VERY INTERESTING 132: 3D PRINTING

 Hello ladies and gents this is the Viking telling you that today we are talking about

3D PRINTING

3D printing, or additive manufacturing, is the construction of a three-dimensional object from a CAD model or a digital 3D model. The term "3D printing" can refer to a variety of processes in which material is deposited, joined or solidified under computer control to create a three-dimensional object, with material being added together (such as liquid molecules or powder grains being fused together), typically layer by layer.

In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping. As of 2019, the precision, repeatability, and material range of 3D printing have increased to the point that some 3D printing processes are considered viable as an industrial-production technology, whereby the term additive manufacturing can be used synonymously with 3D printing. 

One of the key advantages of 3D printing is the ability to produce very complex shapes or geometries that would be otherwise impossible to construct by hand, including hollow parts or parts with internal truss structures to reduce weight. Fused deposition modeling, or FDM, is the most common 3D printing process in use as of 2020.

As the various additive processes matured, it became clear that soon metal removal would no longer be the only metalworking process done through a tool or head moving through a 3D work envelope, transforming a mass of raw material into a desired shape layer by layer. The 2010s were the first decade in which metal end use parts such as engine brackets and large nuts would be grown (either before or instead of machining) in job production rather than obligately being machined from bar stock or plate. It is still the case that casting, fabrication, stamping, and machining are more prevalent than additive manufacturing in metalworking, but AM is now beginning to make significant inroads, and with the advantages of design for additive manufacturing, it is clear to engineers that much more is to come.

One place that AM is making a significant inroad is in the aviation industry. With nearly 3.8 billion air travelers in 2016, the demand for fuel efficient and easily produced jet engines has never been higher. For large OEMs (original equipment manufacturers) like Pratt and Whitney (PW) and General Electric (GE) this means looking towards AM as a way to reduce cost, reduce the number of nonconforming parts, reduce weight in the engines to increase fuel efficiency and find new, highly complex shapes that would not be feasible with the antiquated manufacturing methods. 

One example of AM integration with aerospace was in 2016 when Airbus was delivered the first of GE’s LEAP engine. This engine has integrated 3D printed fuel nozzles giving them a reduction in parts from 20 to 1, a 25% weight reduction and reduced assembly times. A fuel nozzle is the perfect in road for additive manufacturing in a jet engine since it allows for optimized design of the complex internals and it is a low stress, non-rotating part. 

Similarly, in 2015, PW delivered their first AM parts in the PurePower PW1500G to Bombardier. Sticking to low stress, non-rotating parts, PW selected the compressor stators and synch ring brackets to roll out this new manufacturing technology for the first time. While AM is still playing a small role in the total number of parts in the jet engine manufacturing process, the return on investment can already be seen by the reduction in parts, the rapid production capabilities and the “optimized design in terms of performance and cost”.

As technology matured, several authors had begun to speculate that 3D printing could aid in sustainable development in the developing world. In 2012, Filabot developed a system for closing the loop with plastic and allows for any FDM or FFF 3D printer to be able to print with a wider range of plastics.

In 2014, Benjamin S. Cook and Manos M. Tentzeris demonstrate the first multi-material, vertically integrated printed electronics additive manufacturing platform (VIPRE) which enabled 3D printing of functional electronics operating up to 40 GHz.

The term "3D printing" originally referred to a process that deposits a binder material onto a powder bed with inkjet printer heads layer by layer. More recently, the popular vernacular has started using the term to encompass a wider variety of additive-manufacturing techniques such as electron-beam additive manufacturing and selective laser melting. The United States and global technical standards use the official term additive manufacturing for this broader sense.

The most-commonly used 3D printing process (46% as of 2018) is a material extrusion technique called fused deposition modeling, or FDM. While FDM technology was invented after the other two most popular technologies, stereolithography (SLA) and selective laser sintering (SLS), FDM is typically the most inexpensive of the three by a large margin, which lends to the popularity of the process.

And as always have a chilled day from the Viking.