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
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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
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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
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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
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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
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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.