Industrial 3D printing: how has it evolved and is it right for your business?

Additive manufacturing (AM), also referred to as 3D printing (3DP) has its origins in the 80s, becoming a technology that was used for niche purposes like aerospace and industrial prototyping. However, fast forward to 2023 and its benefits are reaching an increasing number of manufacturing businesses.

Thanks to recent technological advances, industrial 3D printers are now able to print faster, with a wider range of materials, and at scale. The result is that a global market worth £1.6bn in 2014 is expected to reach close to £33bn by 2026. But how has this technology evolved in recent years, what are the primary benefits for business, and what are the remaining risks and limitations?

The continued evolution of additive manufacturing

Historically, one of the major barriers to large scale additive manufacturing has been slow speeds and looser tolerances compared to CNC machining and injection moulding. While this remains true for most conventional 3D printers, breakthroughs are happening quickly. A team of researchers in Switzerland have demonstrated a new kind of 3D resin print process they claim is around 30x faster than conventional processes.

As well as becoming faster, the applications of additive manufacturing are also widening thanks to integration with technologies like artificial intelligence and machine learning.

Researchers at MIT are successfully using machine learning to expand the number of materials that can be used in the 3D printing process. Previously, operators would have used a process of trial and error to work out the parameters for printing new material effectively. However today, thanks to simulations and machine learning, a computer can ‘watch’ the printing process and correct errors in real-time.

Additive manufacturing is also becoming increasingly used in the fast-moving consumer goods (FMCG) sector. For example, cosmetics firm Neutrogena has partnered with Nourished to deliver 3D printed health supplements specifically tailored to individual consumer needs. The production speed enabled by additive manufacturing makes the creation of on-demand, personalised supplements viable.

With this kind of innovation, it's clear that the next generation of additive manufacturing is just around the corner. But what are the potential benefits and pitfalls for organisations looking to take advantage of the technology?

What are the main strengths of additive manufacturing?

Flexibility: Global supply chains remain under intense pressure. Combined with ongoing trade friction post-Brexit, and long term issues like the HGV driver shortage, many businesses are reporting parts shortages. Some automakers are already turning to additive manufacturing to keep assembly lines running. As these issues persist, printing parts internally could provide invaluable in many more sectors, either as a stopgap or a permanent solution.

Sustainability: As well as cutting the CO2 emissions associated with transporting parts around the world, printing replacement parts can stop products heading to landfill. And, as 3D printers only use the material needed to print the individual component, material waste is generally lower than in other manufacturing processes.

Customization and prototyping: Thanks to 3D printing technologies, hard to find or completely original components can be rapidly designed and altered using software. For example, creating parts for obsolete machines that would otherwise be hard to source. 3D printing technologies can help in the design process for manufactured objects, reducing cost of development and making it easier to adjust designs in real-time.

Speed: Rather than waiting for a part to arrive, additive manufacturing lets you create an object right away. This is particularly important in the case of replacement parts for broken down machinery, for example. It can also be invaluable in times of emergency. Researchers from the University of Sussex and the Olabisis Onabanjo University turned to 3D printing to quickly and cost effectively deliver urgent PPE equipment to charities in Nigeria during the pandemic.

The risks and limitations of additive manufacturing

While additive manufacturing continues to evolve quickly, limitations and risks remain. For example, although access to more technologically advanced 3D printers is becoming easier, there remains a shortage of skilled workers. Companies looking to print at scale in-house will need access to quality industrial and mechanical engineers, software developers, and industrial designers. Additive manufacturing will never be as simple as buying in the technology and pressing ‘go’.

Cyber and intellectual property risks also need to be considered. 3D printed products are designed using computer-aided drafting tools that generate a file containing proprietary information. With 3D printers more accessible than ever, skilled hackers can steal these files and recreate designs easily (or sell them to someone who can).

The potential for blueprints to be stolen also opens up liability and reputational risks that have not yet been fully tested. For example, if someone uses stolen files to print an object that failed and hurt someone, where does the liability lie?

How standards can help you get started with additive manufacturing

While the potential offered by additive manufacturing has never been greater, there are a lot of things to consider before jumping in.

If you’re thinking about getting started, PAS 6001: 2020 is a good place to start and assess the business case for additive manufacturing and 3D printing. It’s particularly designed to help chief financial officers and directors make well-founded decisions for the adoption of these technologies.

These insights help you understand where AM/3DP can contribute to top-line business growth, bottom-line profitability and productivity improvement. The PAS considers how to build the most appropriate supply chain and how to quantify the broader social, environmental and economic benefits of the technology. It considers the impact of AM/3DP technology adoption both internally and externally, including investment, risk, skills, change management and customer expectation.

If you have any further questions about how standards can help your business with additive manufacturing/3D printing, BSI Members can get in touch with the Knowledge Centre’s information experts.