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3D PRINTING #2 (3. Digital Manufacture (EXAMPLES (Hearing Aid Shells,…
3D PRINTING #2
3. Digital Manufacture
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- "The process of going directly from an electronic digital representation of a part, to the final product via additive manufacturing" - Society of Manufacturing Engineers
- Creates the shape precisely + instantly
- Facilitation of rapid product innovation: allows a much more rapid turnaround than traditional techniques, + can make prototypes overnight if needed
- Reduced requirement to assemble final parts: can print objects out of multiple parts at the same time
- Time, material + energy savings
- Mass local manufacturing [localisation]: better for the environment bc there's less movement of products
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- Mass personalisation: making something according to the characteristics of the customer
- Digital storage + transportation of products/spare parts, w on-demand production
- Facilitation of low-cost access to market
EXAMPLES
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- Hip Implant Acetabular Cups
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- Adidas Futurecraft 4D + New Balance 990S
- Bugatti Chiron Engine Cylinder Head w Water Cooling
4. Personal Fabrication
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- People making their own stuff: either at home, or via a local/online bureau [a few years ago it was anticipated that we'd see bureaus on every high st]
- Anyone can own a 3D printer + design/fabricate products
- Can go online + order objects: individuals can get access to making objects
- In theory it challenges capitalism: if we get to the point where we can make things, we won't need capitalism or ppl to make things for us. However, it's unlikely it will ever get to that point
- Raises questions about manufacturer + designer rights to objects
- Bioprinting = actual 'personal fabrication' aka making parts of people!
- Currently, bioprinting can be used to print tissues/organs to help research drugs
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Sheet Lamination
- A type of 3D printing that involves stacking + laminating thin sheets of material
- Puts down a layer of paper, uses a cutter to get rid of pieces it doesn't want, sprays paper
- The lamination method can be bonding, ultrasonic welding or brazing, + the final shape is achieved either by laser cutting or CNC machining
- Mainly used to produce coloured objects in a high detailed resolution
- Most commonly used material is paper, but can also use plastic and some sheet metals
PROS
- Low cost + fast manufacturing time: allows product designers to make low fidelity prototypes from standard, easily-accessible materials
- Allows build materials to be swapped out in the middle of printing, so can also be used to make composite materials
CONS
- One of the less accurate methods
- Strength + integrity of the models is reliant on the adhesive used
1. Rapid Prototyping
- Using 3D printers to create concept models or functional copies of new products to allow design, fit or function to be assessed
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- A group of techniques used to quickly manufacture a scale model of a physical part
- Expensive to produce, but companies don't tend to worry about the cost of prototypes
- The advantages of 3D printing for this use: applications in many sectors, freedom of shape, ability to cut weight/cost for parts, accuracy, speed
- Prototyping remains the most widely spread application for 3D printing tech
2. Molds + Tooling
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- Using 3D printers to create traditional manufacturing infrastructure
- Molds usually cost thousands of pounds: although 3D printed molds will only last for 5000-10000 parts, bc of their lower cost they can be made again
- This takes a lot of cost out of a business
- A machined tool can take 6-8 weeks to complete, whereas the same mold 3D printed can be ready in hours/days
- Different types: PolyJet injection mold; Casting master; Traditional sand casting; Sand casting core [can now 3D print in sand]
Summary So Far
- 3D Printing isn't a single technology
- Many companies still dismiss its potential application based on knowledge of just a few technologies, e.g the desktop material extrusion of thermoplastics
- The 3D printing industry is now providing printers + materials to support 4 different application areas