ENGR 0011 Vidic 2:00pm RAPID PROTOTYPING: 3D PRINTING USHERING IN A NEW ERA OF MANUFACTURING Adam Paul (amp200@pitt.edu ) 3D PRINTING’S AMAZING NEW TECHNOLOGY In 1993, two engineering professors at the Massachusetts Institute of Technology began work on a new project. Michael Cima and Emanuel Sachs took credit for patenting the first practical 3D printer [1]. What they intended to be used only for advanced 3D modeling software for the purpose of making “rapid prototypes” has now become developed to the point were it could grossly reshape the way we think about the manufacture and development of parts and maybe eventually, complex multi-part products. Not only is 3D printing technology affordable and cost effective because it reduces wasted during the manufacturing process, it also cuts production time of complex parts dramatically by speeding up or eliminating completely the need for traditional molding and casting techniques. In addition to making current parts more economically and faster it also opens a new door regarding the manufacture of parts that currently cannot be made in one piece (the strongest and lightest way) because of complex geometries. The technology is still too expensive for the average house hold but further development would bring the price down. Another important thing to consider is the new ethical considerations that arrive whenever new technology such as this is born. It may seem like any new advancement is a good idea as new advancements are generally seen as improving the lives of the public, which is a priority on the code of ethics provided by the National Society of Professional Engineers (NSPE) and the American Society of Mechanical Engineers (ASME). An important question to ask is where this new technology is acceptable by both the individuals’ code of ethics and the general code of ethics. I believe that 3D printing technology can be used responsible as long as it is intentions are in line with ethical codes. Not only could 3D printing technology improve daily life but it an ethical discussion about the its use is a useful educational experience. The sky is the limited when it comes to this new technology. Faster, lighter, stronger, cheaper, and whole new parts are what is possible if this technology is continued to be developed. Unless we want to stay were we are in terms of efficiencies of production and manufacturing then we need to continue to develop this technology. WHAT EXACTLY IS 3D PRINTING “Rapid prototyping” or “3D printing” is actually part of a larger category of manufacturing known as “additive University Of Pittsburgh, Swanson School of Engineering 1 October 30th , 2012 manufacturing” or “additive fabrication” [5]. Tradition manufacturing of a complex parts usually involve a CNC machining aspect to production where a high-speed drill bit carves the part out of a larger solid block of material. This method, while very effective, is wasteful because much of the original material is cut away and unable to be reused. The essence of additive fabrication is the exact opposite of traditional manufacturing. Instead of cutting material away, a 3D printer adds material to the work piece in very thin layers. This way there is no material wasted at all. The part is always constructed of exactly how much material is need. There is no extra and therefore no waste, and therefore a massive cut in material cost of the production of the same part. No matter what part you are making by additive manufacturing the basic process is always the same. So additive manufacturing promises enormous cost reduction in raw material. Just one example is the Timberland Company (boots, apparel, gear). They were able to achieve a 30-fold reduction in prototype cost after switching to 3D printing [5]. Another direct improvement that comes with purchase of a 3D printer is the incredibly wide range of parts that one machine can make. Traditional factories are set up to make only a few different products. That limitation does not exist with 3D printers. Also long as the part is small enough to fit in the machine then the machine is able to print it. This makes custom parts much more available and much cheaper for the factory to produce them. This all contributes to overall reduced costs. One example of this versatility is in Filton, England. Where the researchers at Filton have ambitions of printing everything from simple metal brackets to the entire wing of an aircraft under the same roof [2]. This would eliminate the need for separate facilities for different parts, leading to time and monetary saving. STRENGHT, LIGHTNESS, SPEED ARE FUTHER SAVINGS, AND THE BIO INDUSTRY Another thing to consider when thinking about the benefits of additive manufacturing is the technology to improve the performance characteristics of already existing parts by making them stronger and lighter. For every 1kg saved on an airplane, $3,000 in fuel costs are saved every year. [2] The titanium brackets for the landing gear of aircraft, produced by the Filton technicians can be made stronger and lighter by using 3D printing technology. Now Adam Paul imagine that all of the thousands of titanium parts of each production of molds for casting. This method is not the most efficient form of 3D printing, though it is more wildly used because advanced 3D printing is still very expensive. But testing by Elena Bassoli and Andrea Gatto, of the Department of Mechanical and Civil Engineering at the University of Modena, Italy shows that 3D printed mold production are effective in obtaining cast technological prototypes in short times with low cost, with dimensional tolerances that are completely consistent with metal casting processes [3]. The only slight difference between conventional molds and printed molds is a negligible difference in surface texture. One example of this speed mold making is the Ford Motor Company when they needed to produce a new complex support bracket in four weeks. This would have been impossible without the speed of the 3D printed mold, the normal wax pattern technique of mold making would have taken to much time. The parts produced had a 100 percent success rate [5]. The automotive industry strikes a cord with me because it was where I had my first encounter with options that rapid prototyping affords you. The University of Pittsburgh FSAE team utilizes 3D printing in a number of applications on their race car. The most complicated piece is the engine intake manifold. Normally it would cost in excess of $2,000 to purchase just one manifold. Because the University invested in a 3D printer the team is now able to make as many copies as necessary to perfect the design. Other part of the car that have 3D printed parts incorporated into them are the steering wheel, dash board, and injector blocks. Another area where 3D printing is taking us is into the biotech industry. Imagine needing a new heart and being able to have your health care provider provide you with a custom heart. Steps have been taken in 3D printing of human tissue. Researchers at the University of Pennsylvania and MIT have printed 3D patterns of blood vessel networks out of sugar that allow tissue to grow around them and then dissolve leaving behind a hollowedout vascular architecture [4]. Time can only tell where the continued development of 3D printing can take us. But a more important question is where the technology should be used at all. aspect of this new technology is certainly supported within the engineering code of ethics. Also to be considers is the appreciation of that would be gained for engineering if one day the technology, further developed, saved someone’s life, perhaps even your life. This would be a good thing because engineers are encouraged to extend public knowledge and appreciation of engineering and its achievements [6]. This may all be true but there are some concerns regarding this technology that must be taken into account. The main problem that has the potential to arise is very similar to the problem that the entertainment industry currently is struggling with, copyright laws. Imagine some time in the future after it is not uncommon for 3D printers to be in the average household. A conventional factory using old technology produces a product. You purchase that product, decide it is a good product, and come to the conclusion you like to have two of said product. Now you are faced with an ethical and legal dilemma. Do you simply scan and print another copy or do you go to the store and buy one [7]? This is an area that the standard codes of ethics to not effectively cover. One must rely on there individual ethical code. The engineer must take that into account when designing a machine with the capacity to scan and reprint certain thing. Does he somehow work in a way to prevent the manufacture of fire arms, drugs, anything that could be used with malicious intent, other illegal items, or not? Does the engineer scrap all this hard work because the machine can also be used for things that don’t have society’s best interests in mind. Does he even have the authority to decide what can and can’t be made? I personally believe that no matter what the future holds, the benefits of additive manufacturing technology out way the risks involved. We simply cannot afford to pass up the opportunities that this technology can open the door to. Yes, there are ways to misuse the technology that will certainly be exploited by someone (who is not an engineer hopefully) that is only thinking about the benefits that he himself with reap. However instead of fearfully hiding this technology with all the good that can come from it, we should continue to develop it. We should fight and shun the people who intend to misuse it. TO USE OR NOT TO USE EDUCATIONAL BENEFITS All the facts point to the benefits of 3D printing and certainly make a strong argument for the continued development. But it is important to consider the ethical problems that such new unexplored technology give rise to. An engineer should always have the public’s best interest in mind [6]. That is the engineer’s soul purpose. He must think about the people and how they will/ or will not be affected by his work before he thinks about what he might personally gain from such research. The potential for additive manufacturing in the health care industry is enormous. Whole new treatments and medical practices can be developed if research is continued in 3D printing. This University Of Pittsburgh, Swanson School of Engineering 2 October 30th , 2012 As an engineer it is also important to discuss the educational future of society. A good way to improve public interest in engineering is actually to incorporate 3D printing technology into the educational curriculum. Imagine a class where a young (possible pre high school) student could actually design something on a computer and then less than a week later, hold the printed result in his or her hands [8]. This would greatly improve the public interest because tangible results are always more exciting than equations and formulas on a white board [8]. Another way to improve general understanding of engineering and how powerful an Adam Paul influence on society engineers have is to discuses the ethical issues that engineers face everyday. With out the consideration of ethics there may be many things in this world today that are harmful to society. Without understanding both the benefits and dangers of the things I, as a future engineer, will be working on I would not be able to accurately judge the impact that my project would have on society. If I was unable to do that then I would not be putting society first which would go against the engineering code of ethics. It is good then that I discussed possible ethical issues. Now that I am fully educated on the matter of additive manufacturing I am finally able to make an informed decision on the matter. I fully support the further advancement and development of 3D printing technology. Its benefits are massive and with a combined effort we can make sure that it the technology is only used for the benefit of society. REFERENCES [1] Betancourt, Gaspar. "MIT Researchers Look to 3D Printing for Next-Gen Manufacturing." Wb-3d.com. N.p., 28 Sept. 2011. Web. 08 Oct. 2012. <http://wb3d.com/2011/09/mit-researchers-look-to-3d-printing-fornext-gen-manufacturing/>. [2] "The Printed World, 3D Print." The Economis 12 Feb. 2011: n. pag. General OneFile. Web. <http://http://go.galegroup.com/ps/i.do?action=interpret&id =GALE%7CA286685406&v=2.1&u=upitt_main&it=r&p=I TOF&sw=w&authCount=1>. [3] Elena Bassoli, Andrea Gatto, Luca Iuliano, Maria Grazia Violante, (2007),"3D printing technique applied to rapid casting", Rapid Prototyping Journal, Vol. 13 Iss: 3 pp. 148 – 155 [4] Paddock, Catherine. "Organ Regeneragtion Steps Closer with 3D Suger Printing." Medical News Today (n.d.): n. pag. Web. <http://http://www.medicalnewstoday.com/articles/247344.p hp>. [5] (2009),"The maturing of rapid prototyping: Market for additive fabrication passes $1billion", Strategic Direction, Vol. 25 Iss: 8 pp. 38 – 40 University Of Pittsburgh, Swanson School of Engineering 3 October 30th , 2012 A NEW FRONTIER It is interesting to think about what lies in the future of the additive manufacturing business. As stated previously there are some complex geometric shapes that are only capable of begin made there strongest by being printed, such as the sphere and other hollow shapes that normally would be made in sections and then binned together. Where these advancement take us we don’t really know. One area of 3D printing that is growing fast is the rapid manufacture or direct digital manufacture (DDM) of production parts compared to mold and prototype making [5]. No matter what the future holds, we must make sure that 3D printing technology is continued to be responsible developed because as it becomes incorporated into more and more business the savings are eventually pasted onto the customer. 3D printing also is poised to be part of the next big healthcare break though in making replacement organs for sick patients. 3D printing technology will one day be able to save your life. But it is paramount that as the technology because more and more powerful that it is use for ethical purposes. [6] "NSPE Code of Ethics for Engineers." NSPE Code of Ethics for Engineers. National Society of Professional Engineers, n.d. Web. 30 Oct. 2012. <http://www.nspe.org/Ethics/CodeofEthics/index.html>. [7] "The Ethics of 3D Printing." » The Ethics of 3D Printing⦠: Rational Conservatism from the Rocky Mountains. N.p., n.d. Web. 30 Oct. 2012. <http://www.cosmicconservative.com/weblog/?p=10328>. [8] "Education." 3D Printing Systems. 3D Printing Systems, n.d. Web. 30 Oct. 2012. <http://3dprintingsystems.com/home/education/>. ADDITIONAL SOURCES 1. "Filton Technicians Emphasize 3D Printing Potential." » Rapid Prototyping Services & 3D Printing Service by EMS. N.p., n.d. Web. 08 Oct. 2012. <http://www.rapidprototypingservices.info/2011/10/17/filton -technicians-emphasize-3d-printing-potential/>. ACKNOWLEDGMENTS I just wanted to thank my roommates for putting up with me during my late night study. Also thanks to the Pitt FSAE team for giving me the idea to write about 3D printing.