing technology, and e-commerce being the mainstays. His vision is to push the boundaries of design and music through Additive Manufacturing.

Like most drummers, customizing and building his own drum kit has always been his dream. His journey began alongside a friend crafting drum sets in wood, but the constraints of traditional methods held him back from making the design truly his own.

Meticulous woodworking is the time-tested way of crafting a bass drum. It begins with selecting quality wood like maple or birch, dried to prevent warping. Wooden staves are shaped and glued together to form a cylinder, creating the drum's shell. Precise bearing edges are then cut to optimize contact between the drumhead and shell, crucial for tone. The holes are then drilled for hardware, and the shell undergoes thorough sanding and finishing. Drumheads, made of synthetic or animal skin, are attached using tension rods. Finally, the hardware is assembled, and fine-tuning adjusts the drum's tension rods for the desired pitch and resonance. This intricate process demands skilled craftsmanship and attention to detail to create a bass drum.

This process has been stagnant and leaves little room for experimenting with sound and design. Oliver saw the potential to produce drums that would be free of these limitations. He turned to 3D printing and his expertise in Additive Manufacturing proved advantageous, with which he began producing small drums. From small prototypes, his ideas snowballed into more ambitious projects. True to the heart of a musician and the mind of an engineer, he couldn’t help thinking BIGger.

"With 3D printing, it was the first time that I felt there are no real borders. You conceptualize an idea, and within hours, you hold a tangible prototype. It's such a dream come true”

Dreaming BIG

The turning point came when Oliver crossed paths with BigRep at Formnext 2022 which led to a collaboration that propelled his vision forward. BigRep's range of materials and large-format 3D printers were instrumental in materializing his vision - A 24 Inch Base Drum with 6 USPs:

Cone-shaped inner shell to explore new unique sounds.
Relief shell design for stability and an aesthetic finish.
Sound + cable hole to release air pressure and also double up as a means to insert microphones into the drum.
Hollow-shaped fill hole to hold granulates such as sand or can also contain water. When empty, it produces more of a violin-like sound, and when filled, results in lower frequencies.
Customized hoops to hold the drumhead.
Experimentation with a range of materials to find the best sound, fit, and finish.

He adds,

"The collaboration with BigRep was a game-changer. Their advanced printing capabilities enabled the creation of drums with exceptional quality."

Anatomy of the 3D Printed 24-inch Bass Drum

Relief Shell Design For stability and an aesthetic finish.
Holes for lugs Space for metal lugs to hold the tuning screws.
Cone Shaped Inner Shell Crafted like a megaphone, it is instrumental in creating new sounds.
The Drum Shell Main body of the drum.
Screw Holes To secure lugs from the inside.
Sound and Cable Hole Releases air pressure and doubles as a space to insert microphones inside the drum.
Hollow Shell with Fill-Hole for granulates such as sand or can also hold water.
Hoops to hold the drumhead crafted for the 3D-printed shell. Produced twice.

Oliver's drum set is an embodiment of unconventional acoustic principles. Inspired by how sound amplifies in conical shapes, his design incorporates two shells with an acoustic space between them—a feat unattainable through conventional methods.

He elaborates,

"Finding the right material and producing a large-scale print of this size was the biggest challenge. The drum took a few days to print. The surface, straight from the printer, was immaculate, there was no need for post-processing."

3D Printing Hits the Right Note

Plastic drums are nothing new, they’ve been around for a while. But they all have a distinct sound and feel that doesn’t stand out the way that the 3D-printed bass drum does. The very first impression of the drum for Oliver was that it sounded incredible. Not only did the sound and design deliver, but also the material and construction of the drum held its ground. When he put it under the microphone in the studio, the real difference showed up. It did not just compete with a regular drum but also sounded distinct because of its USP – The Conical Inner Shell.

BigRep 3D printed drum Oliver Deeg in a recording studio

Starting out, Oliver knew designing the 3D file, pushing print, and producing the drum parts wasn’t going to be a simple ride. What is usually perceived as easy geometry is not, and the drum required expertise and accuracy that, along with BigRep, he was able to achieve making him a firm believer that the next wave of drum customization belongs to Additive Manufacturing.

Given his fascination with 3D printing technology, it’s no surprise that he sees it as not just being a catalyst for a new era in creating musical instruments but also integrating into our everyday lives. For him, the future holds a fascinating prospect—a world where every household could house a 3D printer, becoming an answer for personalized on-demand production.

“I envision a day when a 3D printer sits in every home, where ordering something means it materializes straight out of your own printer,"

Oliver concludes.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

About the author:

Natasha Mathew

Copywriter

The Definitive Guide to 3D Printing: The Past, Present, and Future

January 4, 2024December 13, 2023

From its humble beginnings as a niche technology for rapid prototyping to its current spectrum of capabilities to create forms that are virtually impossible to build any other way, 3D printing has spawned a brand-new generation of manufacturing.

In this article, we’ll take a look at the origins of 3D printing, its big moments in history, applications, and explore the future it holds.

Table of Contents

1. The Basics of 3D Printing

What Is 3D Printing and How It Works

3D printing, also known as additive manufacturing, is a process of building a physical object from a three-dimensional digital model. It creates an object by laying down successive thin layers of a material such as plastic, metal, resin, or even biomaterials—based on a digital design created using computer-aided design (CAD) software.

The process begins with the digital 3D model sliced into numerous thin layers. The 3D printer then follows these instructions, precisely depositing material layer upon layer, gradually constructing the physical object. This technology has found applications across a gamut of industries, including aerospace, healthcare, automotive, fashion, architecture, and more.

Types of 3D Printing Materials

3D printing materials can be categorized under:

Plastics (PLA, ABS, PETG, nylon)
Metals (stainless steel, titanium, aluminum, copper)
Resins (standard, flexible, tough, castable)
Ceramics (porcelain, stoneware, earthenware)
Wood pulp with a binding polymer (Bamboo, Birch, Maple, Cherry)
Composites (carbon fiber, fiberglass)
Paper-based (cardboard and paper)
Food-based (chocolate, dough, sugar)
Bio-based (living cells and tissue)

The History

The roots of 3D printing go back to the 1980s when visionaries like Hideo Kodama proposed methods for fabricating three-dimensional models using photopolymers solidified by UV light. Around the same time, Charles Hull pioneered stereolithography, patenting the concept in 1986. This technique employed UV light to solidify layers of liquid photopolymer resin, laying the groundwork for additive manufacturing. Subsequent decades saw the evolution of various printing methods like Selective Laser Sintering (SLS) and Fused Filament Fabrication (FFF), expanding material options and applications.

By the 2010s, 3D printing had become more accessible, integrating into industries such as aerospace, healthcare, and automotive manufacturing. Bioprinting also made strides, enabling the printing of living tissues and organs. Today, 3D printing stands as a transformative force, reshaping manufacturing, rapid prototyping, and medical advancements through its capability to produce intricate designs with precision and speed.

The advantages

Benefits of 3d printing Across Industries

Rapid Prototyping

3D printing enables quick and cost-effective prototyping, allowing designers and engineers to iterate designs swiftly, reducing time-to-market for new products.

Highly individualized products can easily be produced catering to specific needs and preferences without significantly increasing production costs.

Customization

Complex Geometry

Unlike traditional manufacturing methods, 3D printing can create intricate geometries and complex designs that would be challenging or impossible to achieve otherwise.

Additive manufacturing is inherently more efficient, as it typically uses only the materials necessary for the object being printed, minimizing waste.

Reduced Material Waste

Supply Chain Efficiency

On-demand production enabled by 3D printing reduces the need for large inventories and streamlines the supply chain by producing parts as needed.

For small batches or low-volume production, 3D printing can be more cost-effective than traditional manufacturing methods due to lower setup costs.

Cost-Effectiveness

Innovation in Medicine

Creating patient-specific implants, prosthetics, and medical models for surgical planning requires precision and customization which 3D printing delivers effortlessly.

3D printing has become an invaluable tool allowing students and researchers to visualize concepts and create prototypes to test theories in various fields.

Education and Research

2. Common Types of 3D Printing Technologies

Fused Filament Fabrication (FFF)

FFF is one of the most common 3D printing methods. It works by melting a thermoplastic filament and depositing it layer by layer through a heated nozzle onto a build platform. As each layer cools, it solidifies, gradually building the object. FFF is known for its simplicity, affordability, and versatility, making it popular for hobbyists and prototyping.

Stereolithography (SLA)

SLA employs a vat of liquid photopolymer resin and uses a UV laser to solidify the resin layer by layer, building the object from the bottom up. The UV laser traces the shape of each layer onto the surface of the liquid resin, solidifying it. SLA is known for producing high-resolution, detailed prints, making it suitable for applications requiring precision, such as dental and medical prototypes.

SELECTIVE LASER SINTERING (SLS)

SLS uses a high-powered laser to selectively fuse powdered material, typically nylon or other polymers, into a solid structure layer by layer. Unlike SLA or FFF, SLS doesn't require support structures as the unsintered powder acts as a support. SLS offers design flexibility and can produce complex geometries and functional prototypes with robust strength, making it common in the aerospace and automotive industries.

POLYJET PRINTING

PolyJet technology operates similarly to inkjet printing but with layers of liquid photopolymer cured by UV light. Tiny droplets of liquid photopolymer are instantly cured by UV light, solidifying it, layer by layer, onto a build tray. PolyJet printers can produce multicolor, multi-material parts with high accuracy and fine details. It's often used in industries requiring high-resolution models, such as product design and architectural prototyping.

3. Real-World Applications Across Industries

Advancing-Additive-Manufacturing-in-Aerospace_Hero

1. Aerospace and Defense

Lightweight yet durable components are the lifeblood of the aerospace and defense industry. Components like turbine blades, fuel nozzles, brackets, and even entire rocket engines can be 3D printed. This results in reduced component weight, improved fuel efficiency, and enables rapid prototyping for testing different designs.

2. Automotive

In the automotive industry, 3D printing is used for rapid prototyping, and creating functional prototypes for testing and validation before mass production. Additionally, it's utilized for manufacturing parts like engine components, interior elements, custom tooling, and even entire vehicle bodies. The technology allows for quicker design iterations and the production of complex parts, enhancing overall efficiency in the automotive manufacturing process.

Car Restoration: 3D Printed Center Console

FDM vs SLS Healthcare: 3D Printed Wheelchair

3. Medical and Dental

3D printing has transformed the medical and dental fields by enabling the production of patient-specific implants, prosthetics, and surgical tools. In dentistry, it's used to create crowns, bridges, and dental models tailored to individual patient needs. In medicine, it's utilized for creating anatomical models for surgical planning, prosthetic limbs, customized orthopedic implants, and even bioprinting tissues and organs for transplantation and research purposes. These offerings deliver personalized solutions and improve patient outcomes.

4. Consumer goods

Embraced by leading companies across sectors like consumer electronics and sportswear, 3D printing has democratized manufacturing processes with the accessibility of industrial 3D printers. This accessibility empowers designers and engineers to delve into its immense potential. Its benefits include expediting product development through rapid prototyping, accelerating time-to-market, and enabling mass customization by efficiently catering to individual consumer preferences.

5. Industrial Applications

The industrial goods sector, pivotal in machinery and equipment production, grapples with the need for agility and cost-effectiveness amid escalating costs and digital advancements. To address these challenges, manufacturers turn to 3D printing for its agility, responsiveness, and innovation. Its advantages lie in rapid prototyping, on-demand production, slashing design change times, and cutting lead times by eliminating tooling requirements.

4. Seven Steps to Find the Right 3D Printer

Building on the foundation of 3D printing basics, types, and applications, you can now quickly narrow down the vast choice of 3D printers by considering factors like:

1. Type of Printer

Consider various technologies such as FFF (also called FDM), SLA, and SLS. Inexpensive desktop FFF printers may suit hobbyists, while SLA and SLS offer higher accuracy at a higher cost.

2. Cost of the Printer

Entry-level printers cost less than $500, while industrial-grade printers can go up to hundreds of thousands of dollars. Also, factor in maintenance and filament costs.

3. Printer Size and Volume

Evaluate available space and print size needs. Beginners may opt for smaller, faster printers while for industries it’s recommended to invest in large-format 3D printers.

4. Print Quality and Speed

Take resolution, layer height, and print speed into consideration. Higher resolution often means slower speed and vice versa.

5. Ease of Use

Look for user-friendly interfaces, easy calibration, automation, and reliable performance. Consider reviews for insights into reliability.

6. Support and Maintenance

Check for maintenance instructions, available replacement parts, and technical support. Some companies offer less expensive, build-your-own 3D printers while others offer a full-service package. Also look for community support as it can be a holy grail in troubleshooting your 3D printer.

7. Additional Features

Consider extras like multiple extruders for varied prints, auto-calibration, built-in cameras, touchscreen displays, proprietary 3D software, and internet connectivity based on personal needs and budget considerations.

5. The Future Of 3D Printing

3D printing holds vast unexplored potential to reshape our everyday lives by offering innovation, customization, sustainability, and efficiency through:

Diverse Use of Material
Expect a widening array of printable materials, including advanced polymers, metals, ceramics, and bio-compatible substances, expanding the scope of applications.
Accessibility
As technology progresses, 3D printing might become more accessible, affordable, and user-friendly, potentially integrating into everyday homes and workplaces.
Sustainable Manufacturing
Efforts towards eco-friendly printing using recyclable materials and reducing waste during the printing process are gaining traction, contributing to sustainable manufacturing practices.
Bioprinting and Healthcare
Advancements in bioprinting may revolutionize healthcare by facilitating the creation of tissues, organs, and medical implants, leading to personalized healthcare solutions.
Integration with AI and Robotics
The fusion of 3D printing with AI and robotics could streamline and automate the entire printing process, enhancing efficiency and precision.
Space Exploration
3D printing's potential for on-site construction using locally available materials might revolutionize space missions and support off-world colonization.

Past production advancements were typically gradual, building upon iterations by refining production lines and inventory systems. In contrast, 3D printing reimagines production at a fundamental level. It simplifies, accelerates, and streamlines the creation process using a single machine, deviating from the reliance on a string of machines.

This paradigm shift is why most industries invest in this technology, firmly believing in the promise 3D printing holds in exploring untapped industrial applications in the manufacturing sector. From the invention of the telephone to the personal computer, there have been milestones in human history when a technology has completely transformed society. Now is one of those times.

Want to learn more about Large-format Additive Manufacturing?

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Explore how increasing the build size increases the possibilities for builds, why size matters, how to integrate, 4 applications that benefit from large-format additive, case studies from industry-leading companies like Ford, Steel Case, and more.

GUIDE TO INTEGRATE LARGE-FORMAT ADDITIVE MANUFACTURING

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

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INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

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About the author:

Natasha Mathew

Copywriter

Join the Ranks of Top Universities by Integrating Large-Scale 3D Printing into Your Curriculum

WHY THE STUDIO IS THE BEST-IN-CLASS EDUCATIONAL TOOL

A Generous Build Volume

A Safe, Fully Enclosed Build Chamber

Open Material Platform

Uninterrupted Productivity

Training and eLearning Platform

Space Conscious Machine Design

Intuitive 3D Print Software

Large-Format 3D Printing Applications Across Different Academic Fields

Next-Gen AM Technology for Next-Gen Graduates

Want to learn more about how Universities are upgrading education with 3D printing?

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

About the author:

Natasha Mathew

The Form is More Than Function

Large Scale Printing Creates Unique Design Possibilities

Responding to Customer Demand

3D Printing in a Circular Economy

A Future Filled with 3D-Printed Possibilities

Want to Learn More about 3D Printing Bespoke Furniture?

About the author:

Patrick McCumiskey

Embracing the Open 3D Printing System

Cost and Time Savings with Rapid Prototyping

Large-Scale 3D Printing for Heavy-Duty Trucks

The Future of 3D Printing in Custom Commercial Vehicles

Want to Learn More about 3D Printing for Emergency and Commercial Vehicles?

About the author:

Patrick McCumiskey

1. Emergency Repairs

Why 3D Printing is a Solution

2. Unavailable Spare Parts

Why 3D Printing is a Solution

3. Surrogate Parts for Training

Why 3D Printing is a Solution

Advantages of 3D-Printed Temporary Spare Parts

1. Minimized Disruption in the Production Process

2. Reduces Downtime thereby Saving Money

3. On-Site Manufacturing is the Only Viable Option in Remote Locations

4. Saves Time by Eliminating Traditional Production Steps

5. Surrogate Tools for Operator Training

6. Digital Inventory Replaces Physical Inventory

7. Large-Scale Singular Prints Requiring no Assembly

8. A Full-Spectrum of Industrial-Grade 3D Print Materials

Empowered In-House On-Demand Solutions

Want to learn more about how Low-Volume Production Empowers the Aerospace and Defense Industry?

INDUSTRIAL QUALITY MEETS COST EFFICIENCY. COMPLEX PARTS IN LARGE SCALE.

INDUSTRIAL QUALITY MEETS COST EFFICIENCY. COMPLEX PARTS IN LARGE SCALE.

About the author:

Patrick McCumiskey

Adding 3D Printing to the Palette

Large-Format 3D Printing for Sizeable Sculptures

Analog Roots in a Digital World

Want to Learn More About Large-Format 3D Printing Applications in Exhibitions?

Unlimited Creativity in 3D Printed Exhibitions

About the author:

Patrick McCumiskey

Post-Processing Methods

1. Additive post-processing

2. Subtractive post-processing

3. Property-changing post-processing

Aesthetic and Functional Post-Processing Techniques for 3D Printed Car Parts

The most common sequences of post-processing techniques for the printed car part are:

1. Coating or Filling, Sanding, Painting, and Sealing

Surface Quality

Customizable Design

Enhanced Durability

Water Resistance

2. Gluing and Upholstery

Types of Upholstery

Tactile Comfort

Visually Cohesive

Protection and Durability

Branded Customization

3. Foiling or Wrapping

Types of Wraps and Foils

Quick Installation

Reversible Customization

WHY THE STUDIO IS THE BEST-IN-CLASS
EDUCATIONAL TOOL

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.