Overview of Additive Manufacturing and 3D Printing
In Additive Manufacturing, the building of layers is part of the creation process made by molding the elements, which is 3D printing. Earlier it was known as rapid prototyping, where a scale model was created without a setup process, and expanded its usage by molding it to the final product—development of innovative designs with the use of printers. With the help of rapid prototyping, it enhances market expansion and creates model-based printing with supportive structures (McAndrew, 2023). The computer-aided design of three-dimensional solid objects is 3-D printing. The 3D printer helps translate the computer-aided design file into a model of 3D, which has layers of sizes and printing technology. In the field of operations of manufacturing, 3D printing and additive manufacturing help bring flexibility, efficiency, and opportunities.
Additive Manufacturing – 3D Printing
Technologies and materials used in Additive Manufacturing
Fused Deposition Modelling
It provides a wide range of materials and is easily accessible for both prototyping and functioning
Selective laser sintering
It is used for producing durable parts with the geometries and materials used for solid layers and formations and it is a post-processing requirement that has more excess powder requirement and smoothing (Haleem, et al., 2023). Moreover, it is of high operational cost
Direct metal laser sintering
It helps in the strengthening of material parts and the production of parts with both thermal and mechanical properties.
Inkjet printing
It helps to build the platform with layer-by-layer formation of high resolution and printing capability and usage of various materials with polymer resins. Moreover, it requires consumables and machines to finish the functional parts
Materials
Polylactic acid
It is used for plant-based polymers that is in the simple prototypic model for settings and printing purposes. Moreover, this is flexible and easy to print. Also, it creates at low temperatures, has sharp edge designs, and is available in various range of colors but it is vulnerable to high heat.
PET/PETG
Polyethylene terephthalate is a plastic that is disposable and it contains manufacturing filaments. Additionally, it is a recyclable material with temperature resistant and it gets weak due to UV lighting and provides recyclable.
Nylon
The usage of nylon material for gears and mechanical parts of the machine. The nylon is an inexpensive material in geometrical structures and modelling of accessories. It is flexible and durable and also a good replacement for the molding applications (Krishna, Suman, Dharamkar, & Madhukar, 2023). Moreover, it has mechanical properties with application of dye and colors.
ABS
The previous filament is used in the 3D printers which are more flexible. It is also a recyclable material that helps in degradable processes and printing platforms. It is a readily available product and has different colors with the creation of prototypes and models.
Photopolymer resin
The most important and popular material in 3D printing is resin which is used in creating the details with FDM filament it gives various chemical resistances and it doesn’t shrink like other polymer materials. The reasons are photoreactive and also have smoother surfaces of finishing.
Polycarbonate
The use of polycarbonate in the application of high temperatures and parts. The composites help for enhancing usage. The metal-filled polymers help to provide strength to the metals and for easy printing. The wood-filled polymers help for texture-based creative decorative pieces and wooden objects with the advantages of 3D printing. The ceramics help for post-processing purposes and automotive maintenance. The concrete is maintained for creating large-scale structures such as buildings bridges and architectural designs.
Process of additive manufacturing
Benefits of 3D-printing in custom product development
Rapid prototyping
There are various benefits such as rapid prototyping and fast designing. Moreover, it produces major benefits in giving extensive tooling and setup and immediate realization of concepts. As soon as the development of 3D, the 3D printer is used for bringing the file and making it to the manufacturing process. It helps in processing for designers and testing the model and any modifications for rapid iterations by following the feedback. If any requirements of alterations for the entire manufacturing process based on the demand it will be done very quickly.
Cost-effective
The investment might be costly. It saves a lot of material costs that are required for production. Earlier, in the manufacturing of traditional processes, only skilled laborers managed to operate the machines and the processing. In the 3D printing technology, only a single operator manages multiple 3D printers, reducing labor costs (Behm, Waite, Hsieh, & Helmus, 2018). It also reduces warehouse costs and inventory costs. Companies no longer need many warehouses for the stocking of product. Additionally, it is advantageous like it reduces transport costs and maintains sales.
Freedom of designing
Particularly, it helps with customization and personalization with 3D printing. The traditional process of manufacturing involves individual component development but with 3D printing it assembles a single part with a single assembly time and with no errors. Also, it creates objects with specific applications with complex lattices and good strength.
Sustainability and eco-friendly
It reduces the wastage of material by consuming the necessary items for the print and structures to support. There will be a lot of wastage in the machine manufacturing so the 3D printers add up the materials in a layer form and they use sustainable materials like polylactic acid with great manufacturing techniques and nondegradable products. 3D printing provides eco-friendly manufacturing with good techniques and also cause less harm to the environment. In the traditional systems, there were many causes and emissions involved in global supply chains but now there are businesses that have more demand for 3D printing which reduce the cost of transport.
3D Printing
Challenges of 3D-printing in custom product development
Speed constraints
The traditional manufacturing method for producing large objects would take less time with 3D printing it takes more time in production because it has an additive process which is the layer-by-layer formation, and that is not suitable for the production of high volumes and materials.
Limitations of materials
As there are a large number of materials that are needed and required there is limitation in selection. Sometimes there will be a requirement for specialized materials and high-performance alloys and there is restrictions in some industries. So, these materials may not be readily available for the printing of 3D and usage in some industries
Requirements of post-processing
There are a few requirements such as polishing, painting, finishing the quality, and signing which are the parts of 3D printers for post-processing. It produces cause with additional steps and overall production time increases.
Accuracy concerns
Based on the 3D printing technology there are various finished goods in the manufacturing methods and applications. The accuracy may not be clear in 3D printing and some of the applications require smooth surfaces and high tolerance surfaces that may not be produced by 3D printing.
Limitations in the size
Various objects require limitations and maximum size of 3D printers. There are oversized objects that is not suitable for manufacturing and large-scale productions with 3D printing technologies.
Complications in printing and design
The creation of complex designs it is challenging to produce 3D printing which offers the freedom of designing for beginners (Iftekar, Aabid, Amir, & Baig, 2023). Use of advanced knowledge for both 3D modeling and printing because the design features are of higher knowledge that be typical for beginners to understand.
Structural limitations
Produce different mechanical properties in the manufacturing process with 3D printing and it impacts the strength of manufacturing and durability will be hard. It also affects the performance of manufacturing in the specific applications.
Environmental impact
Generally, most of the additive manufacturing requires plastic which is inexpensive and ends up harming the environment. Harmful particles releases in the air with the usage of those materials. It affects the small-scale manufacturing industries with the use of 3D printers it has as many federation accessories but the environment will be impacted by the consumption of those gases and energies into the air.
Future Trends of 3D-printing in custom product development
Making the supply chain through digitization
One of the purest digital technologies is eliminating the cost of switching and the usage of different locations. In 3D printing technology, it leads to more enhancements with different intensive methods. Furthermore, there is a chance of hybrid model manufacture at large-scale factories and industries, and also in small-scale industries with the equipment of 3D printing and support centers, with a lot of distribution of products and services. It also easily extracts files and prints the products at home in an easy manner. Moreover, it also enhances the customer side interaction and brings the products into the market with closer observation.
The extension of prototyping to production in 3D printing technology
There were a lot of technology gaps and developments made within the industry with the usage of the latest technologies (Singh, Ahmed, & Abhilash, 2015). It extends the form of prototyping to full production, which enhances the management of the life cycle and allows the full production without expertise. Moreover, it also enhances on-demand production and warehouse costing. Also, it has many technological aspects in multi-phase support with the product launch, and it also increases volume-based pricing, which loses its advantage.
Creation of a more sustainable future with 3D printing
Furthermore, by making use of materials and minimizing the waste of materials. Enables the usage of eco-friendly and recycled materials. The usage of recycled plastics for 3D printers to create new products, and this also enhances the economy with the demand for eco-friendly materials. It also makes use of biodegradable elements and renewable sources for making more alternative sources of materials in the environment, which makes less impact to the planet. Depending on the various technologies, the high energy consumption materials, and on-demand products in large-scale production and the development of energy-efficient products and printers into the market. Also, It makes a sustainable future that enhances recycling and localization of products and which promotes growth in sustainable materials and sustainable nature.
Conclusion
Manufacturing creates complex designs by introducing various industries and providing revolutionized development of products. It has various benefits and also challenges regarding the material limitations and obstacles regarding the adoption of these technologies. Usage of many technological advancements in sustainable materials which are in the expansion of management and these are more efficient in the usage of production and manufacturing of ornament services. In conclusion, 3D printing continues its role with custom product development and the ability to maintain operations with various innovative solutions and product developments. Furthermore, it had an impact on the environment and create a sustainable future by contributing to energy-efficient practices.
References
Behm, J. E., Waite, B. R., Hsieh, S. T., & Helmus, M. R. (2018). Benefits and limitations of three-dimensional printing technology for ecological research. BMC Ecology, 18(01), 1-13. Retrieved from https://www.researchgate.net/publication/327565231_Benefits_and_limitations_of_three-dimensional_printing_technology_for_ecological_research#
Haleem, A., Javaid, M., Rab, S., Singh, R. P., Suman, R., & Kumar, L. (2023). Significant potential and materials used in additive manufacturing technologies towards sustainability. Sustainable Operations and Computers, 4, 172-182. Retrieved from https://www.sciencedirect.com/science/article/pii/S2666412723000193
Iftekar, S. F., Aabid, A., Amir, A., & Baig, M. (2023). Advancements and Limitations in 3D Printing Materials and Technologies: A Critical Review. Polymers, 15(11), 1-23. Retrieved from https://www.mdpi.com/2073-4360/15/11/2519
Krishna, G. V., Suman, R., D. S., & Madhukar, S. (2023). Review on Materials Used In Additive Manufacturing. IOSR Journal of Mechanical and Civil Engineering, 20(2), 09-15. Retrieved from https://www.iosrjournals.org/iosr-jmce/papers/vol20-issue2/Ser-4/B2002040915.pdf
McAndrew, C. (2023, Jun 12). Accelerate Product Development with 3D Printing. Retrieved from Engineersrule: https://www.engineersrule.com/accelerate-product-development-with-3d-printing/
Singh, O. P., Ahmed, S. M., & Abhilash, M. (2015). Modern 3D Printing Technologies: Future Trends and Developments. Recent Patents on Engineering, 9(2), 91-103. Retrieved from https://www.researchgate.net/publication/281165435_Modern_3D_Printing_Technologies_Future_Trends_and_Developments
Keywords
3D Printing, Rapid prototyping, custom product development, Innovative designs, Additive Manufacturing
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