Page 6 – BigRep Industrial 3D Printers

Bigger is Better in 3D Printing

May 4, 2021April 6, 2021

Recently, a 3D printed house went on sale in New York, first of its kind. Pretty remarkable, but it’s still considered a novelty and must overcome several barriers before successful market adoption.

The additive manufacturing industry is advancing at an incredible pace and technology improvements, material capabilities, use cases, competitors and adoption are at an all-time high with no signs of slowing.

According to a collection of reports compiled by AMFG, the anticipated annual growth rate until 2023 is anywhere between 18.2 - 27.2%. What was once a $3 billion industry in 2013 may exceed $30 billion in just a decade. This is driven primarily by major industrial players operating in North America, Europe and Asia. As adoption increases, so does the need for scalable technology that can solve the problems of today and tomorrow. As an industry we have historically looked at speed and reliability as major requirements, but recent data suggests that size has become a very important factor to industrial manufacturers, product developers and designers.

Size Matters

There are large format 3D printers available today that are being applied to a variety of industries and applications. For example, fabrication facilities and foundries are integrating larger printing technology to create new casting patterns that are more precise and cost effective. These foundry patterns can range from 100,000mm2 up to 400,000mm2 and are typically built through a manual process that is imperfect and expensive.

Being able to digitally design and 3D print with repeatable results continues to be a distinct advantage. The concept of large in this market is determined by application, and the one size fits all approach does not apply. Below is a list of the prime examples and industrial use cases to further justify what may work for you.

Large Parts

This is highly relevant for automobile, transportation and aerospace manufacturers. Engineers in these industries design all sorts of products, prototypes and tools that can benefit from a large platform 3D printer. For example, a luxury car designer wants to create custom bucket seat options for premium customers who are eager to personalize their vehicles.

Building a human-sized prototype seat would typically require multiple 3D printed parts that must be bonded or welded, and if the tolerance is off on one print then the whole part needs to be redone. Large format 3D printing solves this unique problem by simply starting and finishing the entire part during one print. In addition, this technology has proven to be a useful manufacturing tool for production lines. Train and plane manufacturers work with very large and heavy frames, chassis and doors during the assembly process. Although most of this can be automated with industrial equipment, some of it requires manual labor due to complexity or lack of resources.

Many industrial manufacturers are building custom jigs, fixtures and manufacturing aids to enhance the worker environment and improve efficiencies. These are oftentimes paired with scanning and reverse engineering technology, which tends to be a successful and safe application of large format 3D printing.

Car Production Tool for Positioning in Assembly at Ford

Batch Part Production

3D printing is quickly gaining notoriety as a production tool that will improve manufacturing independence. The global supply chain is shrinking, and antiquated methods of overseas production are becoming a thing of the past. This is apparent for many consumer products, electronics and medical device manufacturing companies who cannot operate with long lead times.

The beauty of large format 3D printing is not just for large parts but for batch production parts. Why not fill up a build tray with 10, 50, 100 or 1,000 parts and print them overnight? Oftentimes referred to as on-demand manufacturing, this enables product development companies to immediately provide products to their customers. This reduces the need for warehousing and eliminates logistical nightmares associated with overseas transportation. As companies begin adopting the digital warehouse concept, they will continue to embrace large format 3D printing as an advantageous way to enhance customer relationships.

Air Duct in a Verizon Kiosk in the NCY Subway by Boyce Technologies

Immediate Iterations

How often do you design the perfect product the first time? It’s almost impossible. As engineers, our job is to iterate and improve upon designs to maximize functionality, aesthetics or any other requirement. Occasionally referred to as rapid prototyping, 3D printing has become the obvious tool selection for most product development companies who are bringing products to market. For reference, the average new product development lifecycle timeline is about five months for consumer products.

This further demonstrates that the competition is constantly innovating and it’s up to the engineering team to identify cost effective ways to get to market faster. One way is with large format 3D printing and the overnight production of multiple parts, assemblies, ideas and product iterations on a single build platform.

Conventional manufacturing methods are limited when it comes to the automation of multiple parts in a single process, and typically requires multiple days of setup time, labor, post processing, etc. Imagine printing multiple variations of your prototype, functionality testing them and having a verifiable design by the end of the week.

3D Printed Water Scooter by Jamade

Conclusion

Size is relative. What works for you may not work for someone else, so it’s always important to conduct your own research. The 3D printing marketplace is full of complicated technologies, so understanding the positives and negatives can become quite challenging.

When it comes to determining what size platform works for you, we invite you to consult with one of our experts. With close to a decade’s worth of experience providing technology solutions and a long list of satisfied customers, we feel confident in our ability to point you in the right direction.

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

Medical 3D Printing Reinvents the Wheelchair – and Orthosis

April 29, 2024March 19, 2021

Medical 3D printing applications have dramatically improved accessibility to healthcare devices in recent years.

3D printing has made small, personalized prosthetics infinitely more affordable, accessible, and effective with on-demand personalized manufacturing. But larger medical devices - like wheelchairs and orthosis - have been limited by the small build volumes widely available.

Today, as large-format 3D printing has become increasingly accessible and reliable, the medical industry is making up for lost time. This past year has seen some incredible innovation in medical 3d printing made possible by large-format additive manufacturing with BigRep technology.

Two of BigRep's partners, Phoenix Instinct and 3Dit Medical, have proven especially noteworthy, having created inspiring innovations and earned the support they need to fully realize their life-changing designs.

Medical 3D Printing allows for a smart Wheelchair

Medial 3D Printing: Self Balancing Wheelchair The wheelchair has remained largely unchanged since the 1980s, said Andrew Slorance, CEO of Phoenix Instinct and a wheelchair user himself. “Wheelchair companies have been unable to stop thinking mechanical,” he says. “All the products around us are evolving – becoming smart. It doesn’t make any sense.”

With a vision to reinvent wheelchairs with smart technology, Slorance and Phoenix Instinct entered the Toyota Mobility Ultimate Challenge: a fund supporting the development of innovative mobility solutions worldwide. In the 18-month competition timeline, the company developed the Phoenix i: a revolutionary wheelchair with a smart center of gravity.

The Phoenix i is an ultra-lightweight carbon-fiber wheelchair with a unique smart weight distribution technology. The chair continually adjusts its center of gravity with user movements, making it easier to control in varied movement, terrain, and contexts while decreasing risks like backward falls. Other smart features like lightweight power assist and automatic breaking make inclines easier to traverse and eliminate most need for physical hand breaking.

The company’s BigRep large-format 3D printer made developing the chair in Toyota’s timeline possible, said Slorance. They reiterated constantly, printing full-scale frames to test on site – an accomplishment that simply wouldn’t be possible with traditional workflows. “My last carbon-fiber chair took about 4 years to develop,” he said. “We’re printing full sized wheelchair frames. It’s transformed the ability to develop a product.”

Now that the company has finished initial prototyping, they’re continuing to use their BigRep by 3D printing carbon fiber moulds used in manufacturing the chairs. There’s another 18 months of development to go, says Slorance, but with the million-dollar development fund the company won from the Toyota Mobility Ultimate Challenge and modern industrial resources like their BigRep industrial 3D printer, the future is bright for the Phoenix i.

3D Printing Orthosis: Personalised Scoliosis Braces

Medial 3D Printing - 3D Printing Prosthetics: Scoliosis Brace Scoliosis affects approximately 3% of the world population, which means there are about 1 million scoliosis patients in Saudi Arabia, according to Dr. Ahmad Basalah, Vice President of 3Dit Corp.

Halting spinal degradation in scoliosis patients requires individually personalized body braces that are tremendously expensive and difficult to produce. But now 3Dit Medical – 3Dit Corp.’s medical arm – say they’ve found a new solution to not only build braces that halt spinal degradation but also show promising results in spinal correction.

With their BigRep ONE’s cubic-meter build volume, 3Dit Medical has already successfully 3D printed scoliosis body braces that show promising results in spinal correction. The braces are already 50% lighter than their traditional counterparts, cost a fraction, and are created in just three days instead of the previous three weeks. But thanks to the digital nature of additive manufacturing, they also allow for simple adjustments before printing that will apply pressure to precise points and help slowly correct a wearer’s spine.

“The practice of making a conventional scoliosis brace is humiliating,” says Dr. Wesam Alsabban, President of 3Dit Corp., as he described the process of measuring scoliosis patients which, before 3D printers, required them to hang naked from a ceiling while measurements are taken.

With 3Dit Medical’s new additive manufacturing process, patients only require a simple x-ray and 3D scan to gather measurements.

The groundbreaking application won third place in Saudi Arabia’s MIT Enterprise Forum. Excited by the potential, 3Dit Medical says they’ll continue developing the technology and think it will lead to even more valuable products in the future.

How could you change the world with an industrial 3D printer to streamline innovation and production?

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

Explore the PRO

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

March 28, 2024February 9, 2024

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

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

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.

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

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.

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.

Want to learn more about how Vestas leverages 3D printing for tooling?

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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.

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LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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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?

Download the eBook Guide to Integrate Large-Format Additive Manufacturing.

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

BLADE 3.8.0

July 23, 2024November 8, 2023

Software Improvements
- Auto orientation plugin now operates via a tool bar
- Add Tab Anti Warping plugin (https://github.com/5axes/TabAntiWarping v1.3.0)
- BigRep materials now have a link to their web page
PRO.1 and PRO.2
- Added material profile: HI-TEMP
ONE.4
- Added PEX CU 1mm and PEX CU 0.6mm
- New material profile: Pro HT for PEX CU 1mm
- New material profile: HI-TEMP for PEX CU 1mm
- New material profile: HI-TEMP-CF for PEX CU 1mm

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BigRep Turns Up The Heat With HAGE3D Acquisition

May 13, 2024November 7, 2023

Reinhard Festag (Managing Director, BigRep), Matthias Katschnig (CTO, HAGE3D), Sven Thate (Managing Director, BigRep), and Thomas Janics (CEO, HAGE3D) at Formnext 2023.

In our quest to offer exceptional Additive Manufacturing technology, and solutions and expand our capabilities, today marks a monumental day in the history of BigRep as we announce the acquisition of HAGE3D. This partnership signals a giant leap toward our vision of becoming a full-solution ecosystem for a range of low to high-temperature applications, offering a powerhouse of innovation and possibilities.

The collaborative path with HAGE3D will unlock new opportunities in the industrial 3D printing landscape. Together, we offer a comprehensive portfolio of industrial 3D printers, featuring up to one cubic meter build volume and the capabilities of a wide range of high-performance, engineering-grade thermoplastic materials in low, mid, and high-temperature build chambers.

Redrawing the AM Landscape

HAGE3D, renowned for its high-temperature 3D printers and open AM platform, will empower BigRep to offer a full spectrum of low-to-high-temperature solutions. The acquisition is built on a foundation of extensive technological synergies, data-driven innovation, exceptional customer experiences, and an ambitious expansion plan, further strengthening BigRep's position in the industry and extending our market reach.

The Collabosphere, a 3D printed demonstration of the joined forces of BigRep and HAGE3D with a wide range of materials from both companies, seen here at Formnext 2023.

The Acquisition Disrupts Existing Possibilities

Both companies are committed to the development of intelligent FFF technology, making the production of complex, large-format functional parts accessible to manufacturers worldwide.

Dr.‐Ing. Sven Thate, Managing Director of BigRep GmbH, expressed his excitement about the merger, highlighting how it positions BigRep as the AM market continues to grow dynamically. The 3D printing world is driven by megatrends such as digitization and decentralization of manufacturing and BigRep, with the addition of HAGE3D, is well-prepared to capture this opportunity.

Dr.‐Ing. Sven Thate, Managing Director of BigRep GmbH, elaborated:

“For our worldwide customers, this acquisition makes us their local provider of open industrial AM solutions across all temperature levels, unlocking limitless material options. Together, with similar mindsets of customer-centric, data-driven innovation, we plan to form a European leader pushing the limits of what is possible with FFF.”

The BigRep PRO and the BigRep SHIELD

The HAGE3D MEX ONE

Thomas Janics, Managing Director of HAGE3D, emphasized the global growth opportunities enabled by HAGE3D's high-temperature FFF platforms expanding BigRep's material portfolio and large-format AM solutions. Complementing its current low‐temperature and energy‐conscious large format AM platforms, this will open a broad spectrum of new applications and markets.

Thomas Janics, Managing Director of HAGE3D, explained:

“With BigRep we have found a perfect partner to accelerate global growth opportunities in the industrial AM sector. While our focus was previously on the German‐speaking markets, we now can provide our products globally through BigRep´s sales network, adding Graz to the map of technology centers next to BigRep’s in Berlin, Boston, Shanghai, and Singapore. It’s a win‐win in R&D, production, and sales. We jointly look forward to an innovative future together.”

Joining Forces for Innovation

With more than 1,000 large-scale 3D printers already in operation across various industrial sectors, BigRep has earned its reputation with its expertise in large-scale Fused Filament Fabrication (FFF). The German-engineered 3D printers empower engineers, designers, and manufacturers, spanning from startups to Fortune 100 corporations, to expedite the transition from prototyping to production, ensuring their products reach the market promptly.

On the other hand, HAGE3D is an advanced engineering company with 40 years of experience in large-format, special-purpose machine building. Their state-of-the-art large-format mid- and high-temperature 3D printing systems are known for their precision and reliability. Fully assembled in Austria using industrial-quality components, these machines perform consistently across a wide range of industries and applications.

By forming an alliance with HAGE3D, BigRep is poised to expedite innovation and redefine manufacturing practices. This integration is underpinned by a fully integrated open AM business model, promising to offer users a replete solution.

As BigRep and HAGE3D come together, we will continue to push the limits of what is possible with FFF technology, accessing a world of opportunities in large-format, open additive manufacturing.

Find out more at https://bigrep.com/press-media/

About the author:

Natasha Mathew

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