Brian H. Breneman, CEO, Chief Technology Officer, Brentek International Inc.
Almost daily, we learn of new approaches, new uses and benefits of 3D printing technology. And because of the recent rapid deployment of this three-decade-old technology, there might even be a bit of confusion and possibly some disillusionment with this oft referred to ‘disruptive technology.’ There is, however, an approach to take, which will allow us to maximize its full potential and avoid common pitfalls.
Albeit, the terms 3D printing (3DP) and Additive Manufacturing (AM) are used interchangeably, neither term describes the technology well. For example, at a recent public library 3DP demonstration, a graphics art lady came in expecting to be able to apply 3D printing as some new method of printing in her commercial printing business. It took some explaining to try to set her straight, because of the confusion of terms. Perhaps “3D Creating” (3DC) might describe it better. It is different things to different people and in very differing applications. I believe this is the basic reason why many are having difficulty getting their hands around it. The overwhelming number of uses and growing methods of 3D printing itself is ‘mind boggling.’
The first step to maximize the benefits and potential of this technology is to accept it for what it is. “It is a tool, a powerful tool with endless uses and possibilities.” What it can’t do today, it might very well do tomorrow. And as with any new tool, we need to have a good understanding of it so we can effectively use it in our own world of applications. Like the first days of the personal computer (PC) in the early 1980s, many stories were told of computer salesmen telling their buyer that they could do anything they wanted with their new computer, only to take it out of the box, turn it on and watch the blinking prompt. Of course, everyone knows now what a powerful tool the PC is, but only after the early pioneers muddled through pitfalls and ‘trial and error’ learning experiences. Much of this can be avoided in the case of 3DP/AM, if it is approached logically and methodically:
– Envision and grasp the overall concept of 3D printing, aside from any particular software or hardware platform. This perspective enables the latitude to grow with the technology itself. The ‘layer-by-layer’ build concept is common to many of the current known methods of 3DP/AM (such as FFF/FDM, SLA, CLIP, SLM, and so on), whether vertical or horizontal printing; or using liquid resin, powdered material or fused filament, it is all done ‘one layer at a time.’
– Learn how to approach creating and manufacturing challenges in distinctly different ways from previously known methods. By really grasping the potential of “what is now possible” (and what is not yet possible), this technology will provide an immeasurable return on investment, even from day one.
Once we can visualize the practical possibilities of improving the way we make (manufacture) things, we will effectively be able to use it to its maximum potential. Some examples of this ‘new school of thought’ include the ability to 3D print functional assemblies (individual parts already assembled and functional at birth – also known as ‘functional 3D printing’). Another capability is the ability to produce/reproduce parts with integral features, such as precisely located threaded holes/studs. This capability alone eliminates many secondary steps of conventional manufacturing, such as the need to locate and drill a hole and limit the depth and cut threads, thus reducing or eliminating many post-processing steps and saving time and improving quality through consistency. And unlike other methods of conventional manufacturing, full control of material density of a 3D printed part (from 0 to 100% fully dense) is a new added benefit that can allow the optimization of strength, weight reduction and material conservation.
– Continuously monitor what is accomplished by others with 3DP/AM. Check out new methods, new materials, new applications, and new tools (software and hardware). Users will continue to find new ways to improve our world, both in creating and using manufacturing. For example, prior to our own investment in 3D printing, we began visiting engineers who had been using these devices to try to learn all we could about it. On one such visit, a young innovative engineer, who initially began 3D printing to make prototypes and provide custom parts on demand, found himself fixing and improving almost every aspect of his customers’ production processes. He was repairing broken equipment and making fixtures to optimize production. His 3D printer had now become one of the company’s most valuable assets, and I have never seen an engineer so satisfied with his work.
– Allow it to find the applications which can provide positive benefits, whether it is used in direct production, design engineering, production support, R & D, medical applications, repair/maintenance or wherever. Perhaps a dentist who intended it to model teeth now finds it can also be used it to make jigs to perform implants with more accuracy than before.
Change is only good when the benefits exceed sacrifice and compromise. As in the case of the innovative engineer, using it constructively throughout the manufacturing process also maximized the ROI. Though the initial purpose might be for prototyping or for use in direct production, by allowing 3D printing to solve other problems (such as equipment repairs) and to streamline the whole manufacturing process (such as production fixtures), it will prove invaluable quickly. Using this technology for production fixtures has proven to be a clean approach to making the perfect jig in many production applications. Aligning decals, hole location, part positioning, and so on, are all uses that will reap many benefits in manufacturing and assembly.
A new mindset
New mindsets must be applied at the design level. For example, dispelling the notion of forming existing stock material from a few two-dimensional views on a 2D drawing, but rather adding and removing mass from the native 3D ‘solid model.’
Working with a solid model requires every part of its geometry to be defined three-dimensionally. Perhaps like graduating from a bicycle to an automobile, it’s different, it’s better, but it requires a few new skills and a new way of thinking. But we can go more places and get there faster. Although some might think the younger generation is more tech-savvy, the skilled professional can appreciate the benefits of this technology as it finds new ways to improve what we do best – create things and solve problems.
If 3D printing technology is viewed and implemented in positive ways, in order to realize it’s full potential, it will be a powerful and innovative asset.
Brain H. Breneman is the author of the book 3D Printing Explained, which explains the aspects of 3DP/AM technology, apart from specific tools or methods. The book (ISBN# 978-0-692-72436-1) is available from any authorized distributor of Brentek products or from Brentek International, Inc., phone 1-800-BRENTEK.
