3D printing has come a long way since its creation in the 1980s. The technology is so advanced now, that is making waves in various sectors, and engineering has been impacted in marvelous ways. This article explores three areas of engineering where its impact is most visible.
Additive fabrication, commonly known as 3D printing, emerged in the 1980s as an innovative solution for rapid prototyping. Initially confined to mechanical engineering for prototype creation, the technology was expensive and complex, limiting its use to industrial and research environments.
As advancements in technology occurred, it became more accessible, and its applications began to extend beyond engineering. By the 2000s, industries such as aerospace and automotive adopted it for manufacturing intricate parts, and even the culinary world began using it to craft elaborate edible designs.
Today, this groundbreaking technology has become integral to engineering, revolutionizing how products are conceptualized and produced across mechanical, civil, and biomedical sectors. It has drastically reshaped engineering design, prototyping, and manufacturing, offering unprecedented flexibility, efficiency, and design freedom.
This versatile technology has evolved from a niche process to a mainstream tool, now used in multiple engineering fields. In this article, we explore how additive fabrication is transforming mechanical, civil, and biomedical engineering, along with examples where it’s redefining conventional practices.
What is it and Where Did It Begin?
The journey of this transformative technology began in the 1980s, initially developed to create prototypes in the field of mechanical engineering.
The first machine, created by Charles (Chuck) Hull in 1983, used stereolithography, a technique where layers of resin were hardened using ultraviolet light to form objects. This marked the beginning of a new era in design and manufacturing, allowing engineers to swiftly produce prototypes and test designs without the need for costly molds or tooling.
In its early stages, the technology was largely confined to industrial and research settings, used primarily for prototyping and small-scale production.
The high costs and specialized applications restricted its use to fields like aerospace, automotive, and defense. However, as materials and fabrication technologies advanced, the process became more accessible, eventually branching into industries beyond engineering.
By the early 2000s, cheaper desktop machines began to emerge, opening up new possibilities for hobbyists, small businesses, and even artists. During this period, a variety of industries explored digital fabrication for purposes extending beyond prototypes.
For instance, in the culinary arts, chefs started to experiment with creating intricate edible designs. Chocolate printers, developed by companies such as Choc Edge, enabled chefs to print detailed designs from chocolate, adding a new level of creativity to food production and decoration.
The capability to produce intricate, customized designs made this technique an invaluable tool across industries, from aerospace to automotive to healthcare. As it continued to evolve, it gained particular importance in mechanical, civil, and biomedical engineering with huge benefits to these sectors.
Key Benefits of Additive Fabrication in Engineering
Design Flexibility: Engineers can produce complex geometries once considered impossible with traditional manufacturing methods, such as intricate internal structures, organic shapes, and lightweight designs that require fewer parts.
Cost Efficiency: Traditional manufacturing methods often involve expensive molds and tooling. In contrast, additive processes eliminate these costs, reducing production expenses, especially for small runs or custom parts.
Faster Prototyping: The ability to quickly produce prototypes and modify designs in real time has revolutionized product development, cutting down time-to-market for new technologies.
Customization: This method allows for the creation of highly tailored components, which is crucial in industries like healthcare and automotive, where bespoke solutions are often necessary.
Reduced Waste: As an additive process, this technique generates significantly less waste compared to traditional subtractive manufacturing methods, supporting sustainability and eco-friendly manufacturing practices.
Biomedical Engineering
Digital manufacturing is making a significant impact on biomedical, particularly in the production of personalized medical devices and implants. Traditional methods often fall short in addressing the highly specific needs of patients, but this innovative approach provides unmatched levels of customization.
One notable example is patient-specific implants. In orthopedics, 3D fabrication is used to create custom implants tailored to a patient’s unique anatomy. Materialie, a leader in healthcare digital manufacturing, developed titanium jaw implants for patients with jawbone defects.
These implants are crafted using CT scans of a patient’s jaw, ensuring a perfect fit and minimizing the risk of complications after surgery. The ability to create such personalized solutions is revolutionizing medical treatments and significantly improving patient outcomes.
Another fascinating application lies in the development of prosthetics. Traditional prosthetic limbs are often expensive and may not offer an ideal fit, but 3D printing allows for the rapid production of affordable, custom prosthetics. Open Bionics, for example, creates affordable, functional prosthetic limbs tailored to individual needs. This has made prosthetics more accessible and significantly enhanced the quality of life for many users.
Additionally, in the field of bioprinting, this technology is being used to create human tissues and organs. While still in the early stages, research into printing living cells to form tissues for research or medical use is advancing rapidly. Companies like Organovo are exploring the potential of bioprinting to produce human tissues that could one day be used in transplants or disease modeling.
3 Engineering Areas Where it’s is Making a Change
From jet engine parts to entire homes and orthopedic devices, digital manufacturing is making waves in engineering.
Let’s explore some areas where this technology’s impact is especially evident:
Mechanical Engineering
In mechanical engineering, additive processes have reshaped the way products are designed and made. One of the most significant advantages is the ability to create complex and lightweight components that conventional manufacturing methods cannot achieve.
For instance, GE Aviation utilizes this technology to produce fuel nozzles for their jet engines. These nozzles are crafted from a single piece rather than multiple parts, enhancing both strength and performance while reducing weight.
The fuel nozzles are also more efficient, leading to fuel savings and lower emissions. This example showcases how digital manufacturing creates components that are not only lighter but also more reliable and optimized for performance.
Another exciting advancement in mechanical engineering is the design of robotic parts. Companies like BMW and Ford use additive fabrication to create custom, lightweight components for high-performance vehicles. These components help improve fuel efficiency and reduce the overall weight of the vehicle, contributing to enhanced performance and sustainability.
Civil Engineering
In civil engineering, additive manufacturing is disrupting traditional construction methods, especially in the design and creation of building structures. The ability to produce large-scale, durable components is poised to revolutionize the construction of buildings, bridges, and infrastructure.
ICON, a construction tech company, has developed the world’s first 3D-printed homes. They employ a large-scale printer known as Vulcan to print houses in under 24 hours, significantly reducing both construction time and costs.
These homes are not only quick to build but can also be highly customized, addressing the unique needs of different communities. ICON’s approach to 3D-printed housing is paving the way for affordable homes, offering potential solutions for global housing shortages.
In bridge construction, this technique is also making waves. For example, Madrid, Spain, features a pedestrian bridge built with concrete-based 3D printing. The bridge was created in modular sections and assembled on-site, reducing material waste and shortening construction time. This development demonstrates how additive fabrication can be used to construct large-scale infrastructure with reduced environmental impact and lower costs.
Its Future in Engineering Design
As this manufacturing technology continues to evolve, its impact on engineering will only intensify. In mechanical engineering, developments in material science will lead to even stronger and more versatile components.
The integration of artificial intelligence and robotics with additive manufacturing will also expand the capabilities of engineers, allowing the automation of more complex design and production processes. This convergence of technologies promises to unlock new possibilities for innovation and efficiency in engineering.
References
3D Printing and Its Impact on Engineering
The World’s Largest 3D Printer is Set to Redefine Engineering
