SlideShare a Scribd company logo
1 of 11
1
Introduction
3D Printing Technology has become an industry revolution challenging risk mangement and insurance
underwriting. This once future technology to reproduce virtually any type of end product imaginable is
now a reality.
From initial prototype modeling of various types (and end uses) of equipment and machine parts to the
production of food products, products for artists, designers, architects as well as medical devices,
including personalized implantable devicesand prosthetics 3D Printing technology has developed at a
rate which is challenging risk management and insurance underwriting.
Information provided in this document explains how 3D printing technology developed to where it is today,
the technical aspects of 3D printing and provides additional information and guidance to assist with risk
management solutions and insurance underwriting.
3D printing or additive manufacturing is the process of fabricating 3-dimensional objects in just about any shape
from a digital model. This is a content-to-print solution that typically will include the 3D printers, print materials and
on-demand custom parts services for both professionals and consumers. The technology allows for creative
content development and design productivity tools through stereolithography (SLA, printers, selective laser
sintering (SLS) printers, multi-jet modeling (MJM) printers, film transfer imaging (FTI) printers, selective laser
melting (SLM) printers and plastic jet printers (PJP).
The additive process unlike traditional manufacturing with it’s subtractive process involves the successive layering
of material to reproduce the digital model. The term additive manufacturing refers to technologies that create
objects through sequential layering. Objects that are manufactured additively can be used anywhere throughout
the product life cycle, from pre-production (i.e. rapid prototyping) to full-scale production (i.e. rapid manufacturing)
in addition to tooling applications and post-production customization.
Some additive manufacturing techniques are capable of using multiple materials in the course of constructing
parts. Some are able to print in multiple colors and color combinations simultaneously. Some also utilize supports
when building. Supports are removable or dissolvable upon completion of the print and are used to support
overhanging features during construction.
The 3D model is created using computer aided design or 3D scanners which send a digital image in the form of an
STL electronic file to the printer. Traditional manufacturing subtracts material (cutting, edging, sawing, drilling) to
remove material to create an object whereby 3D printing adds material to create the desired object.
While 3D printing technology has been around since the 1980s, it was not until the early 2010s that the printers
became widely available commercially. The first working 3D printer was created in 1984 by Chuck Hull of 3D
Systems Corp. Today there are consumer, commercial, and industrial printers. Initially the printers were used to
develop product prototypes; saving R&D costs and resources to bring products to market. Today they are being
used to create finished products in architecture, consumer products, construction, industrial design, automotive,
aerospace, food, engineering, biotechnology, fashion and other industries.
Technical Reference
3D Printing Technology
2
The current slow print speed of 3D printers limits their use for mass production. To reduce this overhead, several
fused filament machines now offer multiple extruder heads. These can be used to print in multiple colors with
different polymers or to make multiple prints simultaneously. This increases their overall print speed during multiple
instance production while requiring less capital cost than duplicate machines since they can share a single
controller.
With the expiration of the patent on these technologies there is now a large open-source development community
as well as commercial and do-it-yourself variants. This has led to orders of magnitude price drops since this
technology's creation opening up the consumer market and other applications such as food-grade products. The
cost of 3D printers has decreased dramatically since about 2010 with machines that used to cost $20,000 now
costing less than $1,000.
Since most people are not CAD professionals they have to use third party designs. 3D Printing marketplaces are
the largest sources of 3D printable designs and it is believed that they will dominate the market of 3D printable
objects.
3D Printing Marketplaces are a combination of file sharing websites with or without a built in e-commerce
capability. Designers upload suitable files for 3D printing while other users buy or freely download the uploaded
files for printing. The marketplaces facilitate the account management, infrastructure, server resources and
guarantees safe settlement of payments (e-commerce). Some of the marketplaces also offer additional services
such as 3D printing on demand, location of commercial 3D print shops, associated software for model rendering
and dynamic viewing of items using packages such as sketchfab.
Some of them like Thingiverse are dedicated to free sharing of 3D printable files. Others such as Shapeways offer
a 3D printing service for objects which have been provided for sale by designers. Another category are websites
such as by Threeding and 3DprintWise which offer free and commercial exchange of digital 3D printable files for
use on 3D printers but do not directly include 3D printing services themselves.
Examples include:
 Engineers, jewelry makers and architects developing prototypes and turning out finished products .
 Consumers are soon able to create complete garments, meals, cookies and cupcakes, self-modeled
bobble dolls, new sponges and other replacement products for home use bypassing the traditional
purchasing models.
 Big Box retail stores such as Target and Home Depot are installing 3D systems in their stores to enhance
sales changing their operations from strictly a retailer to a manufacturer where the customer is doing the
manufacturing. Newer retail printers will be able to produce a part or model up to 5” cubed .
 Systems are being used for reconstructive surgical consultation using imaging, surgical software and 3D
printing using biocompatible polymer and titanium powder and liquid photopolymer resin to produce
patient-specific implantable medical devices. This allows for the achievement of improved outcomes from
traditional reconstructive surgery to include surgical and dental needs (implantable jaw, facial bones, etc.)
as well as spinal and hip implants ( also the potential for replacing traditional hip replacement technology ).
In this process layers of living cells are deposited onto a gel medium or sugar matrix and slowly built up to
form three-dimensional structures including vascular systems. Bioprinting of human tissues will accelerate
the preclinical drug testing and discovery process enabling treatments to be created more quickly and at
lower cost.
 3D printing technology has been used to create entire concrete residential homes.
 Biotechnologists are researching the use of human cellular lab cultures and 3D printing to produce human
organs which would solve the shortage of organs for transplantation and enable the production of patient-
specific organs which are not subject to rejection.
 3D printing has spread into the world of clothing with fashion designers experimenting with 3D-printed
bikinis, shoes and dresses.
 Rocket parts built using this technology have passed NASA firing tests. In July 2013 two rocket engine
3
injectors performed as well as traditionally constructed parts during hot-fire tests which exposed them to
temperatures approaching 6,000 degrees Fahrenheit (3,316 degrees Celsius) and extreme pressures.
NASA is also preparing to launch a 3D printer into space; the agency hopes to demonstrate that with the
printer making spare parts on the fly astronauts need not carry large loads of spares with them.
 Firearms - The U.S. Department of Homeland Security and the Joint Regional Intelligence Center released
a memo stating that "significant advances in three-dimensional (3D) printing capabilities, availability of free
digital 3D printable files for firearms components and difficulty regulating file sharing may present public
safety risks from unqualified gun seekers who obtain or manufacture 3D printed guns," and that "proposed
legislation to ban 3D printing of weapons may deter but cannot completely prevent their production”. Even
if the practice is prohibited by new legislation online distribution of these 3D printable files will be as difficult
to control as any other illegally traded music, movie or software files."
Internationally where gun controls are generally tighter than in the United States some commentators have said
the impact may be more strongly felt as alternative firearms are not as easily obtainable. Downloads of the
plans, "[design] a working plastic gun that could be downloaded and reproduced by anybody with a 3D printer"
from the UK, Germany, Spain, and Brazil were especially heavy and in demand.
Discussion
These printing hardware and software systems allow for the creation of a single object at a cost equal to a full
production cycle and run with simple and easy customization without the factory or assembly line. Each piece is a
one-off customized piece allowing for the modeling and production of almost anything one can imagine. Using
traditional reduction manufacturing methods of large and complex 3D printed objects one can achieve finishing
techniques to create exact copies of large and complex finished objects.
The 3D printing process uses a variety of materials to create the object including various thermoplastic powders
and liquids, metal alloys, rubber, clay, plaster and photopolymers. Nanotechnology can also be used to alter the
charactieristics of 3D printable materials. Thus combining two new technologies an object can be readily created
with specific physical or chemical characteristics. A large number of additive processes are now available. They
differ in the way layers are deposited to create parts and in the materials that can be used.
Regardless of the material selected they all have to be heated and dependent upon the process used some may
be melted to be able to layer together the model into a finished object. Dependent upon the material used and the
desired object determines the 3D process used which may include:
• Selective laser melting
• Direct metal laser sintering
• Select laser sintering
• Fused deposition
• Stereolithography
• Laminated object manufacturing
The current slow print speed of 3D printers limits their use for mass production. To reduce this overhead several
fused filament machines now offer multiple extruder heads. These can be used to print in multiple colors with
different polymers or to make multiple prints simultaneously.
4
Type Technologies Materials
Extrusion Fused deposition
modeling (FDM)
Thermoplastics (e.g. PLA, ABS), HDPE, eutectic metals, edible
materials, Rubber (Sugru), Modelling clay, Plasticine, RTV
silicone, Porcelain, Metal clay (including Precious Metal Clay)
Wire Electron Beam Freeform
Fabrication (EBF3)
Almost any metal alloy
Granular Direct metal laser
sintering (DMLS)
Almost any metal alloy
Electron-beam melting
(EBM)
Titanium alloys
Selective laser melting
(SLM)
Titanium alloys, Cobalt Chrome alloys, Stainless Steel,
Aluminium
Selective heat sintering
(SHS) [21]
Thermoplastic powder
Selective laser sintering
(SLS)
Thermoplastics, metal powders, ceramic powders
Powder bed and
inkjet head 3D
printing
Plaster-based 3D
printing (PP)
Plaster
Laminated Laminated object
manufacturing (LOM)
Paper, metal foil, plastic film
Light polymerised Stereolithography (SLA) photopolymer
Digital Light Processing
(DLP)
photopolymer
Extrusion deposition:
Example - Fused deposition modeling: 1 – nozzle ejecting molten plastic,
2 – deposited material (modeled part), 3 – controlled movable table.
In fused deposition modeling the model or part is produced by extruding small beads of material which harden
immediately to form layers. A thermoplastic filament or metal wire that is wound on a coil is unreeled to supply
material to an extrusion nozzle head. The nozzle head heats the material and turns the flow on and off. Typically
stepper motors or servo motors are employed to move the extrusion head and adjust the flow and the head can be
moved in both horizontal and vertical directions. Control of this mechanism is typically done by a computer-aided
manufacturing (CAM) software package running on a microcontroller. FDM usually cannot produce stalactite-like
structures, since they would be unsupported during the build.
Various polymers are used, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid
(PLA), high density polyethylene (HDPE), PC/ABS, and polyphenylsulfone (PPSU). In general the polymer is in the
form of a filament fabricated from virgin resins. Multiple projects in the open-source community exist that are aimed
at processing post-consumer plastic waste into filament.
5
Granular materials binding:
The CandyFab granular printing system uses heated air and granulated sugar to produce food-grade art objects.
Another 3D printing approach is the selective fusing of materials in a granular bed. The technique fuses parts of
the layer and then moves the working area downwards adding another layer of granules and repeating the process
until the piece has built up. This process uses the unfused media to support overhangs and thin walls in the part
being produced, which reduces the need for temporary auxiliary supports for the piece. A laser is typically used to
sinter the media into a solid. Examples include selective laser sintering (SLS) with both metals and polymers (e.g.
PA, PA-GF, Rigid GF, PEEK, PS, Alumide, Carbonmide, elastomers) and direct metal laser sintering (DMLS).
Selective Laser Melting (SLM) does not use sintering for the fusion of powder granules but will completely melt the
powder using a high-energy laser to create fully dense materials in a layer-wise method with similar mechanical
properties to conventional manufactured metals.
Electron beam melting (EBM) is a similar type of additive manufacturing technology for metal parts (e.g. titanium
alloys). EBM manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum.
Unlike metal sintering techniques that operate below melting point EBM parts are fully dense, void-free and very
strong.
Another method consists of an inkjet 3D printing system. The printer creates the model one layer at a time by
spreading a layer of powder (plaster, or resins) and printing a binder in the cross-section of the part using an inkjet-
like process. This is repeated until every layer has been printed. This technology allows the printing of full color
prototypes, overhangs, and elastomer parts. The strength of bonded powder prints can be enhanced with wax or
thermoset polymer impregnation.
Lamination:
In some printers, paper can be used as the build material, resulting in a lower cost to print. This process can now
use ordinary sheets of office paper, a Tungsten carbide blade to cut the shape, and selective deposition of
adhesive and pressure to bond the prototype. There are also a number of companies selling printers that print
laminated objects using thin plastic and metal sheets.
Photopolymerization
Example - Stereolithography apparatus
Photopolymerization is primarily used in stereolithography (SLA) to produce a solid part from a liquid. In Digital
Light Processing (DLP), a vat of liquid polymer is exposed to light from a DLP projector under safelight conditions.
The exposed liquid polymer hardens. The build plate then moves down in small increments and the liquid polymer
is again exposed to light. The process repeats until the model has been built. The liquid polymer is then drained
from the vat leaving the solid model.
6
Inkjet printer systems spray photopolymer materials onto a build tray in ultra-thin layers (between 16 and 30 µm)
until the part is completed. Each photopolymer layer is cured with UV light after it is jetted producing fully cured
models that can be handled and used immediately without post-curing. The gel-like support material, which is
designed to support complicated geometries, is removed by hand and water jetting. It is also suitable for
elastomers.
Ultra-small features can be made with the 3D microfabrication technique used in multiphoton photopolymerization.
This approach traces the desired 3D object in a block of gel using a focused laser. Due to the nonlinear nature of
photoexcitation, the gel is cured to a solid only in the places where the laser was focused and the remaining gel is
then washed away. Feature sizes of under 100 nm are easily produced, as well as complex structures with moving
and interlocked parts. Yet another approach uses a synthetic resin that is solidified using LEDs.
Mask-image-projection-based stereolithography
In this technique a 3D digital model is sliced by a set of horizontal planes. Each slice is converted into a two-
dimensional mask image. The mask image is then projected onto a photocurable liquid resin surface and light is
projected onto the resin to cure it in the shape of the layer. In research systems the light is projected from below
allowing the resin to be quickly spread into uniform thin layers reducing production time from hours to minutes. The
technique has been used to create objects composed of multiple materials that cure at different rates.
Risk Guidance
The coverages most significantly impacted are General Liability, Product Liability and Worker’s Compensation.
Other coveages impacted may include Errors & Omissions, Product Recall, Construction Defect and others. 3D-
printed products are treated the same as any other new operation that poses new risks.
 Instead of underwriting a product or production exposure insurance carriers are now underwriting multiple
exposures as well as potentially unknown product applications that will continue to evolve. An example would
be the evolution of nano-technology based products.
The 3D printing process presents exposures which may include heat sources and toxic fumes being emitted from
melting and decomposition. There are also equipment exposures not unlike traditional manufacturing equipment
such as machine guarding exposures.
Defective and counterfeit product exposures, among others, will arise for all participants along the manufacturing
continuum industry experts said. As long as an individual is in possession of the proper printer, material and digital
file they can theoretically replicate a product designed by others. Thus the risk of counterfeit and potentially
defective product risks increase too.
The above material exposures as well as the sourcing of the materials used present a significant exposure.
 Contaminated, defective or the incorrect materials used could create a defective product. For these reasons
the materials used may be an overall greater potential liability exposure than those presented by the 3D
printer. Similar to traditional manufacturing failure to determine the material used and source of material
ordered increases the risk of product failure/contamination.
There is also a risk of weapons and other prohibited products being produced which is challenging security experts
to create new security technologies to replace traditional security scanners. Newer security equipment sniffs -out
the presence of chemicals rather than look for the finished product.
In addition to the inherent and potential 3D printing exposures there are printer-specific exposures dependent upon
the application. 3D printer manufacturers sell printers and supplies for a wide range of applications. A traditional
industrial machine manufacturer may produce machines for cutting wood or steel. The 3D printer manufacturer
produces and sells equipment for creating solid objects, medical products, clothes, food and other finished
products likely unknown to the seller with differing technologies and exposures to loss.
The current intellectual property legislation in the developed countries does not explicitly regulate 3D printing. This
creates numerous questions about the legal statute status of the 3D printing marketplaces and the technology
itself. Some analysts predict that 3D printing marketplaces will be "the next Napster" in terms of legal complexity.
There is also the unknown as to how a loss will be defined in a court of law and how a loss would be apportioned
to those involved in the entire chain of getting the printed product to market and many legal regimes, including
7
patents, industrial design rights, copyright and trademark could apply. Any of the mentioned legal regimes may
prohibit the distribution of the designs used in 3d printing, or the distribution or sale of the printed item. At this time
there is no case law for 3D Printing losses.
Although the challenges and potential risks are many there are some basic guidelines which can be used
to help reduce the overall risk both in risk assessment and risk improvement.
First, the team of the underwriters, risk engineers and brokers should first assess the company’s risk management
profile and risk appetite. In particular the company’s production, research and development teams should be
integrated on a regular basis with risk management.
Consider the production environment and output of the company; if 3D printing enables production of, say, just 100
hip implants or 100 hearing aids, such work will generally take place outside of a traditional mass -production
factories and may not be subject to government regulation and inspection such as from OSHA, FDA, EPA, etc. The
technologies emerging risks may include unregulated manufacturing.
Multiple projects in the open-source community also exist that are aimed at processing post-consumer plastic
waste into filament. These involve machines to shred and extrude the plastic material into filament and if included
in the work environment may pose additional non-traditional exposures to include property loss potentials and the
issue of plastics fire-loading and control needs.
Supply chain management is critical if a 3D printer is used to replicate a cupcake, the manufacturer should be as
careful of contaminants in the mix as traditional bakers would need to be. This would involve an assessment of an
organization’s quality control systems and storage and handling of raw materials, work-in-progress and finished
goods through shipping and delivery.
3D printing increases the risk of counterfeit products. So long as a person has access to a 3D printer and a
digitized product counterfeits can be produced. Using inferior material there is the risk the counterfeit product will
be of inferior quality too and not match the anticipated specifications for use of an original. Because of the reduced
time needed to produce products the risk of counterfeit products being placed into the stream of commerce on a
rapid basis could increase. Because of this risk protecting proprietary product software is very important to prevent
“identical” but potentially defective products from being sold.
Additional Guidance:
Because of the complexity of this risk it should be assessed by a Risk Engineer who has knowledge of 3D printing
technology. This may be determined through the risk engineering Q2P database accessible through your portfolio
executive. The guidance offered below is not exhaustive in scope and may or may not be applicable depending on
the risks of a user versus a manufacturer of the 3D Printing technology.
 It is imperative that Risk Engineering be provided risk contacts that are intimately familiar with the printers
produced or sold as well as their applications; preferably through the operations, QA, finance and risk
management departments.
 Does the printer manufacturer have adequate contractual risk transfer controls from the raw material and
component suppliers?
 Does the risk have adequate contractual risk transfer controls from the suppliers of the materials to be
used?
 Does the risk have adequate contractual risk transfer controls with the purchasers/clients?
 Are changes in contract requirements, especially requirements for hold harmless, additional insured status
reviewed by Legal Staff.
 Do they install their product?
 Contingent Business Income Exposure - Do they manufacture all parts used in the printers? Do they have
multiple suppliers for component parts?
 What software / CAD do they design? Do they purchase Professional Liability to cover the software /
CAD? Do they perform any inside QC or third party testing on the raw materials to insure they are the
materials purchased and of the quality certified?
 If they produce the materials what kinds of in-process and finished product quality controls are in place?
8
 If the risk sells 3D printing material do they provide their customers with MSDS Sheets?
 When evaluating materials do you include an assessment of material/ingredient toxicity?
 Are there any new applications in the near future?
 Are there any new printers in development for new applications?
 Do you have any licensing agreements or other contracts with others to co-produce materials, products,
etc?
 Have you made any acquisitions of related firms?
Conclusion
3D Printing has the potential to radically alter both the business and personal lives of millions of people in the
coming years and create significant impacts on how we work, live and plan. It may even kick off the next industrial
revolution.
1. Environmental impacts
It is readily known that traditional manufacturing is often wasteful and dirty. In many ways 3D printing can lessens
that waste and the carbon footprint manufacturing has on the Earth although it does tend to be energy greedy.
 Fewer wasted materials: Only the raw materials needed to create the object—be it plastic filament, metal
powder, or carbon fiber—are used. Using biodegradable PLA plastic filament in fused deposition modeling
printers like MakerBot is a good start and example.
 Possibility of longer life spans for products: Individual product parts can be replaced with 3D printing so
the entire product doesn't have to be discarded and replaced each time it malfunctions, improving our
disposable life-styles and product qualities.
 Less transport: Products often have to travel across multiple continents to get to their final destination. With
3D printing production and assembly can be local with only raw materials possibly being the only things
shipped and should take less space, weight and transport cost. Some raw materials are also reusable or
recyclables and readily available at hand.
 Fewer unsold products: If a company makes a product on spec orders or to fill potential future orders the
ones that are discontinued or not sold often end up piling up in landfills or sold at deep discounts. With 3D
printing this can be improved upon as it is a by demand production process.
It should be noted that research shows 3D printers themselves have inefficiencies that make them less
environmentally friendly. An inkjet 3D printer wastes 40 to 45 percent of its ink. If a printer is not turned off or
unplugged it can use an excessive amount of electricity known as the electricity vampire syndrome. These are
issues for future resolution for the manufacturers.
2. Creating a new art medium
3D Printing is opening up the world to the artisanal movement and allowing the creation of art previously un-
makeable. They also allow for the recreation of historical and architectural art and pieces not available to everyone,
helping museum curators with their inventories. This can extend to the recreation of the Budda statues destroyed
by the Taliban in Afganistan to Van Gogh paintings.
3. Innovation in education
One manufacturer, MakerBot, announced a crowd funded plan to get a 3D printer into every school in America. "It
can change the whole paradigm of how our children will see innovation and manufacturing in America," MakerBot
CEO Bre Pettis said in the announcement. The company also recently announced a plan to do the same in certain
colleges and universities. Starting with State University of New York at New Palz, the centers are equipped with
9
30-3D printers, along with several 3D scanners to help train engineers, architects and artists to increase
motivation and increase motivation for growth in the industry.
4. 3D printing in zero-gravity
NASA and the defense industries are extremely excited about the technologies’ potentials. Due to the critical need
for weight reduction and payload management it is cheaper, easier and of less weight to haul raw materials into
space and create the needed parts and tools while in space. It might also allow for printing of food in space rather
than hauled freeze dried products. It can also help accelerate the building of parts for the International Space
Station. A partnership has developed with NASA's Marshall Space Flight Center to launch the first 3D printer in
space. It will manufacture parts in zero-gravity and the hope is to make space missions more self-sufficient.
5. The Revolutionizing mass manufacturing
Mass production is the biggest challenge in 3D printing as it was not designed for that type of production initially.
The adoption of large-scale printers and rapidly evolving technology to produce parts faster allows for the potential
for the technology to change traditional manufacturing in many industries:
 Food: Anything that exists in liquid or powder form may be 3D printed. Food is one of the next big
conversations on opportunities and controls.
 Military: The machinery for the military is often customized and replacements must be made quickly. A 3D
gun has already been printed, so it's only a matter of time before the technology catches on in this indus try.
 Electronics: The size, shape, and materials used to make electronics make this industry a natural candidate
for 3D printing.
 Toys: Home 3D printers and open source design software will change the way children create and play with
toys.
 Automotive: This industry is already utilizing the technology—Ford reportedly uses 3D printing to test parts.
High-end and smaller auto companies will benefit first.
6. Changing medicine and healthcare industries
Bioprinting is one of the fastest-growing areas of 3D printing with the using inkjet-style printers to make living
tissue. Organovo, a Chinese firm is one of the most well-known company who does this and who plans to
commercialize 3D-printed liver tissue in the very near future. They have also partnered with the National Eye
Institute and the National Center for Advancing Translational Sciences to print eye tissue.
Researchers at Human Methodist Research Institute said they have created a more efficient way to create cells
allowing for 100 percent of the cells to live instead of the 50 to 80 percent that normally survive using current
technology.
All of this will raise questions about the development of complex organs and will engage societies in a debate of
moral, ethical and political concerns.
Most recently an American based team of scientists have 3D printed the severed ear of late painter Vincent van
Gogh out of living tissue, creating a living and functioning replica of the self-severed ear of the artist.
7. Transforming the home
As almost all of us love new technology and especially convenience and with home 3D printers becoming smaller
and more affordable (MakerBot's smallest printer is just over $1,300) people will want to print custom jewelry,
household goods, toys and tools to whatever size, shape, or color they want. They will also be able to print and
make replacement parts right at home rather than ordering them and waiting for them to be shipped rapeidly.
Home 3D printing could evolve into a $70 billion industry per year by 2030. Think how this will impact the
replacement parts industry for all areas of society.
10
8. Reaching disconnected markets worldwide
Developing countries are often partially or completely disconnected from global supply chains for even the most
basic products. 3D printing has the ability to bring them into the supply chain. The best example of this is Austin-
based startup re: 3D, which had a hugely successful Kickstarter campaign last May with Gigabot, an industrial-
sized, affordable printer.
The Gigabot will be used for many of the projects in Chile, like 3D design internships, manufacturing clothing and
experimenting with printing using recyclable materials. Another way 3D printing can help developing countries is
through partnerships with 3D printing researchers such as many countries in the developing world are in dire need
of prosthetic limbs but do not have access to the technology or the education required to make their own. A
Canadian professor is creating a way to make a prosthetic limb that is about 80 percent as good as one that could
be made by hand. The lab is sending the prosthetics to disabled Ugandans.
9. Impacts on the global economy
The 3D printing industry will have far-reaching effects on the global economy. The McKinsey Global Institute
recently released a report that said 3D printing will cause major disruptions in the global economy by 2025
predicting that it will bring about new product development cycles as the systems become cheaper. More and more
companies will adopt the technology and product creation will focus more than ever on client feedback and
customer-centered design and customization. The industry is also reducing the cost of entry into markets allowing
very niche businesses to develop.
China is investing heavily in the technology to rival this rapid growth rate in the U.S. and Europe. In June 2013, the
country announced a gigantic 3D printer they claimed was the world's largest at the time. t's not clear what impact
the technology will have on the economy but it could give China a competitive edge in domestic production and
technological advancement. With its localized production the technology will significantly affect China's current
large-scale manufacturing industries.
10. Intellectual property considerations
Sharing 3D printing schematics on open websites like Thingiverse and Shapeways with free designs are bound to
cause issues with intellectual property as 3D printing becomes more mainstream. The current majority of current
designs are unpatented, allowing them to be copied repeatedly and sold by anyone. Expensive or designer objects
can also be reverse-engineered or replicated and sold at a cheaper price.
While some of the more established companies are starting to go after users of these sites arguing that they are
infringing on copyright or violating intellectual property laws most of these users are building upon original designs,
changing the base designs, improving upon them, making them better, or localizing the products to better reflect
local population needs and desires. Think of the third-world applications. The industry will have to figure out how to
make sure large corporations react appropriately and legally to entrepreneurs and open-software designers in their
fight to protect company copyright laws.
Bill Enos, CRM, MESH
Senior Risk Engineering Consultant - Zurich NA Risk Engineering
(803) 396-8166 office
(803) 207-9761 cell
Bill.Enos@zurichna.com
11
References
Research@IDTechEx.com
http://www.publicknowledge.org/blog/3
d-printing-non-engineers-rapidly-
prototyping
Excell, Jon. "The rise of additive
manufacturing".The engineer.
Retrieved 2013-10-30.
"3D Printing:What You Need to Know".
PCMag.com. Retrieved 2013-10-30.
"3D printing:3D printing scales up".
The Economist.2013-09-07.
Zelinski,Peter (2013-11-08),"Hybrid
machine combines milling and additive
manufacturing",Modern Machine Shop.
Zelinski,Peter (2014-02-21),"The
capacity to build 3D metal forms is a
retrofittable option for subtractive CNC
machine tools",Modern Machine Shop
Additive Manufacturing supplement.
Kelly, Heather (July 31, 2013). "Study:
At-home 3D printing could save
consumers 'thousands'".CNN.
Freedman,David H. "Layer By Layer."
TechnologyReview 115.1 (2012): 50–
53. Academic Search Premier.Web. 26
July 2013.
Jane Bird (2012-08-08)."Exploring the
3D printing opportunity". The Financial
Times.
www.3ders.org (2012-09-25)."Casting
aluminum parts directlyfrom 3D printed
PLA parts". 3ders.org
3D Printing:Challenges and
Opportunities for International
Relations".Transcript.Council on
Foreign Relations.October 23, 2013
Cubify - Express Yourselfin 3D".
myrobotnation.com
3D-printed sugar network to help grow
artificial liver", BBC, 2 July 2012.
3D Human Tissues | Organovo".
organovo.com
Keith Perry (12 March 2014)."Man
makes surgical historyafter having his
shattered face rebuiltusing 3D printed
parts". London:The Daily Telegraph
The World’s First3D-Printed Building
Will Arrive In 2014".TechCrunch.2012-
01-20
3D Printing:Challenges and
Opportunities for International
Relations".Transcript.Council on
Foreign Relations.October 23, 2013
Analysis:3D-Printing Spare Human
Parts; Ears and Jaws Already, Livers
Coming Up ; Need an Organ? Just
Print It".
Globaleconomicanalysis.blogspot.co.uk
. 2013-08-18
Clive Thompson on 3-D Printing’s
Legal Morass Wired,Clive Thompson
05.30.12
Poeter, Damon (2012-08-24)."Could a
'Printable Gun' Change the World?".
PC Magazine
Homeland Securitybulletin warns 3D-
printed guns maybe 'impossible'to
stop". Fox News.2013-05-23
Ball, James (10 May 2013)."US
governmentattempts to stifle 3D-printer
gun designs will ultimatelyfail"
3D Printing Industry (3DPI)
THRE3D
Editor In Chief, physics.org,Institute of
Physics,76 Portland Place,London,
W1B 1NT
Richard A. D’Aveni is the Bakala
Professor ofStrategy at Dartmouth’s
Tuck School of Business and the
author of Strategic Capitalism
(McGraw-Hill, 2012).
ExplainingTheFuture.com and
Christopher Barnatt,3D Printing

More Related Content

What's hot

Future 3D Print Fashion-Zara (no appendix)
Future 3D Print Fashion-Zara (no appendix)Future 3D Print Fashion-Zara (no appendix)
Future 3D Print Fashion-Zara (no appendix)Min Kao
 
3D Printing: Edge Manufacturing - Executive Overview
3D Printing: Edge Manufacturing - Executive Overview3D Printing: Edge Manufacturing - Executive Overview
3D Printing: Edge Manufacturing - Executive OverviewPatrick Seaman
 
3d printing technology
3d printing technology3d printing technology
3d printing technologyPrachi Agarwal
 
Stratasys_Strategic Analysis
Stratasys_Strategic AnalysisStratasys_Strategic Analysis
Stratasys_Strategic AnalysisJohn McGinn
 
3D Printing and Affordable Healthcare
3D Printing and Affordable Healthcare3D Printing and Affordable Healthcare
3D Printing and Affordable HealthcareICFAIEDGE
 
Seminar report 3d printing
Seminar report 3d printingSeminar report 3d printing
Seminar report 3d printingUmang Dadheech
 
Marvelous 3D Printing Trends Of 2019
Marvelous 3D Printing Trends Of 2019Marvelous 3D Printing Trends Of 2019
Marvelous 3D Printing Trends Of 2019Animation Kolkata
 
Misconceptions about decentralized 3 d printing challenging traditional manuf...
Misconceptions about decentralized 3 d printing challenging traditional manuf...Misconceptions about decentralized 3 d printing challenging traditional manuf...
Misconceptions about decentralized 3 d printing challenging traditional manuf...Abhishek Kapoor
 
3D printing market - a global study (2014-2022)
3D printing market - a global study (2014-2022)3D printing market - a global study (2014-2022)
3D printing market - a global study (2014-2022)BIS Research
 
(updated) How 3D printers will change the supply chain management in I4.0
(updated) How 3D printers will change the supply chain management in I4.0(updated) How 3D printers will change the supply chain management in I4.0
(updated) How 3D printers will change the supply chain management in I4.0Diogo Quental
 
3D PRINTING OF PHARMACEUTICALS
3D PRINTING OF PHARMACEUTICALS3D PRINTING OF PHARMACEUTICALS
3D PRINTING OF PHARMACEUTICALSSayed Shakil Ahmed
 
IRJET- 3D Printer for Printing Biological Structures
IRJET- 3D Printer for Printing Biological StructuresIRJET- 3D Printer for Printing Biological Structures
IRJET- 3D Printer for Printing Biological StructuresIRJET Journal
 
State of 3D Printing 2017
State of 3D Printing 2017State of 3D Printing 2017
State of 3D Printing 2017Diogo Quental
 
3D Printing Executive Overview
3D Printing Executive Overview  3D Printing Executive Overview
3D Printing Executive Overview Patrick Seaman
 
3 D pharmaceutical printing
3 D pharmaceutical printing3 D pharmaceutical printing
3 D pharmaceutical printingDivyaSharma802
 

What's hot (19)

3 d printer의 현재와 미래
3 d printer의 현재와 미래3 d printer의 현재와 미래
3 d printer의 현재와 미래
 
Future 3D Print Fashion-Zara (no appendix)
Future 3D Print Fashion-Zara (no appendix)Future 3D Print Fashion-Zara (no appendix)
Future 3D Print Fashion-Zara (no appendix)
 
3D Printing: Edge Manufacturing - Executive Overview
3D Printing: Edge Manufacturing - Executive Overview3D Printing: Edge Manufacturing - Executive Overview
3D Printing: Edge Manufacturing - Executive Overview
 
Bryan So
Bryan SoBryan So
Bryan So
 
3d printing technology
3d printing technology3d printing technology
3d printing technology
 
Stratasys_Strategic Analysis
Stratasys_Strategic AnalysisStratasys_Strategic Analysis
Stratasys_Strategic Analysis
 
3D Printing and Affordable Healthcare
3D Printing and Affordable Healthcare3D Printing and Affordable Healthcare
3D Printing and Affordable Healthcare
 
Seminar report 3d printing
Seminar report 3d printingSeminar report 3d printing
Seminar report 3d printing
 
Marvelous 3D Printing Trends Of 2019
Marvelous 3D Printing Trends Of 2019Marvelous 3D Printing Trends Of 2019
Marvelous 3D Printing Trends Of 2019
 
Misconceptions about decentralized 3 d printing challenging traditional manuf...
Misconceptions about decentralized 3 d printing challenging traditional manuf...Misconceptions about decentralized 3 d printing challenging traditional manuf...
Misconceptions about decentralized 3 d printing challenging traditional manuf...
 
3D printing market - a global study (2014-2022)
3D printing market - a global study (2014-2022)3D printing market - a global study (2014-2022)
3D printing market - a global study (2014-2022)
 
(updated) How 3D printers will change the supply chain management in I4.0
(updated) How 3D printers will change the supply chain management in I4.0(updated) How 3D printers will change the supply chain management in I4.0
(updated) How 3D printers will change the supply chain management in I4.0
 
3D PRINTING OF PHARMACEUTICALS
3D PRINTING OF PHARMACEUTICALS3D PRINTING OF PHARMACEUTICALS
3D PRINTING OF PHARMACEUTICALS
 
IRJET- 3D Printer for Printing Biological Structures
IRJET- 3D Printer for Printing Biological StructuresIRJET- 3D Printer for Printing Biological Structures
IRJET- 3D Printer for Printing Biological Structures
 
3 d printing revised
3 d printing revised3 d printing revised
3 d printing revised
 
State of 3D Printing 2017
State of 3D Printing 2017State of 3D Printing 2017
State of 3D Printing 2017
 
3D printing of Medical Implants
3D printing of Medical Implants3D printing of Medical Implants
3D printing of Medical Implants
 
3D Printing Executive Overview
3D Printing Executive Overview  3D Printing Executive Overview
3D Printing Executive Overview
 
3 D pharmaceutical printing
3 D pharmaceutical printing3 D pharmaceutical printing
3 D pharmaceutical printing
 

Similar to 3D Printing Technology White Paper June 22 2014 Final

An indepth analysis(3d printers)
An indepth analysis(3d printers)An indepth analysis(3d printers)
An indepth analysis(3d printers)Daisy Sowah
 
3D Printing in Business An Overview
3D Printing in Business An Overview3D Printing in Business An Overview
3D Printing in Business An Overviewijtsrd
 
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...Jeffrey Ito
 
Fourth revolution through 3 d technology
Fourth revolution through 3 d technologyFourth revolution through 3 d technology
Fourth revolution through 3 d technologyM S Siddiqui
 
BA 453 Business Strategy & Planning Spring 2014 1 .docx
BA 453 Business Strategy & Planning  Spring 2014 1   .docxBA 453 Business Strategy & Planning  Spring 2014 1   .docx
BA 453 Business Strategy & Planning Spring 2014 1 .docxikirkton
 
Innovation Excellence Weekly - Issue 20
Innovation Excellence Weekly - Issue 20Innovation Excellence Weekly - Issue 20
Innovation Excellence Weekly - Issue 20Innovation Excellence
 
Technology virginia gonzález
Technology  virginia gonzálezTechnology  virginia gonzález
Technology virginia gonzálezVegaGmezGonzlez
 
The emerging world of 3 d printing
The emerging world of 3 d printingThe emerging world of 3 d printing
The emerging world of 3 d printingVivek Bhurat
 

Similar to 3D Printing Technology White Paper June 22 2014 Final (15)

An indepth analysis(3d printers)
An indepth analysis(3d printers)An indepth analysis(3d printers)
An indepth analysis(3d printers)
 
3d printing
3d printing3d printing
3d printing
 
3D Printing in Business An Overview
3D Printing in Business An Overview3D Printing in Business An Overview
3D Printing in Business An Overview
 
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...
How To Make Money With 3D Printing: An Overview Of The 3D Printing Industry A...
 
The potential of 3D printing
The potential of 3D printingThe potential of 3D printing
The potential of 3D printing
 
3-D Printing
3-D Printing3-D Printing
3-D Printing
 
Task 2
Task 2Task 2
Task 2
 
Fourth revolution through 3 d technology
Fourth revolution through 3 d technologyFourth revolution through 3 d technology
Fourth revolution through 3 d technology
 
3 d printing
3 d printing3 d printing
3 d printing
 
BA 453 Business Strategy & Planning Spring 2014 1 .docx
BA 453 Business Strategy & Planning  Spring 2014 1   .docxBA 453 Business Strategy & Planning  Spring 2014 1   .docx
BA 453 Business Strategy & Planning Spring 2014 1 .docx
 
Innovation Excellence Weekly - Issue 20
Innovation Excellence Weekly - Issue 20Innovation Excellence Weekly - Issue 20
Innovation Excellence Weekly - Issue 20
 
Technology virginia gonzález
Technology  virginia gonzálezTechnology  virginia gonzález
Technology virginia gonzález
 
3DPrinting Technologies
3DPrinting Technologies3DPrinting Technologies
3DPrinting Technologies
 
The emerging world of 3 d printing
The emerging world of 3 d printingThe emerging world of 3 d printing
The emerging world of 3 d printing
 
3D PRINTING
3D PRINTING3D PRINTING
3D PRINTING
 

3D Printing Technology White Paper June 22 2014 Final

  • 1. 1 Introduction 3D Printing Technology has become an industry revolution challenging risk mangement and insurance underwriting. This once future technology to reproduce virtually any type of end product imaginable is now a reality. From initial prototype modeling of various types (and end uses) of equipment and machine parts to the production of food products, products for artists, designers, architects as well as medical devices, including personalized implantable devicesand prosthetics 3D Printing technology has developed at a rate which is challenging risk management and insurance underwriting. Information provided in this document explains how 3D printing technology developed to where it is today, the technical aspects of 3D printing and provides additional information and guidance to assist with risk management solutions and insurance underwriting. 3D printing or additive manufacturing is the process of fabricating 3-dimensional objects in just about any shape from a digital model. This is a content-to-print solution that typically will include the 3D printers, print materials and on-demand custom parts services for both professionals and consumers. The technology allows for creative content development and design productivity tools through stereolithography (SLA, printers, selective laser sintering (SLS) printers, multi-jet modeling (MJM) printers, film transfer imaging (FTI) printers, selective laser melting (SLM) printers and plastic jet printers (PJP). The additive process unlike traditional manufacturing with it’s subtractive process involves the successive layering of material to reproduce the digital model. The term additive manufacturing refers to technologies that create objects through sequential layering. Objects that are manufactured additively can be used anywhere throughout the product life cycle, from pre-production (i.e. rapid prototyping) to full-scale production (i.e. rapid manufacturing) in addition to tooling applications and post-production customization. Some additive manufacturing techniques are capable of using multiple materials in the course of constructing parts. Some are able to print in multiple colors and color combinations simultaneously. Some also utilize supports when building. Supports are removable or dissolvable upon completion of the print and are used to support overhanging features during construction. The 3D model is created using computer aided design or 3D scanners which send a digital image in the form of an STL electronic file to the printer. Traditional manufacturing subtracts material (cutting, edging, sawing, drilling) to remove material to create an object whereby 3D printing adds material to create the desired object. While 3D printing technology has been around since the 1980s, it was not until the early 2010s that the printers became widely available commercially. The first working 3D printer was created in 1984 by Chuck Hull of 3D Systems Corp. Today there are consumer, commercial, and industrial printers. Initially the printers were used to develop product prototypes; saving R&D costs and resources to bring products to market. Today they are being used to create finished products in architecture, consumer products, construction, industrial design, automotive, aerospace, food, engineering, biotechnology, fashion and other industries. Technical Reference 3D Printing Technology
  • 2. 2 The current slow print speed of 3D printers limits their use for mass production. To reduce this overhead, several fused filament machines now offer multiple extruder heads. These can be used to print in multiple colors with different polymers or to make multiple prints simultaneously. This increases their overall print speed during multiple instance production while requiring less capital cost than duplicate machines since they can share a single controller. With the expiration of the patent on these technologies there is now a large open-source development community as well as commercial and do-it-yourself variants. This has led to orders of magnitude price drops since this technology's creation opening up the consumer market and other applications such as food-grade products. The cost of 3D printers has decreased dramatically since about 2010 with machines that used to cost $20,000 now costing less than $1,000. Since most people are not CAD professionals they have to use third party designs. 3D Printing marketplaces are the largest sources of 3D printable designs and it is believed that they will dominate the market of 3D printable objects. 3D Printing Marketplaces are a combination of file sharing websites with or without a built in e-commerce capability. Designers upload suitable files for 3D printing while other users buy or freely download the uploaded files for printing. The marketplaces facilitate the account management, infrastructure, server resources and guarantees safe settlement of payments (e-commerce). Some of the marketplaces also offer additional services such as 3D printing on demand, location of commercial 3D print shops, associated software for model rendering and dynamic viewing of items using packages such as sketchfab. Some of them like Thingiverse are dedicated to free sharing of 3D printable files. Others such as Shapeways offer a 3D printing service for objects which have been provided for sale by designers. Another category are websites such as by Threeding and 3DprintWise which offer free and commercial exchange of digital 3D printable files for use on 3D printers but do not directly include 3D printing services themselves. Examples include:  Engineers, jewelry makers and architects developing prototypes and turning out finished products .  Consumers are soon able to create complete garments, meals, cookies and cupcakes, self-modeled bobble dolls, new sponges and other replacement products for home use bypassing the traditional purchasing models.  Big Box retail stores such as Target and Home Depot are installing 3D systems in their stores to enhance sales changing their operations from strictly a retailer to a manufacturer where the customer is doing the manufacturing. Newer retail printers will be able to produce a part or model up to 5” cubed .  Systems are being used for reconstructive surgical consultation using imaging, surgical software and 3D printing using biocompatible polymer and titanium powder and liquid photopolymer resin to produce patient-specific implantable medical devices. This allows for the achievement of improved outcomes from traditional reconstructive surgery to include surgical and dental needs (implantable jaw, facial bones, etc.) as well as spinal and hip implants ( also the potential for replacing traditional hip replacement technology ). In this process layers of living cells are deposited onto a gel medium or sugar matrix and slowly built up to form three-dimensional structures including vascular systems. Bioprinting of human tissues will accelerate the preclinical drug testing and discovery process enabling treatments to be created more quickly and at lower cost.  3D printing technology has been used to create entire concrete residential homes.  Biotechnologists are researching the use of human cellular lab cultures and 3D printing to produce human organs which would solve the shortage of organs for transplantation and enable the production of patient- specific organs which are not subject to rejection.  3D printing has spread into the world of clothing with fashion designers experimenting with 3D-printed bikinis, shoes and dresses.  Rocket parts built using this technology have passed NASA firing tests. In July 2013 two rocket engine
  • 3. 3 injectors performed as well as traditionally constructed parts during hot-fire tests which exposed them to temperatures approaching 6,000 degrees Fahrenheit (3,316 degrees Celsius) and extreme pressures. NASA is also preparing to launch a 3D printer into space; the agency hopes to demonstrate that with the printer making spare parts on the fly astronauts need not carry large loads of spares with them.  Firearms - The U.S. Department of Homeland Security and the Joint Regional Intelligence Center released a memo stating that "significant advances in three-dimensional (3D) printing capabilities, availability of free digital 3D printable files for firearms components and difficulty regulating file sharing may present public safety risks from unqualified gun seekers who obtain or manufacture 3D printed guns," and that "proposed legislation to ban 3D printing of weapons may deter but cannot completely prevent their production”. Even if the practice is prohibited by new legislation online distribution of these 3D printable files will be as difficult to control as any other illegally traded music, movie or software files." Internationally where gun controls are generally tighter than in the United States some commentators have said the impact may be more strongly felt as alternative firearms are not as easily obtainable. Downloads of the plans, "[design] a working plastic gun that could be downloaded and reproduced by anybody with a 3D printer" from the UK, Germany, Spain, and Brazil were especially heavy and in demand. Discussion These printing hardware and software systems allow for the creation of a single object at a cost equal to a full production cycle and run with simple and easy customization without the factory or assembly line. Each piece is a one-off customized piece allowing for the modeling and production of almost anything one can imagine. Using traditional reduction manufacturing methods of large and complex 3D printed objects one can achieve finishing techniques to create exact copies of large and complex finished objects. The 3D printing process uses a variety of materials to create the object including various thermoplastic powders and liquids, metal alloys, rubber, clay, plaster and photopolymers. Nanotechnology can also be used to alter the charactieristics of 3D printable materials. Thus combining two new technologies an object can be readily created with specific physical or chemical characteristics. A large number of additive processes are now available. They differ in the way layers are deposited to create parts and in the materials that can be used. Regardless of the material selected they all have to be heated and dependent upon the process used some may be melted to be able to layer together the model into a finished object. Dependent upon the material used and the desired object determines the 3D process used which may include: • Selective laser melting • Direct metal laser sintering • Select laser sintering • Fused deposition • Stereolithography • Laminated object manufacturing The current slow print speed of 3D printers limits their use for mass production. To reduce this overhead several fused filament machines now offer multiple extruder heads. These can be used to print in multiple colors with different polymers or to make multiple prints simultaneously.
  • 4. 4 Type Technologies Materials Extrusion Fused deposition modeling (FDM) Thermoplastics (e.g. PLA, ABS), HDPE, eutectic metals, edible materials, Rubber (Sugru), Modelling clay, Plasticine, RTV silicone, Porcelain, Metal clay (including Precious Metal Clay) Wire Electron Beam Freeform Fabrication (EBF3) Almost any metal alloy Granular Direct metal laser sintering (DMLS) Almost any metal alloy Electron-beam melting (EBM) Titanium alloys Selective laser melting (SLM) Titanium alloys, Cobalt Chrome alloys, Stainless Steel, Aluminium Selective heat sintering (SHS) [21] Thermoplastic powder Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders Powder bed and inkjet head 3D printing Plaster-based 3D printing (PP) Plaster Laminated Laminated object manufacturing (LOM) Paper, metal foil, plastic film Light polymerised Stereolithography (SLA) photopolymer Digital Light Processing (DLP) photopolymer Extrusion deposition: Example - Fused deposition modeling: 1 – nozzle ejecting molten plastic, 2 – deposited material (modeled part), 3 – controlled movable table. In fused deposition modeling the model or part is produced by extruding small beads of material which harden immediately to form layers. A thermoplastic filament or metal wire that is wound on a coil is unreeled to supply material to an extrusion nozzle head. The nozzle head heats the material and turns the flow on and off. Typically stepper motors or servo motors are employed to move the extrusion head and adjust the flow and the head can be moved in both horizontal and vertical directions. Control of this mechanism is typically done by a computer-aided manufacturing (CAM) software package running on a microcontroller. FDM usually cannot produce stalactite-like structures, since they would be unsupported during the build. Various polymers are used, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), high density polyethylene (HDPE), PC/ABS, and polyphenylsulfone (PPSU). In general the polymer is in the form of a filament fabricated from virgin resins. Multiple projects in the open-source community exist that are aimed at processing post-consumer plastic waste into filament.
  • 5. 5 Granular materials binding: The CandyFab granular printing system uses heated air and granulated sugar to produce food-grade art objects. Another 3D printing approach is the selective fusing of materials in a granular bed. The technique fuses parts of the layer and then moves the working area downwards adding another layer of granules and repeating the process until the piece has built up. This process uses the unfused media to support overhangs and thin walls in the part being produced, which reduces the need for temporary auxiliary supports for the piece. A laser is typically used to sinter the media into a solid. Examples include selective laser sintering (SLS) with both metals and polymers (e.g. PA, PA-GF, Rigid GF, PEEK, PS, Alumide, Carbonmide, elastomers) and direct metal laser sintering (DMLS). Selective Laser Melting (SLM) does not use sintering for the fusion of powder granules but will completely melt the powder using a high-energy laser to create fully dense materials in a layer-wise method with similar mechanical properties to conventional manufactured metals. Electron beam melting (EBM) is a similar type of additive manufacturing technology for metal parts (e.g. titanium alloys). EBM manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum. Unlike metal sintering techniques that operate below melting point EBM parts are fully dense, void-free and very strong. Another method consists of an inkjet 3D printing system. The printer creates the model one layer at a time by spreading a layer of powder (plaster, or resins) and printing a binder in the cross-section of the part using an inkjet- like process. This is repeated until every layer has been printed. This technology allows the printing of full color prototypes, overhangs, and elastomer parts. The strength of bonded powder prints can be enhanced with wax or thermoset polymer impregnation. Lamination: In some printers, paper can be used as the build material, resulting in a lower cost to print. This process can now use ordinary sheets of office paper, a Tungsten carbide blade to cut the shape, and selective deposition of adhesive and pressure to bond the prototype. There are also a number of companies selling printers that print laminated objects using thin plastic and metal sheets. Photopolymerization Example - Stereolithography apparatus Photopolymerization is primarily used in stereolithography (SLA) to produce a solid part from a liquid. In Digital Light Processing (DLP), a vat of liquid polymer is exposed to light from a DLP projector under safelight conditions. The exposed liquid polymer hardens. The build plate then moves down in small increments and the liquid polymer is again exposed to light. The process repeats until the model has been built. The liquid polymer is then drained from the vat leaving the solid model.
  • 6. 6 Inkjet printer systems spray photopolymer materials onto a build tray in ultra-thin layers (between 16 and 30 µm) until the part is completed. Each photopolymer layer is cured with UV light after it is jetted producing fully cured models that can be handled and used immediately without post-curing. The gel-like support material, which is designed to support complicated geometries, is removed by hand and water jetting. It is also suitable for elastomers. Ultra-small features can be made with the 3D microfabrication technique used in multiphoton photopolymerization. This approach traces the desired 3D object in a block of gel using a focused laser. Due to the nonlinear nature of photoexcitation, the gel is cured to a solid only in the places where the laser was focused and the remaining gel is then washed away. Feature sizes of under 100 nm are easily produced, as well as complex structures with moving and interlocked parts. Yet another approach uses a synthetic resin that is solidified using LEDs. Mask-image-projection-based stereolithography In this technique a 3D digital model is sliced by a set of horizontal planes. Each slice is converted into a two- dimensional mask image. The mask image is then projected onto a photocurable liquid resin surface and light is projected onto the resin to cure it in the shape of the layer. In research systems the light is projected from below allowing the resin to be quickly spread into uniform thin layers reducing production time from hours to minutes. The technique has been used to create objects composed of multiple materials that cure at different rates. Risk Guidance The coverages most significantly impacted are General Liability, Product Liability and Worker’s Compensation. Other coveages impacted may include Errors & Omissions, Product Recall, Construction Defect and others. 3D- printed products are treated the same as any other new operation that poses new risks.  Instead of underwriting a product or production exposure insurance carriers are now underwriting multiple exposures as well as potentially unknown product applications that will continue to evolve. An example would be the evolution of nano-technology based products. The 3D printing process presents exposures which may include heat sources and toxic fumes being emitted from melting and decomposition. There are also equipment exposures not unlike traditional manufacturing equipment such as machine guarding exposures. Defective and counterfeit product exposures, among others, will arise for all participants along the manufacturing continuum industry experts said. As long as an individual is in possession of the proper printer, material and digital file they can theoretically replicate a product designed by others. Thus the risk of counterfeit and potentially defective product risks increase too. The above material exposures as well as the sourcing of the materials used present a significant exposure.  Contaminated, defective or the incorrect materials used could create a defective product. For these reasons the materials used may be an overall greater potential liability exposure than those presented by the 3D printer. Similar to traditional manufacturing failure to determine the material used and source of material ordered increases the risk of product failure/contamination. There is also a risk of weapons and other prohibited products being produced which is challenging security experts to create new security technologies to replace traditional security scanners. Newer security equipment sniffs -out the presence of chemicals rather than look for the finished product. In addition to the inherent and potential 3D printing exposures there are printer-specific exposures dependent upon the application. 3D printer manufacturers sell printers and supplies for a wide range of applications. A traditional industrial machine manufacturer may produce machines for cutting wood or steel. The 3D printer manufacturer produces and sells equipment for creating solid objects, medical products, clothes, food and other finished products likely unknown to the seller with differing technologies and exposures to loss. The current intellectual property legislation in the developed countries does not explicitly regulate 3D printing. This creates numerous questions about the legal statute status of the 3D printing marketplaces and the technology itself. Some analysts predict that 3D printing marketplaces will be "the next Napster" in terms of legal complexity. There is also the unknown as to how a loss will be defined in a court of law and how a loss would be apportioned to those involved in the entire chain of getting the printed product to market and many legal regimes, including
  • 7. 7 patents, industrial design rights, copyright and trademark could apply. Any of the mentioned legal regimes may prohibit the distribution of the designs used in 3d printing, or the distribution or sale of the printed item. At this time there is no case law for 3D Printing losses. Although the challenges and potential risks are many there are some basic guidelines which can be used to help reduce the overall risk both in risk assessment and risk improvement. First, the team of the underwriters, risk engineers and brokers should first assess the company’s risk management profile and risk appetite. In particular the company’s production, research and development teams should be integrated on a regular basis with risk management. Consider the production environment and output of the company; if 3D printing enables production of, say, just 100 hip implants or 100 hearing aids, such work will generally take place outside of a traditional mass -production factories and may not be subject to government regulation and inspection such as from OSHA, FDA, EPA, etc. The technologies emerging risks may include unregulated manufacturing. Multiple projects in the open-source community also exist that are aimed at processing post-consumer plastic waste into filament. These involve machines to shred and extrude the plastic material into filament and if included in the work environment may pose additional non-traditional exposures to include property loss potentials and the issue of plastics fire-loading and control needs. Supply chain management is critical if a 3D printer is used to replicate a cupcake, the manufacturer should be as careful of contaminants in the mix as traditional bakers would need to be. This would involve an assessment of an organization’s quality control systems and storage and handling of raw materials, work-in-progress and finished goods through shipping and delivery. 3D printing increases the risk of counterfeit products. So long as a person has access to a 3D printer and a digitized product counterfeits can be produced. Using inferior material there is the risk the counterfeit product will be of inferior quality too and not match the anticipated specifications for use of an original. Because of the reduced time needed to produce products the risk of counterfeit products being placed into the stream of commerce on a rapid basis could increase. Because of this risk protecting proprietary product software is very important to prevent “identical” but potentially defective products from being sold. Additional Guidance: Because of the complexity of this risk it should be assessed by a Risk Engineer who has knowledge of 3D printing technology. This may be determined through the risk engineering Q2P database accessible through your portfolio executive. The guidance offered below is not exhaustive in scope and may or may not be applicable depending on the risks of a user versus a manufacturer of the 3D Printing technology.  It is imperative that Risk Engineering be provided risk contacts that are intimately familiar with the printers produced or sold as well as their applications; preferably through the operations, QA, finance and risk management departments.  Does the printer manufacturer have adequate contractual risk transfer controls from the raw material and component suppliers?  Does the risk have adequate contractual risk transfer controls from the suppliers of the materials to be used?  Does the risk have adequate contractual risk transfer controls with the purchasers/clients?  Are changes in contract requirements, especially requirements for hold harmless, additional insured status reviewed by Legal Staff.  Do they install their product?  Contingent Business Income Exposure - Do they manufacture all parts used in the printers? Do they have multiple suppliers for component parts?  What software / CAD do they design? Do they purchase Professional Liability to cover the software / CAD? Do they perform any inside QC or third party testing on the raw materials to insure they are the materials purchased and of the quality certified?  If they produce the materials what kinds of in-process and finished product quality controls are in place?
  • 8. 8  If the risk sells 3D printing material do they provide their customers with MSDS Sheets?  When evaluating materials do you include an assessment of material/ingredient toxicity?  Are there any new applications in the near future?  Are there any new printers in development for new applications?  Do you have any licensing agreements or other contracts with others to co-produce materials, products, etc?  Have you made any acquisitions of related firms? Conclusion 3D Printing has the potential to radically alter both the business and personal lives of millions of people in the coming years and create significant impacts on how we work, live and plan. It may even kick off the next industrial revolution. 1. Environmental impacts It is readily known that traditional manufacturing is often wasteful and dirty. In many ways 3D printing can lessens that waste and the carbon footprint manufacturing has on the Earth although it does tend to be energy greedy.  Fewer wasted materials: Only the raw materials needed to create the object—be it plastic filament, metal powder, or carbon fiber—are used. Using biodegradable PLA plastic filament in fused deposition modeling printers like MakerBot is a good start and example.  Possibility of longer life spans for products: Individual product parts can be replaced with 3D printing so the entire product doesn't have to be discarded and replaced each time it malfunctions, improving our disposable life-styles and product qualities.  Less transport: Products often have to travel across multiple continents to get to their final destination. With 3D printing production and assembly can be local with only raw materials possibly being the only things shipped and should take less space, weight and transport cost. Some raw materials are also reusable or recyclables and readily available at hand.  Fewer unsold products: If a company makes a product on spec orders or to fill potential future orders the ones that are discontinued or not sold often end up piling up in landfills or sold at deep discounts. With 3D printing this can be improved upon as it is a by demand production process. It should be noted that research shows 3D printers themselves have inefficiencies that make them less environmentally friendly. An inkjet 3D printer wastes 40 to 45 percent of its ink. If a printer is not turned off or unplugged it can use an excessive amount of electricity known as the electricity vampire syndrome. These are issues for future resolution for the manufacturers. 2. Creating a new art medium 3D Printing is opening up the world to the artisanal movement and allowing the creation of art previously un- makeable. They also allow for the recreation of historical and architectural art and pieces not available to everyone, helping museum curators with their inventories. This can extend to the recreation of the Budda statues destroyed by the Taliban in Afganistan to Van Gogh paintings. 3. Innovation in education One manufacturer, MakerBot, announced a crowd funded plan to get a 3D printer into every school in America. "It can change the whole paradigm of how our children will see innovation and manufacturing in America," MakerBot CEO Bre Pettis said in the announcement. The company also recently announced a plan to do the same in certain colleges and universities. Starting with State University of New York at New Palz, the centers are equipped with
  • 9. 9 30-3D printers, along with several 3D scanners to help train engineers, architects and artists to increase motivation and increase motivation for growth in the industry. 4. 3D printing in zero-gravity NASA and the defense industries are extremely excited about the technologies’ potentials. Due to the critical need for weight reduction and payload management it is cheaper, easier and of less weight to haul raw materials into space and create the needed parts and tools while in space. It might also allow for printing of food in space rather than hauled freeze dried products. It can also help accelerate the building of parts for the International Space Station. A partnership has developed with NASA's Marshall Space Flight Center to launch the first 3D printer in space. It will manufacture parts in zero-gravity and the hope is to make space missions more self-sufficient. 5. The Revolutionizing mass manufacturing Mass production is the biggest challenge in 3D printing as it was not designed for that type of production initially. The adoption of large-scale printers and rapidly evolving technology to produce parts faster allows for the potential for the technology to change traditional manufacturing in many industries:  Food: Anything that exists in liquid or powder form may be 3D printed. Food is one of the next big conversations on opportunities and controls.  Military: The machinery for the military is often customized and replacements must be made quickly. A 3D gun has already been printed, so it's only a matter of time before the technology catches on in this indus try.  Electronics: The size, shape, and materials used to make electronics make this industry a natural candidate for 3D printing.  Toys: Home 3D printers and open source design software will change the way children create and play with toys.  Automotive: This industry is already utilizing the technology—Ford reportedly uses 3D printing to test parts. High-end and smaller auto companies will benefit first. 6. Changing medicine and healthcare industries Bioprinting is one of the fastest-growing areas of 3D printing with the using inkjet-style printers to make living tissue. Organovo, a Chinese firm is one of the most well-known company who does this and who plans to commercialize 3D-printed liver tissue in the very near future. They have also partnered with the National Eye Institute and the National Center for Advancing Translational Sciences to print eye tissue. Researchers at Human Methodist Research Institute said they have created a more efficient way to create cells allowing for 100 percent of the cells to live instead of the 50 to 80 percent that normally survive using current technology. All of this will raise questions about the development of complex organs and will engage societies in a debate of moral, ethical and political concerns. Most recently an American based team of scientists have 3D printed the severed ear of late painter Vincent van Gogh out of living tissue, creating a living and functioning replica of the self-severed ear of the artist. 7. Transforming the home As almost all of us love new technology and especially convenience and with home 3D printers becoming smaller and more affordable (MakerBot's smallest printer is just over $1,300) people will want to print custom jewelry, household goods, toys and tools to whatever size, shape, or color they want. They will also be able to print and make replacement parts right at home rather than ordering them and waiting for them to be shipped rapeidly. Home 3D printing could evolve into a $70 billion industry per year by 2030. Think how this will impact the replacement parts industry for all areas of society.
  • 10. 10 8. Reaching disconnected markets worldwide Developing countries are often partially or completely disconnected from global supply chains for even the most basic products. 3D printing has the ability to bring them into the supply chain. The best example of this is Austin- based startup re: 3D, which had a hugely successful Kickstarter campaign last May with Gigabot, an industrial- sized, affordable printer. The Gigabot will be used for many of the projects in Chile, like 3D design internships, manufacturing clothing and experimenting with printing using recyclable materials. Another way 3D printing can help developing countries is through partnerships with 3D printing researchers such as many countries in the developing world are in dire need of prosthetic limbs but do not have access to the technology or the education required to make their own. A Canadian professor is creating a way to make a prosthetic limb that is about 80 percent as good as one that could be made by hand. The lab is sending the prosthetics to disabled Ugandans. 9. Impacts on the global economy The 3D printing industry will have far-reaching effects on the global economy. The McKinsey Global Institute recently released a report that said 3D printing will cause major disruptions in the global economy by 2025 predicting that it will bring about new product development cycles as the systems become cheaper. More and more companies will adopt the technology and product creation will focus more than ever on client feedback and customer-centered design and customization. The industry is also reducing the cost of entry into markets allowing very niche businesses to develop. China is investing heavily in the technology to rival this rapid growth rate in the U.S. and Europe. In June 2013, the country announced a gigantic 3D printer they claimed was the world's largest at the time. t's not clear what impact the technology will have on the economy but it could give China a competitive edge in domestic production and technological advancement. With its localized production the technology will significantly affect China's current large-scale manufacturing industries. 10. Intellectual property considerations Sharing 3D printing schematics on open websites like Thingiverse and Shapeways with free designs are bound to cause issues with intellectual property as 3D printing becomes more mainstream. The current majority of current designs are unpatented, allowing them to be copied repeatedly and sold by anyone. Expensive or designer objects can also be reverse-engineered or replicated and sold at a cheaper price. While some of the more established companies are starting to go after users of these sites arguing that they are infringing on copyright or violating intellectual property laws most of these users are building upon original designs, changing the base designs, improving upon them, making them better, or localizing the products to better reflect local population needs and desires. Think of the third-world applications. The industry will have to figure out how to make sure large corporations react appropriately and legally to entrepreneurs and open-software designers in their fight to protect company copyright laws. Bill Enos, CRM, MESH Senior Risk Engineering Consultant - Zurich NA Risk Engineering (803) 396-8166 office (803) 207-9761 cell Bill.Enos@zurichna.com
  • 11. 11 References Research@IDTechEx.com http://www.publicknowledge.org/blog/3 d-printing-non-engineers-rapidly- prototyping Excell, Jon. "The rise of additive manufacturing".The engineer. Retrieved 2013-10-30. "3D Printing:What You Need to Know". PCMag.com. Retrieved 2013-10-30. "3D printing:3D printing scales up". The Economist.2013-09-07. Zelinski,Peter (2013-11-08),"Hybrid machine combines milling and additive manufacturing",Modern Machine Shop. Zelinski,Peter (2014-02-21),"The capacity to build 3D metal forms is a retrofittable option for subtractive CNC machine tools",Modern Machine Shop Additive Manufacturing supplement. Kelly, Heather (July 31, 2013). "Study: At-home 3D printing could save consumers 'thousands'".CNN. Freedman,David H. "Layer By Layer." TechnologyReview 115.1 (2012): 50– 53. Academic Search Premier.Web. 26 July 2013. Jane Bird (2012-08-08)."Exploring the 3D printing opportunity". The Financial Times. www.3ders.org (2012-09-25)."Casting aluminum parts directlyfrom 3D printed PLA parts". 3ders.org 3D Printing:Challenges and Opportunities for International Relations".Transcript.Council on Foreign Relations.October 23, 2013 Cubify - Express Yourselfin 3D". myrobotnation.com 3D-printed sugar network to help grow artificial liver", BBC, 2 July 2012. 3D Human Tissues | Organovo". organovo.com Keith Perry (12 March 2014)."Man makes surgical historyafter having his shattered face rebuiltusing 3D printed parts". London:The Daily Telegraph The World’s First3D-Printed Building Will Arrive In 2014".TechCrunch.2012- 01-20 3D Printing:Challenges and Opportunities for International Relations".Transcript.Council on Foreign Relations.October 23, 2013 Analysis:3D-Printing Spare Human Parts; Ears and Jaws Already, Livers Coming Up ; Need an Organ? Just Print It". Globaleconomicanalysis.blogspot.co.uk . 2013-08-18 Clive Thompson on 3-D Printing’s Legal Morass Wired,Clive Thompson 05.30.12 Poeter, Damon (2012-08-24)."Could a 'Printable Gun' Change the World?". PC Magazine Homeland Securitybulletin warns 3D- printed guns maybe 'impossible'to stop". Fox News.2013-05-23 Ball, James (10 May 2013)."US governmentattempts to stifle 3D-printer gun designs will ultimatelyfail" 3D Printing Industry (3DPI) THRE3D Editor In Chief, physics.org,Institute of Physics,76 Portland Place,London, W1B 1NT Richard A. D’Aveni is the Bakala Professor ofStrategy at Dartmouth’s Tuck School of Business and the author of Strategic Capitalism (McGraw-Hill, 2012). ExplainingTheFuture.com and Christopher Barnatt,3D Printing