Promoting AM

The state of the Additive Manufacturing (AM) market is discussed extensively. The common belief is that AM has a lot of potential but the AM solutions (materials, machines etc.) are not there yet.

That said, I don't see many technology-centered discussions on ideas aiming to promote AM, apart from good old wishful thinking.

Being a problem-solver, and based on my experience in technology development, here is my take on what can and should be done.

Phase one: Time perspective.

Let's look at injection molding. Injection molding was invented in 1872. Along the years, and especially at the beginning of the 20th century, there were some advances in molds structure combined with material research, especially in order to prevent molds from combusting. But the major progress in this manufacturing methods was introduce with the invention of the extrusion screw injection machine, post WWII - in 1946.

We are now in 2024, 152 years from inception of injection molding and 78 years from the major technological breakthrough, and still there is innovation around it.

Now let's look at AM. AM is said to start with the honorable Chuck Hull's SLA invention in 1983. That's 41 yers ago. Even with humanity's bigger innovation resources potential and tools for expedited design, it seems like we are quite early in the process of maturing AM. Things take their time with this customer base (I.e. mechanical engineers).

In other words, let's put aside the 3DP hype factor, which builds up expectations for miracles. It will take time and resources to get the needed solutions.

Phase two : what are the technological advancements needed to make AM a truly effective manufacturing process?

Here are my suggestions, based on my experience and in some cases involvement over the years:

First, Materials - making the huge effort to use known engineering materials with as little chemical changes as possible. Only for significantly high value applications (basically aerospace and defense) development of application-specific-materials for AM should be considered. Most engineering projects do not have the resources for new materials development. Engineers want to use the materials they know. I am talking about Al6061, Al7075, PA6 etc.

Secondly, build the machines to fit the materials engineers NEED, not the other way around. It's is a complicated and resources consuming task, but it can be done. Been there, done that. Multiple times. Indeed, physics and economics will determine if a solution is feasible, but my experience is that using the right materials brings huge value to the customers and this will cover the cost of developing the right machines and processes for the materials.

Phase three: What do I mean by "the right machine"?

Here are some ideas, none of them are science fiction nor easy to implement:

For FFF - we need positive displacement low capacity extruders. This will make parts with fine features AND with predictable and repeatable physical properties.

For SLA, SLS and SLM - rastering with multiple lasers arrays. And I mean vast arrays of solid state lasers which have the suitable wave length for the materials. No more one-wavelength-fits-all. These array should be driven across the build platforms and make those machines scalable.

For Inkjet based technologies - build the printheads for the materials. As an example, printheads for high viscosity materials. Using printheads that were designed for 2D inks are limiting the material properties.

And last but not least: ALL AM machines should be true IIoT capable. They must be connected devices which can easily interface with ERP systems in factories etc. This naturally includes complying with cybersecurity standards.

Again, none of this is trivial. But my belief and experience is that it can be done. These developments will take AM to where we dream it to be.

It would be great to hear more ideas.

P.S.

in the picture: AI generated "future manufacturing machine"...