114.3.1 - Total Manufacturing

Intro to ADD MFG

What is "Additive Manufacturing"?

- Additive Manufacturing (AM) - AKA 3D-Printing - is a process of building parts by adding layers of material on top of each other until the desired shape is achieved. The material can be in the form of powders, filaments, or liquids, and can include a wide range of materials such as plastics, metals, ceramics, and even living cells.
  - AM is a key technology in Industry 4.0, as it allows for the rapid and flexible production of parts, customized to specific needs, with reduced costs and environmental impact.
- Overall, AM has the potential to transform manufacturing processes, disrupt existing industries, and create new opportunities for innovation and sustainability. While the full impact of AM on society is still uncertain, it is clear that this technology will play a significant role in shaping the future of manufacturing and society as a whole.

History of AM

The history of AM dates back to the 1980s, although some of the key technologies and ideas that underpin AM can be traced back to the mid-20th century. Here is a brief history of AM:
- 1950s-1960s: Researchers began exploring the use of various technologies, such as photopolymerization and stereolithography, to create three-dimensional objects.
- 1970s: Researchers at the University of Utah developed a process called "stereolithography," which involved using a laser to solidify layers of liquid polymer. This technology laid the foundation for many of the AM processes that are used today.
- 1980s: A number of different AM processes were developed, including fused deposition modeling (FDM), selective laser sintering (SLS), and laminated object manufacturing (LOM). These technologies enabled the rapid prototyping of parts and paved the way for the use of AM in manufacturing.
- 1990s: AM began to be used in a range of applications, from prototyping to small-scale production. The aerospace and automotive industries were early adopters of AM, using the technology to produce complex parts with high precision.
- 2000s: AM continued to grow in popularity, with advances in materials, software, and hardware making the technology more accessible and cost-effective. The medical industry also began to adopt AM, using it to produce customized implants and prosthetics.
- 2010s: AM continued to expand into new applications and industries, with the rise of "desktop" 3D printing making the technology accessible to individuals and small businesses. Additive manufacturing also began to be used in large-scale production, with companies such as GE and Airbus using the technology to produce parts for their products.
- 2020s: Advances in materials science have led to the development of new materials that are better suited for AM, including high-performance polymers and metals. The use of AM in the production of medical devices has also continued to expand, with 3D-printed organs and tissues becoming a reality. Additionally, the COVID-19 pandemic highlighted the importance of supply chain resilience and the potential of AM to address supply chain disruptions. When the pandemic caused shutdowns and disruptions to traditional manufacturing and supply chain operations, AM emerged as a valuable tool for producing critical medical supplies and equipment, as well as for other industries.
Today AM is a rapidly growing field, with a wide range of applications and technologies. While the full impact of AM on manufacturing and society is still uncertain, it is clear that this technology will play a significant role in shaping the future of manufacturing and society as a whole.

The first 3D printed part, produced by Chuck Hull in 1983.

On December 29, 2014, NASA Engineers emailed a file up to Astronauts on the International Space Station (ISS), who then used an on-board 3D-Printer to produce to part - a 3-in.lb., print-in-place Torque Ratchet.

On March 22, 2023, Relativity Space's Terran 1 rocket "GLHF" successfully launched from earth to space encompassing many historic firsts, most importantly being the first nearly entirely (~85%) 3D printed rocket to fly and prove 3D printing is viable by passing Max-Q, the max stress on the rocket.

AM Applications

Good Tasks for AM

AM excels at tasks with the following characteristics:
- Complexity: Good tasks for AM are those that are too complex or too difficult to produce using traditional manufacturing methods. AM can produce intricate geometries, internal structures, and curved shapes that are difficult or impossible to create using traditional methods.
- Customization: AM is particularly well-suited for creating customized products. Good tasks for AM involve creating products that are tailored to individual customers' needs or preferences, such as custom prosthetics or dental implants.
- Low-Volume Production: AM is a cost-effective way to produce low volumes of products. Good tasks for AM involve producing small quantities of parts or products, such as aerospace components or medical devices.
- Material Properties: AM can produce parts with unique material properties that are difficult to achieve using traditional manufacturing methods. Good tasks for AM involve creating parts that require specific material properties, such as parts with high strength-to-weight ratios or high thermal conductivity.

Bad Tasks for AM

Conversely, AM does not excel or compete at tasks that include:
- Simple Geometries: AM is not always the most efficient method for producing simple geometric shapes. These can often be produced more quickly and cost-effectively using traditional manufacturing methods such as injection molding or casting.
- High-Volume Production: AM can be time-consuming and expensive for high-volume production runs. For example, producing thousands of identical parts may be better suited to traditional manufacturing methods.
- Large, Heavy, or Bulky Parts: AM is typically limited in terms of the size and weight of the parts it can produce. Producing large, heavy, or bulky parts may require specialized equipment or multiple print jobs, which can be time-consuming and expensive.
- Parts with Strict Tolerances: AM can produce parts with high accuracy and precision, but there are limits to the tolerances that can be achieved. Parts with very strict tolerance requirements may need to be produced using traditional manufacturing methods or via hybrid processes.

3 Primary Additive Use-Cases

1 - RAPID PROTOTYPING

Works-Like Prototypes test product functionality through replication of product/material properties.
Looks-Like Prototypes test design iterations and communicate ideas to stakeholders efficiently.
Feels-Like Prototypes simulate a range of materials from soft and flexible to hard and rigid, as well as test textures.

2 - TOOLING

3D-Printed Tooling assists with the production of manufactured goods.
Additive processes and materials allow for rapid production of jigs, fixtures, molds, and other tools that indirectly accelerate production through increased efficiency and/or reduction of waste via traditional processes

3 - FINAL PRODUCTS

Many end-use consumer products can now be directly 3D-printed.
Each day, hundreds of thousands of totally unique Invisalign trays are printed for customers, with estimates ranging from 200k to 320k made every 24 hours

Industrial Applications for AM

Aerospace

Manufacturing lightweight and complex components for aircraft and spacecraft, reducing weight and improving fuel efficiency. It also enables the rapid production of prototypes and replacement parts.

Automotive

Production of lightweight and complex parts to improve fuel efficiency and performance. It also allows for the creation of customized components and rapid prototyping for design evaluation.

Construction

The use of AM in the construction industry has the potential to revolutionize the way buildings are designed and constructed. It offers significant benefits in terms of cost, time, design flexibility, and sustainability.

Dental

Manufacturing of dental crowns, bridges, and implants with high precision and customization. It reduces production time and cost compared to traditional methods.

Conventional Manufacturing Processes

Creation of molds, fixtures, and tooling for use in traditional manufacturing processes. AM can reduce lead times and costs associated with creating these tools.

Medical

Production of customized implants, prosthetics, and surgical tools tailored to individual patients. It enables the creation of complex, porous structures that facilitate integration with the human body.

Electronics

Production of customized electronic components, such as circuit boards, sensors, and antennas. AM enables rapid prototyping and the integration of complex geometries.

Energy

Manufacturing of complex and efficient components for the renewable energy sector, such as wind turbine blades, fuel cells, and solar panel components. It can help improve the performance and durability of energy systems.

Robotics

Manufacturing of lightweight, customized, and complex robotic components that can enhance the performance and capabilities of robots.

Biomanufacturing

Creation of tissue structures and organs for research, drug testing, and eventually transplantation. AM allows precise control over the placement of cells and biomaterials, enabling the construction of complex biological structures.

Non-Industrial Applications for AM

Architecture

Production of scale models and prototypes for design evaluation and communication. It allows architects to visualize and test their designs more effectively, as well as clearly show their clients the end result before building.

Art

Artists use AM to create intricate and unique sculptures, jewelry, and other works of art. It enables new forms of expression by allowing the production of complex shapes not possible with traditional methods.

Assistive Devices

Production of customized and adaptive devices for individuals with disabilities, such as wheelchair components, hearing aids, and orthotics. AM enables personalized solutions that improve the quality of life for people with special needs.

Entertainment

Creation of props, set pieces, and costumes for film, theater, and television. AM allows for rapid prototyping and production of unique and complex designs.

Consumer Products

Creation of customized and personalized products, such as phone cases, toys, and home decor items. AM enables small-scale, on-demand production.

Education

3D printing is used in schools and universities to teach design, engineering, and manufacturing concepts. It fosters creativity and innovation by allowing students to prototype their ideas quickly. Additionally, it can be used to easily create physical visual demonstration pieces of theoretical concepts, such as internal bodily organs, math, physics, chemistry, etc.

Food

3D printing of edible materials to create intricate designs, textures, and structures. It offers new possibilities for presentation, personalization, and nutritional optimization in the culinary industry.

Fashion/Clothing

Production of customized and intricate clothing, footwear, and accessories using a variety of materials, including polymers, textiles, and metals. It enables designers to create unique and innovative fashion items.

Restoration and Archaeology

Recreation of historical artifacts and architectural elements for restoration and preservation purposes. AM can help maintain cultural heritage by enabling accurate reproductions of original items.

DIY and Maker Movement

AM empowers individuals to design, create, and customize their own products at home or in makerspaces. This fosters creativity, innovation, and entrepreneurship.

AM = Disruptive or Transformative?

The impact of additive manufacturing (AM) on manufacturing processes and supply chains is likely to be significant, and whether it is seen as disruptive or transformative depends on a range of factors, including:
- Existing Manufacturing Processes: AM has the potential to disrupt existing manufacturing processes, particularly those that rely on traditional tooling and machining techniques. If AM is used to replace or significantly alter these processes, it could be seen as disruptive. However, if AM is used to complement existing processes, for example by producing complex parts that are difficult to manufacture traditionally, it could be seen as transformative.
- Supply Chains: AM has the potential to disrupt traditional supply chains, particularly those that rely on long-distance shipping and large inventories of parts. If AM is used to produce parts on-demand, closer to the point of use, it could disrupt existing supply chains. However, if AM is used to enable distributed manufacturing and local production, it could be seen as transformative.
- Economic Impact: The economic impact of AM will depend on how it is used and who benefits from its adoption. If AM is used to produce products more efficiently and cost-effectively, it could lead to lower prices and increased competition. This could be seen as disruptive for established players in the industry. However, if AM is used to create new products and industries, it could be seen as transformative, leading to new job opportunities and economic growth.
- Organizational Adaptability: The adoption of AM requires a shift in mindset and culture, as well as the ability to adapt to new technologies, processes, and organizational structures. AM requires new skills and expertise, such as 3D design and programming, which may not be present in traditional manufacturing organizations. In addition, AM requires a different approach to product development and production, which may challenge existing organizational structures and processes. Organizations that are flexible and adaptable are better equipped to take advantage of the benefits of AM, such as increased efficiency, reduced lead times, and enhanced customization.
Overall, whether AM is seen as disruptive or transformative will depend on how it is used and how it impacts existing manufacturing processes and supply chains. While the full impact of AM on manufacturing and society is still uncertain, it is clear that this technology has the potential to revolutionize the way we produce and consume goods.

Your Thoughts on AM?

What was your first experience seeing or interacting with 3D-Printing of any kind? What was it? What did you think of it?
What are your thoughts (positive, negative, or otherwise) on the use of AM in industry and society, both currently and looking forward to the future?
If you could have something be 3D-Printed that isn't currently, what would that thing be, and why?
What do you think are the ethical considerations surrounding the use of AM, and how do we ensure that the technology is developed and used in a responsible and ethical manner?
What are some of the most innovative or exciting applications of 3D-Printing that you have seen recently, and how do you see them evolving in the future?

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